Dispensing Systems

Abstract

The dispensing system includes a composition comprising one or more of a deodorant composition, a fragrance composition, or a cleaning composition. The system includes a container having a body. The composition is disposed within the container, and a pressure within the container is at least 930 kPa. The system further includes an actuator assembly coupled to the container. The actuator assembly includes a housing, an actuator disposed within the housing and having a fluid passage in fluid communication with the composition, and a nozzle insert disposed within the fluid passage. The nozzle insert defines a nozzle orifice having an orifice diameter of about 0.335 mm to about 0.385 mm, and the composition includes a compressed gas and about 5% to about 10% ethanol by volume.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of and priority to U.S. patent application Ser. No. 63 / 213,528, filed June 22, 2021, and entitled “DISPENSING SYSTEMS,” which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates generally to a dispensing system that includes an actuator assembly for placement on a container, and more particularly to an improved nozzle insert for achieving compressed gas within the container, modified formulations and pressures, and a more desirable spray pattern that reduces drop. [Background technology]

[0003] Aerosol containers are commonly used to store and dispense products such as air fresheners, deodorants, insecticides, disinfectants, decongestants, fragrances, or any other known products. The product is forced out of the container through an aerosol valve by a hydrocarbon or non-hydrocarbon propellant. A typical aerosol container includes a body having an opening at its top end. A mounting cup is crimped to the container opening to seal the top end of the body. The mounting cup is generally circular in shape and may include an outer wall extending upwardly from a base of the mounting cup adjacent the crimped area. A pedestal also extends upwardly from a central portion of the base. The valve assembly includes a valve stem, a valve body, and a valve spring. The valve stem extends through the pedestal with a distal end extending upwardly away from the pedestal and a proximal end disposed within the valve body. The valve body may be secured inside the mounting cup and a dip tube attached to the valve body. The dip tube extends downwardly into the interior of the container body. The distal end of the valve stem is depressed axially along its longitudinal axis to open the valve assembly. In other containers, the valve stem is tilted or displaced transversely to the longitudinal axis to radially actuate the valve stem. When the valve assembly is opened, the pressure differential between the interior of the container and the atmosphere forces the contents of the container through an orifice in the valve stem.

[0004] Aerosol containers often include an actuator assembly that covers the top of the container. A typical overcap or actuator assembly is releasably attached to the container by an outwardly projecting ridge that surrounds the inner lower edge of the actuator assembly and interacts with a crimped seam that surrounds the top of the container. When the assembly is placed on the top of the container, downward pressure is applied to the assembly, which causes the ridge to ride up the outer edge of the seam and lock under the ledge defined by the underside of the seam. In some systems, the actuator assembly includes a dispensing orifice through which the product can escape. In such systems, the actuator typically interacts with a valve stem to release the product into the actuator and out through the dispensing orifice of the actuator assembly. Additionally, such actuators typically include an actuation mechanism, such as a button or trigger, that is integral with the actuator. In some cases, for example, a nozzle assembly for a container included in a larger actuator assembly can include a nozzle insert and a corresponding nozzle insert cavity. During manufacturing (or at other times), a particular nozzle insert can be inserted into the nozzle insert cavity to form a composite nozzle assembly that can provide desired flow characteristics (e.g., spray pattern, flow rate, metering effect, etc.). Summary of the Invention [Problem to be solved by the invention]

[0005] All of the aforementioned characteristics of a dispensing system affect spray characteristics. In the specific context of fragrance dispensing systems, drop is the spray characteristic resulting from an aerosol spray, which can be troublesome by generating residue along various surfaces within the spray zone. Unwanted residue resulting from increased drop is generally an undesirable effect and can cause undesired wetting by consumers. Furthermore, many prior art dispensing systems dispense inconsistent sprays over the life of the product and fail to provide sufficient fragrance coverage within an enclosed room. The present disclosure relates generally to dispensing systems, and more particularly to product dispensing systems having actuators with nozzle inserts that address one or more aspects of prior art dispensing systems. [Means for solving the problem]

[0006] According to some embodiments of the present disclosure, the dispensing system contains a composition comprising one or more of a deodorant composition, a fragrance composition, or a cleaning composition. The dispensing system further includes a container having a cylindrical body and defining a pressure therein. The composition is disposed within the container, and the pressure is at least 930 kPa. An actuator assembly is attached to the container, the actuator assembly including a housing, an actuator disposed within the housing having a fluid passage in fluid communication with the composition, and a nozzle insert disposed within the fluid passage. The nozzle insert defines a nozzle orifice having an orifice diameter of about 0.335 mm to about 0.385 mm, and the composition includes a compressed gas and about 5% to about 10% ethanol by volume.

[0007] In some embodiments, the dispensing system contains a composition comprising one or more of a deodorant composition, a fragrance composition, or a cleaning composition. The dispensing system includes a container having a valve stem defining a longitudinal axis and a body defining a pressure therein. The composition is disposed within the container, and the pressure is at least 930 kPa. An actuator assembly is attached to the container. The actuator assembly includes a housing, an actuator disposed within the housing and having a fluid passageway in fluid communication with the composition, and a nozzle insert disposed within the fluid passageway and defining a spray axis offset from the longitudinal axis by about 60° to about 70°. The composition includes compressed gas and about 5% to about 10% ethanol by volume.

[0008] In some embodiments, a method of dispensing a composition comprising one or more of a deodorant composition, a fragrance composition, or a cleaning composition includes providing a container having a body and defining a pressure therein, the composition being disposed within the container, the pressure being at least 930 kPa. The method further includes attaching an actuator assembly to the container, the actuator assembly including a housing, an actuator disposed within the housing and having a fluid passageway in fluid communication with the composition, and a nozzle insert disposed within the fluid passageway. The method also includes spraying the composition with a 25% to 30% drop from a spray height of 4 feet to 5 feet. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a rear isometric view of a product dispensing system including a container and an actuator assembly attached to the container. [Diagram 2] 2 is a cross-sectional view of the product dispensing system taken along line 2-2 of FIG. 1. [Diagram 3] FIG. 2 is a front view of the actuator assembly of FIG. 1. [Figure 4] FIG. 2 is a left side view of the actuator assembly of FIG. 1 , the actuator being shown in an unactuated or first configuration. [Diagram 5] FIG. 2 is a rear elevational view of the actuator assembly of FIG. 1. [Figure 6] FIG. 2 is a right side view of the actuator assembly of FIG. 1, the actuator being shown in an actuated or second configuration. [Figure 7] 7 is a side cross-sectional view of the actuator assembly shown in a first configuration taken along line 7-7 of FIG. 3. [Figure 8] 8 is a rear cross-sectional view of the actuator assembly shown in a second configuration, taken along line 8-8 of FIG. 6. [Figure 9] 9 is a rear cross-sectional view of the actuator assembly shown in a first configuration taken along line 9-9 of FIG. 7. [Figure 10] FIG. 2 is a front isometric view of a housing of the actuator assembly of FIG. 1. [Figure 11] FIG. 11 is a front view of the housing of FIG. 10. [Figure 12] FIG. 11 is a side view of the housing of FIG. 10. [Figure 13] FIG. 11 is a top view of the housing of FIG. 10. [Figure 14] 14 is a side cross-sectional view of the housing taken along line 14-14 of FIG. 11. [Figure 15] 15 is a rear cross-sectional view of the housing taken along line 15-15 of FIG. 12. [Figure 16] 16 is an oblique side cross-sectional view of the housing taken along line 16-16 of FIG. 13. [Figure 17] FIG. 2 is a front isometric view of an actuator of the actuator assembly of FIG. 1. [Figure 18] FIG. 18 is a side view of the actuator of FIG. 17. [Figure 19] FIG. 18 is a front view of the actuator of FIG. 17. [Figure 20] FIG. 18 is a top view of the actuator of FIG. 17. [Figure 21] 21 is a side cross-sectional view of the actuator taken along line 21-21 of FIG. 19. [Figure 22] 22 is a rear cross-sectional view of the actuator taken along line 22-22 of FIG. 20. [Figure 23] FIG. 22 is a detailed cross-sectional view of the nozzle end of the cross-sectional view of the actuator of FIG. 21. [Figure 24] FIG. 22 is a detailed cross-sectional view of the valve seat of the cross-sectional view of the actuator of FIG. 21. [Diagram 25] FIG. 2 is a front isometric view of a nozzle insert of the actuator assembly of FIG. [Figure 26] FIG. 26 is a front view of the nozzle insert of FIG. 25. [Figure 27] FIG. 26 is a side view of the nozzle insert of FIG. 25. [Figure 28] 28 is a side cross-sectional view of the nozzle insert taken through line 28-28 of FIG. 26. [Figure 29] FIG. 26 is a rear view of the nozzle insert of FIG. 25. [Diagram 30] 2 is a first image in a sequence comparing spray distribution patterns of the dispensing system of FIG. 1 and a prior art dispensing system. [Diagram 31] 2 is a second image in a sequence comparing spray distribution patterns of the dispensing system of FIG. 1 and a prior art dispensing system. [Diagram 32] 2 is a third image in a sequence comparing spray distribution patterns of the dispensing system of FIG. 1 and a prior art dispensing system. [Diagram 33] 2 is a graph showing a comparison of perceptible fragrance coverage at 100% fill for the dispensing system of FIG. 1 and a prior art dispensing system. [Diagram 34] 2 is a graph showing a comparison of perceptible fragrance coverage at 25% fill for the dispensing system of FIG. 1 and a prior art dispensing system. [Diagram 35] 2 is a graph showing a comparison of drop rates from various spray heights for the dispensing system of FIG. 1 and a prior art dispensing system. [Diagram 36]2 is a graph showing a comparison of total dropped mass at 100% fill for the dispensing system of FIG. 1 and a prior art dispensing system. [Figure 37] 2 is a graph showing a comparison of total dropped mass at 25% fill for the dispensing system of FIG. 1 and a prior art dispensing system. [Figure 38] 2 is a graph showing a comparison of average spray pattern diameter compared to the percentage of product remaining in the container for the dispensing system of FIG. 1 and a prior art dispensing system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The present disclosure provides a dispensing system including a compressed gas aerosol with improved spray performance for use as a deodorant spray and / or deodorant. The dispensing system disclosed herein achieves spray characteristics that provide an improved consumer experience by reducing fallout from the spray of the aerosol. Fallout can be characterized as the wetting of the spray plume in the air and / or the accumulation of residue on surfaces after use of the dispensing system. The present disclosure identifies key spray characteristics and formulation parameters that have been found to reduce and / or improve fallout from compressed gas dispensing systems. Spray characteristics include particle size, release rate, spray angle, throw distance, spray cone diameter, fallout rate, fallout pattern, and particle velocity. Formulation parameters include percent composition of volatile organic compounds ("VOCs"), solvent use, fill pressure, and percent headspace.

[0011] The spray performance of compressed gas aerosols is affected by the formulation and the ingredients used to contain the formulation. More specifically, the performance can be significantly affected by the spray insert or mechanical breakup unit ("MBU") used to aerosolize the formulation. The function of the MBU is to break down the liquid formulation to create particles for delivery for its intended use. The formulation and ingredients are designed to produce the desired spray characteristics. The methods and systems disclosed herein can be embodied in many different forms, and several specific embodiments are discussed herein with the understanding that the embodiments described in this disclosure should be considered merely illustrative of the principles described herein, and that the disclosure is not intended to be limited to the illustrated embodiments. Throughout this disclosure, the terms "about" and "approximately" mean ±5% of the number or value to which each term precedes.

[0012] 1, there is shown a product dispensing system 60 configured to store and / or dispense an aerosol product (not shown). The dispensing system 60 includes a container 62, an actuator assembly 64 including a housing 66, an actuator 68, and a nozzle insert 70 (see FIG. 2). In use, the actuator assembly 64 is configured to release the product from the container 62 upon the occurrence of a particular condition. For example, a user of the product dispensing system 60 can manually depress or otherwise actuate the actuator 68 of the actuator assembly 64 to release the aerosol from the container 62. Throughout this disclosure, the actuator assembly 64 is shown in various configurations.

[0013] The composition may be an aqueous formulation intended for release as a pressurized product. The composition is preferably pressurized using one or more compressed gases, such as carbon dioxide, helium, hydrogen, neon, oxygen, xenon, nitrous oxide, or nitrogen, and further includes one or more polar solvents, such as alcohols, ketones, carboxylic acids, or amides. In a preferred embodiment, the polar solvent is an alcohol, more specifically ethanol. Although the product dispensing system 60 is broadly adapted to dispense any number of aqueous formulations, the present dispensing system 60 is particularly configured to dispense one or more of a deodorant composition, a fragrance composition, and a cleaning composition, as disclosed herein. In a preferred embodiment, the composition includes an organic compound having a hydroxyl group and is pressurized using one or more of the compressed gases listed above.

[0014] 2, the container 62 includes a substantially cylindrical body 74 that defines an outer sidewall 76. Additionally, a seam 78 and / or mounting cup 80 provide a location to which the actuator assembly 64 may be attached, as known in the art. A conventional valve assembly 84 is shown including a valve body (not shown) disposed within the container 62 and a valve stem 86 connected to a valve spring (not shown). The valve stem 86 extends upwardly through a pedestal 88, with a distal end 90 extending upwardly away from the pedestal 88 and adapted to interact with a valve seat 92 disposed within the actuator 68. A longitudinal axis 94 extends through the valve stem 86. Prior to use, the actuator 68 is disposed in fluid communication with the distal end 90 of the valve stem 86. A user manually or automatically operates the actuator 68 to open the valve assembly, which creates a pressure differential between the interior of the container and the atmosphere, forcing the contents out of the container 62, through the valve stem 86 and the actuator assembly 64, and into the atmosphere. It should be noted that the valve stem 86 is shown in a configuration in which it is not fully seated within the valve seat 92 of the actuator 68, and that an additional assembly step is required to fully seat the valve stem 86 therein. Additionally, although the valve stem 86 is shown as an integral component with the container 62, the valve stem 86 may be provided in a variety of configurations and is provided for illustrative purposes only.

[0015] 2, the container 62 includes a lower base 98 that is crimped or otherwise coupled to the body 74 at a lower end 100, the body 74 further defining an upper end 102 that defines an opening 104. The mounting cup 80 is crimped to a tapered portion of the container 62 that defines the opening 104. The mounting cup 80 seals the upper end 102 of the body 74. The crimped portion between the mounting cup 80 and the container 62 defines a seam 78, which provides a location along which the actuator assembly 64 may be attached, as is known in the art.

[0016] While any number of pressurized products can be used within the container 62, the preferred composition is pressurized using compressed gas and includes an alcohol, e.g., ethanol. More specifically, the composition includes about 4% by volume (%v) to about 15%v ethanol, or about 6%v to about 13%v ethanol, or about 8%v to about 11%v ethanol, or at least 5%v ethanol, or at least 7%v ethanol, or at least 8%v ethanol, or at least 9%v ethanol, or at least 10%v ethanol, or at least 11% ethanol. Through testing, it has been determined that the aforementioned levels of ethanol in the composition within the container 62 help facilitate evaporation to reduce undesirable fallout along various surfaces in the vicinity of the spray. To that end, it has been found that increasing the amount of ethanol in the composition accelerates or increases the evaporation rate and reduces corrosion of the container 62.

[0017] 2, the exterior sidewall 76 defines a thickness 108. The sidewall 76 of the container 62 preferably comprises steel, although the sidewall 76 may comprise a wide variety of materials known in the art, such as aluminum or plastic. In preferred embodiments, the thickness 108 of the container sidewall 76 is between about 0.005 inches (0.13 mm) and about 0.04 inches (1.02 mm), between about 0.01 inches (0.25 mm) and about 0.03 inches (0.76 mm), about 0.02 inches (0.51 mm), or at least 0.005 inches (0.13 mm), or at least 0.01 inches (0.25 mm), or at least 0.015 inches (0.38 mm), or at least 0.02 inches (0.51 mm), or at least 0.025 inches (0.64 mm), or at least 0.03 inches (0.76 mm). The thickness of the container 62 may be increased in light of the pressure within the container.

[0018] As discussed below, increasing the pressure within the reservoir 62 assists in reducing droop by dispersing the particles of the spray and sending them farther away from the dispensing system 60 when the user activates the actuator 68. In some embodiments, the reservoir is pressurized to between about 120 pounds per square inch (psi) (827 kPa) and about 180 psi (896 kPa), or between about 130 psi (896 kPa) and about 170 psi (1172 kPa), or between about 140 psi (965 kPa) and about 160 psi (1103 kPa), or between about 150 psi (1034 kPa) and about 155 psi (1068 kPa), between about 152 psi (1048 kPa) and about 153 psi (1055 kPa), or between about 150 psi (1034 kPa), or ... The container 62 may have a pressure of 52 psi (1048 kPa), about 153 psi (1055 kPa), or at least 120 psi (827 kPa), or at least 130 psi (896 kPa), at least 140 psi (965 kPa), or at least 145 psi (999 kPa), or at least 150 psi (1034 kPa), at least 155 psi (1068 kPa), or at least 160 psi (1103 kPa), or at least 170 psi (1172 kPa). Additionally, when at 100% capacity, i.e., completely full, the container 62 may define a headspace of about 10% to about 70% of the volume of the container 62, or about 20% to about 60% of the volume of the container 62, or about 30% to about 50%, or about 35% to about 45%, or about 40%.

[0019] The following includes preferred ranges for particle size of particles sprayed by dispensing system 60. As referred to herein, Dv is a designation of diameter (a measure of particle size) on a volume basis. Thus, Dv(10) represents the 10th percentile of the particle size distribution. It is further noted herein that the above particle size ranges cover the range of 100% to 25% filled cans, i.e., 100% to 25% filled cans. In some embodiments, the Dv(10) particle size of the spray may be about 5 μm to about 150 μm, or about 15 μm to about 130 μm, or about 20 μm to about 120 μm, or about 23 μm to about 94 μm, or about 35 μm to about 60 μm, or at least 5 μm, or at least 15 μm, or at least 20 μm, or at least 23 μm, or at least 30 μm, or at least 36 μm. In some embodiments, the Dv(50) particle size of the spray may be from about 10 μm to about 300 μm, or from about 20 μm to about 275 μm, or from about 30 μm to about 250 μm, or from about 55 μm to about 200 μm, or from about 65 μm to about 105 μm, or at least 10 μm, or at least 20 μm, or at least 30 μm, or at least 54 μm, or at least 60 μm, or at least 64 μm. In some embodiments, the Dv(90) particle size of the spray may be from about 30 μm to about 500 μm, or from about 50 μm to about 420 μm, or from about 75 μm to about 400 μm, or from about 105 μm to about 373 μm, or from about 100 μm to about 200 μm, or at least 30 μm, or at least 50 μm, or at least 75 μm, or at least 90 μm, or at least 105 μm.

[0020] In some embodiments, the spray rate measured over about 10 seconds may be in the range of about 0.2 grams per second (g / s) to about 3.5 g / s, or in the range of about 0.8 g / s to about 2.8 g / s, or in the range of about 1.1 g / s to about 2.6 g / s, or in the range of about 1.2 g / s to about 2.0 g / s, or in the range of about 1.7 g / s, or at least 0.2 g / s, or at least 0.8 g / s, or at least 1.0 g / s, or at least 1.1 g / s, or at least 1.2 g / s. Unless otherwise noted herein, the various spray rates were measured by weighing a particular dispensing system, spraying for a particular time, weighing the particular dispensing system a second time, and calculating the spray rate based on the difference in weight over the spray time. As described herein, the above spray rates cover a range of 100% to 25% filled cans, i.e., 100% to 25% filled cans. In some embodiments, the cone angle of the spray (see FIG. 31), measured at the apex of the spray, may be from about 10° to about 60°, or from about 20° to about 50°, or from about 30° to about 40°, or about 35°, or at least 10°, or at least 20°, or at least 30°, or at least 35°. In some embodiments, the spray projection distance, measured from the spray orifice 176 of the nozzle insert 70, may be from about 5 inches (12.7 cm) to about 100 inches (254 cm), or from about 15 inches (38.1 cm) to about 70 inches (177.8 cm), or from about 27 inches (68.6 cm) to about 45 inches (114.3 cm), or about 35 inches (88.9 cm), or at least 5 inches (12.7 cm), or at least 15 inches (38.1 cm), or at least 20 inches (50.8 cm), or at least 27 inches (68.6 cm).

[0021] In some embodiments, the spray cone diameter / spray pattern diameter may be from about 0.5 inches (12.7 mm) to about 15 inches (381 mm), from about 2.4 inches (61.0 mm) to about 6.6 inches (168 mm), from about 3.2 inches (81.3 mm) to about 5.1 inches (130 mm), about 4.3 inches (109 mm), or at least 0.5 inches (12.7 mm), at least 2.4 inches (61.0 mm), or at least 3.2 inches (81.3 mm), or at least 4.3 inches (109 mm). In other embodiments, the spray cone diameter / spray pattern diameter is from about 2.4 inches (61.0 mm) to about 12.5 inches (318 mm), or from about 5.0 inches (127 mm) to about 9.5 inches (241 mm). In some embodiments, the particle velocity of the spray may be from about 10 meters per second (m / s) to about 90 m / s, or from about 30 m / s to about 70 m / s, or from about 40 m / s to about 57 m / s, or at least 10 m / s, or at least 30 m / s, or at least 35 m / s, or at least 40 m / s, as measured at the spray orifice 176 of the nozzle insert 70. As discussed herein, the above particle velocities provide coverage of 100% to 25% filled cans. In a preferred embodiment, Dv(10) is about 36 μm to about 58 μm, Dv(50) is about 64 μm to about 105 μm, Dv(90) is about 105 μm to about 220 μm, the spray velocity is about 1.1 g / s to about 2.6 g / s, the potential cone angle is about 35°, the throw distance is about 27 inches (68.6 cm) to about 45 inches (114 cm), the spray pattern is about 3.2 inches (8.13 cm) to about 5.1 inches (13.0 cm), and the particle velocity is about 40 m / s to about 57 m / s. In a preferred embodiment, the composition is 9% by volume ethanol.

[0022] 3-8, the actuator assembly 64 is shown in more detail. The actuator assembly 64 is shown in a top (non-actuated) or first configuration in FIGS. 3-5, 7, and 9, and the actuator assembly 64 is shown in a bottom (actuated) or second configuration in FIGS. 5 and 7. The non-actuated or first configuration in FIGS. 3-5, 7, and 9 can be considered a configuration before shipping or actuation, and the configuration after actuation includes the actuator 68 disposed at a point intermediate the first and second configurations, and the actuator 68 is configured to actuate. The actuator assembly 64 includes an actuator 68 configured to receive at least a portion of the nozzle insert 70 into a portion of the actuator 68. In some embodiments, the actuator 68 may be manufactured from a single piece of material, more specifically a plastic material. In some embodiments, the actuator 68 may be manufactured from a copolymer, for example, a polypropylene copolymer. In some embodiments, the actuator 68 may be manufactured from polypropylene, propylene, HDPE, nylon, or other copolymers or homopolymers.

[0023] With particular reference to Figures 3-6, the housing 66 is shown in detail. The housing 66 includes a lower edge 110 from which a continuous outer wall 112 extends upwardly and inwardly, curving toward the longitudinal axis 94 of the valve stem 86. With reference to the front view of Figure 3, the left side 114 and right side 116 of the outer wall 112 curve inwardly to define a slightly curved outer wall 112. A racetrack shaped front opening 118 is provided along the front side 120 of the housing 66, allowing the nozzle insert 70 to move up and down along it from a first configuration (not actuated) to a second configuration (fully actuated) to dispense product therethrough. The opening 118 can take a variety of shapes and is not limited to the embodiment shown herein. It should be noted that Figure 3 shows the actuator assembly 64 in a configuration not coupled with the valve stem, and an additional assembly step of depressing the actuator 68 will fully seat the actuator 68 on the valve stem 86.

[0024] With reference to the side view of FIG. 4 and the rear view of FIG. 5, the actuator 68 is shown extending above the top wall 124 of the housing 66. As further shown in FIG. 5, the rear side 126 of the housing 66 is relatively shorter than the front side 120 of the housing 66, and the top wall 124 extends between the rear side 126 and the front side 120. The top wall 124 is curved or arcuate and extends upwardly from the rear side 126 to the front side 120. Because the actuator assembly 64 is shown in a first configuration in FIGS. 4 and 5, the actuator 68 is at its highest position in these figures and extends above the top wall 124 when viewed from the side. With particular reference to FIG. 5, the top wall 124 is shown in more detail, with the top wall 124 extending around the periphery of the actuator 68 and sloping inwardly and downwardly toward the longitudinal axis 94. The actuator 68 also includes a button 130 that defines a concave top wall 132 that curves downwardly from left to right and front to back. The button 130 is configured to interact with a user's thumb or finger such that the button 130 can be depressed to activate the dispensing system 60. Referring to the side view of Figure 6, the actuator assembly 64 is shown in a second configuration such that the actuator 68 is fully depressed and not visible from the side.

[0025] Referring to FIG. 7, the actuator 68 is shown in a first configuration and at least partially disposed within the housing 66. Further shown is a nozzle insert 70 disposed within a fluid passageway 134 of the actuator 68. The fluid passageway 134 defines a vertical conduit 136 and an angled conduit 138 that intersects with the vertical conduit 136. The vertical conduit 136 is a chamber that allows the formulation to accumulate between sprays and may be included to reduce material from an otherwise thick portion of the actuator 68. In some embodiments, the vertical conduit 136 may be substantially shorter and the actuator cavity 140 shown above the angled conduit 138 may extend above the shorter vertical conduit 136. The actuator cavity 140 is an open space along the underside of the button 130.

[0026] Spray angle 144 is further shown in FIG. 7, which defines an angle relative to longitudinal axis 94 and spray axis 146. Spray angle 144 may be about 45° to about 85°, or about 50° to about 80°, or about 55° to about 75°, or about 60° to about 70°, or up to 80°, or up to 75°, or up to 70°, or up to 68°, or about 66°, or about 67°, or about 68°, or about 69°, or about 70°, or about 71°. The preferred angle ranges disclosed herein allow for reduced drop by spraying the composition at an angle that increases the distance between the spray and the ground surface. As described below, spray angle 144 may be noted in terms of an angle offset from a horizontal plane (not shown) disposed at a right angle to longitudinal axis 94. Thus, the angles disclosed above may be discussed using the horizontal plane as a frame of reference.

[0027] 7, the housing 66 further includes a lower opening 150 adjacent the lower edge 110 for receiving a portion of the container 62. The housing 66 further includes a plurality of outwardly extending securing ribs 152, stabilizing ribs 154, and alignment ribs 156 disposed along an inner surface 160 of the outer wall 112. The securing ribs 152 are oriented substantially parallel to the lower edge 110. Any number and size of securing ribs 152 surrounding the inner surface 160 of the actuator 68 may be included to assist in attaching the actuator 68 to the container 62. The stabilizing ribs 154 are provided around the inner surface 160 of the outer wall 112 to assist in the stability of the actuator assembly 64, particularly when a force is applied thereto. As will be described below, the alignment ribs 156 also act as stabilizing ribs, but are particularly provided in a position to assist in aligning the actuator 68 during assembly and to hold the actuator 68 in a non-rotatable configuration during use of the dispenser 60.

[0028] Also shown in Figure 7 is an inner wall 162 extending downwardly from the top wall 124 of the housing 66. The inner wall 162 includes a surface that interacts with the actuator 68, for example along the front side 120 of the housing 66. As shown in Figure 7, the inner wall 162 is configured to prevent upward movement of the actuator 68 when the actuator 68 is disposed within the housing 66 by preventing upward movement of a nozzle barrel 164 of the actuator 68. A plurality of fastening ribs 152 are further shown along the inner surface 160 of the housing 66 and are spaced apart to assist in mounting the container 62 to the actuator assembly 64, as is known in the art.

[0029] 7, as described above, a number of stabilizing ribs 154 are shown circumscribing the inner surface 160 of the outer wall 112. The stabilizing ribs 154 can provide additional structural integrity to the housing 66 to allow for increased top load on the actuator 68. Specifically, the bottom surface of the stabilizing ribs 154 interacts with a portion of the container 62 to assist in spreading the force applied to the top of the actuator 68 around the container 62. Additionally, alignment ribs 156 located along the sides and front of the housing 66 assist in aligning and positioning the actuator 68 in the proper position during and / or after the capping process. Such alignment assist helps ensure that the actuator assembly 64 is accurately positioned on the valve stem 86. The alignment ribs 156 generally extend farther toward the longitudinal axis 94 than the stabilizing ribs 154. In some embodiments, the stabilizing ribs 154 and the alignment ribs 156 are substantially identical in shape and there may be more or fewer ribs 154, 156.

[0030] The assembled actuator 68 is seated and held on the container 62 as described above, i.e., the ribs 154, 156 of the actuator 68 interact with the seam 78 of the container 62 to secure the actuator 68 to the container 62 in a snap-fit ​​type manner. In this condition, the actuator 68 of the actuator assembly 64 extends upwardly through the actuator 68 and out through an opening 166 located in the top wall 132 of the actuator 68. When properly seated, the actuator 68 extends upwardly through the opening 166 to form a surface against which a user can apply pressure to perform the actuation process. Furthermore, in this condition, the valve stem 86 of the container 62 seats within the inlet orifice 170 of the actuator 68, such that the surfaces defining the inlet orifice 170 and the vertical conduit 136 provide a substantially fluid-tight seal therebetween.

[0031] The actuator 68 and nozzle insert 70 are also shown in FIG. 7 in an assembled configuration. The actuator 68 extends along the vertical conduit 136 and defines a chamber axis 172 coextensive with the longitudinal axis 94 described above in FIG. 2. When the actuator assembly 64 is seated on the container 62, the chamber axis 172 is generally aligned with the longitudinal axis 94 and the nozzle insert 70 is inserted into an insert cavity 174 of the actuator 68. The spray orifice 176 of the nozzle insert 70 is shown disposed at or slightly below the top end of the front opening 118 of the housing 66, but when the actuator 68 is in the actuated configuration, the spray orifice 176 is positioned such that aerosolized fluid exits the spray orifice 176 through the front opening 118. The valve seat 92 is shown in the actuator 68 and defines a seat height 180, which is the height measured from the lower edge of the stabilizing rib 154 to the upper surface 182 of the valve seat 92. The valve seat 92 receives the valve of the container 62 and defines an inlet orifice 170 in the fluid passageway 134 of the actuator 68 through which product is dispensed.

[0032] 8, a rear cross-sectional view of the actuator assembly 64 is shown in a second configuration, i.e., in an actuated state. The interior aspects of the housing 66 are shown in detail, such as the first or left retention arm 186, the second or right retention arm 188, the first or left transportation lock 190, and the second or right transportation lock 192. Each of the arms 186, 188, and the transportation locks 190, 192 depend downwardly from and are integral with the inner wall 162 of the housing 66. Additionally, an interior cavity 194 is shown, which is defined as the space between the inner wall 162 and the outer wall 112 of the housing 66. Each of the arms 186, 188, and the transportation locks 190, 192 further include an internally disposed catch or hook 196, which have various purposes. For example, the catches 196 on the first and second retention arms 186, 188 are configured to prevent over-actuation of the actuator 68, as shown in FIG. 8, while the catches 196 on the first and second transportation locks 190, 192 interact with detents 198 along the actuator 68 (see FIG. 9) to keep the actuator 68 separated from the valve stem 86 during capping.

[0033] The inner wall 162 is further shown as defining a semi-circular notch 200 along the front side 120 of the housing 66, which is configured to receive the nozzle barrel 164 of the actuator 68 (see FIG. 7). Thus, the notch 200 and the first and second retention arms 186, 188 act in conjunction to prevent the actuator 68 from exiting the actuator profile, while the alignment rib 156 prevents the actuator 68 from rotating. A second height 202, defined as the distance from the lower edge of the stabilizing rib 154 to the upper surface 182 of the valve seat 92, is also shown in FIG. 8. The second height 202 may be about 20% to about 100% of the first height 180, or about 30% to about 90% of the first height 180, or about 40% to about 80% of the first height 180, or about 50% to about 60% of the first height 180. A vertical conduit 136 of the fluid passageway 134 of the actuator 68 is further shown, along with an entrance to an angled conduit 138 of the fluid passageway 134. The curvature of the button 130 is also shown in detail.

[0034] 8, the left and right arms 210, 212 of the actuator 68 are shown, each of which is disposed within the interior cavity 194 of the housing 66. The left and right arms 210, 212 define angled walls 214 along their outer portions, which follow the contour of a portion of the outer wall 112 of the housing 66. When the actuator 68 is forced upwardly by the valve assembly 84, the left and right arms 210, 212 of the actuator 68 extend further upwardly into the inner cavity 194 and remain nested therein. To assemble the actuator 68 to the housing 66, the actuator 68 is inserted through the lower opening 150 and the retaining arms 186, 188 are inserted through the arm openings 216 (see FIG. 19) in the actuator 68 until the catches 196 of the retaining arms 186, 188 snap into place, as shown in FIG. Thus, the retention arms 186, 188 of the housing 66 flex partway during assembly to capture the actuator 68 when assembled. Once the catches 196 of the retention arms 186, 188 are seated along the underside of the actuator 68, i.e., translated at least to the same height as shown in FIG. 8, the actuator assembly 64 can be assembled to the container 62.

[0035] 9, another cross-sectional view of the actuator assembly 64 is shown showing the shipping locks 190, 192 of the housing 66 and the detents or locking tabs 198 of the actuator 68. The shipping locks 190, 192 hold the actuator 68 during shipping so that it does not contact the valve stem 86 during capping and shipping. During initial use of the dispenser 60, the consumer overcomes the shipping locks 190, 192, after which the actuator 68 seats on the valve stem 86. To that end, the shipping locks 190, 192 are provided to hold the actuator 68 until initial use of the dispenser 60. The angled conduit 138 of the fluid passageway 134 is also shown in FIG. 9 along with the various stabilizing ribs 154 and alignment ribs 156.

[0036] 10-16 illustrate aspects of the housing 66 in more detail, particularly without the actuator 68 shown disposed therein. The various ribs 152, 154, 156 are shown unobstructed, along with the front opening 118 of the housing 66. With particular reference to FIGS. 11 and 12, the housing width 220 and the housing height 222 are shown. The housing height 222 can be about 50% to about 150% of the housing width 220, or about 70% to about 130% of the housing width 220, or about 90% to about 110% of the housing width 220, or about 100% of the housing width 220. FIG. 13 illustrates a vertical plane 224 that extends centrally through the housing 66 and passes through the longitudinal axis 94 of the actuator assembly 64 when seated on the container 62. The arms 186, 188 are shown as being offset by a first angle 226 relative to a vertical plane 224, while the locks 190, 192 are shown as being offset by a second angle 228 that is less than the first angle 226 taken relative to the intersection of the vertical plane 224 with the longitudinal axis 94.

[0037] Referring to FIG. 14, the housing 66 is shown in cross section through a vertical plane 224. The right shipping lock 192 and the right retention arm 188 are shown in detail. The lock height 230 is shown, which defines the distance from the lower edge 110 of the stabilizing rib 154 to the upper surface 232 of the catch 196 of the shipping locks 190, 192. The catch 196 of the right retention arm 188 is also shown in detail. As mentioned above, the arms 186, 188 and the shipping locks 190, 192 extend downwardly from the inner wall 162 of the housing 66 and partially define an internal cavity 194 therein. The alignment ribs 156, i.e., ribs disposed along opposite sides of the retention arms 186, 188, are also shown. The alignment ribs 156 are positioned to prevent rotational movement of the actuator 68 and hold the left and right arms 186, 188 between the alignment ribs 156. 15 and 16 provide further views of the interior side of the housing 66, including views of the various ribs 154, 156 and the various arms 186, 188, as well as transportation locks 190, 192 that extend downwardly and are configured to suspend or hold the actuator 68. With particular reference to FIG. 15, an interior cavity 194 is shown disposed along both the front side 120 and the rear side 126 of the housing 66. The interior cavity 194 is generally interrupted by the stabilizing ribs 154 and alignment ribs 156, but otherwise extends around the entire housing 66.

[0038] 17-24, the actuator 68 is shown in greater detail. With particular reference to FIG. 17, an isometric view of the actuator 68 of the actuator assembly 64 is shown. The actuator 68 includes a button 130 defining a top wall 124, a rounded peripheral wall 236 extending outwardly from the button 130, a left arm 210, and a right arm 212. As described above, the left arm 210 and the right arm 212 are configured to slidably translate within the internal cavity 194, between the alignment ribs 156, along opposing sides of the housing 66. Arm openings 216 are provided in the left arm 210 and the right arm 212 of the actuator 68 to receive the left retention arm 186 and the right retention arm 188 of the housing 66, respectively. The nozzle barrel 164 of the actuator 68 is shown in greater detail with a post 240 disposed within the fluid passageway 134 which in combination with the nozzle barrel 164 defines a nozzle conduit 242 which receives the nozzle insert 70. A front wall 244 depends downwardly from the nozzle barrel 164 and has a front tab 246 extending therefrom which may be configured to interact with the housing 66 to prevent over-actuation of the actuator 68. Also shown is a locking tab or detent 198 extending from the peripheral wall 236 of the actuator 68.

[0039] 18 and 19, the actuator depth 250 and the actuator height 252 are shown. Referring specifically to FIG. 18, the top wall 132 of the actuator 68 is shown curving downwardly from its front end 254 to its rear end 256. The post 240 is further shown projecting slightly outwardly from the nozzle conduit 242. The front wall 244 is also shown along with the front tab 246 which defines the forward most point of the actuator 68. Referring now to FIG. 19, both the arms 210, 212 and the locking tab 198 are shown in greater detail. The angled profile of the arms 210, 212 is apparent in FIG. 19 along with the symmetrical nature of the actuator 68. The opening 216 defined between the left and right arms 210, 212 and the button 130 is further shown which provides clearance for the left and right stabilizing arms 186, 188 to be inserted therethrough during assembly of the actuator assembly 64.

[0040] 20, a top view of the actuator 68 is shown including an opening 216 through which the retention arms 186, 188 of the housing 66 extend to hold the actuator 68 in place. The generally circular profile of the button 130 of the actuator 68 is also shown along with the generally outwardly sloping contours of the left and right arms 186, 188, front wall 244, and front tab 246. Because the actuator 68 preferably comprises a polymer, various features of the actuator 68 are configured to flex during assembly of the actuator assembly 64. The sloping profile of the left and right arms 186, 188 allows the actuator 68 to be inserted upwardly into the interior cavity 194 when the retention arms 186, 188 are inserted into the opening 216 while the left and right arms 210, 212 of the actuator 68 as well as the left and right retention arms 186, 188 can flex.

[0041] 21-23, a cross-sectional view of the actuator 68 is shown in greater detail. Shown in greater detail are the valve seat 92, the upper surface 182 of the valve seat 92, the fluid passageway 134 including the vertical conduit 136, the angled conduit 138, the nozzle conduit 242, and the top wall 132. With particular reference to FIG. 22, the openings 216 along the left and right sides of the actuator 68 between the left and right arms 210, 212 and the button 130 are shown in greater detail. The nozzle conduit 242 is shown in greater detail in FIG. 23, and the valve seat 92 in greater detail in FIG. 24.

[0042] With particular reference to FIG. 23 , the actuator 68 includes a nozzle conduit 242 configured to receive the nozzle insert 70. In the illustrated embodiment, the nozzle insert conduit 242 defines a generally cylindrical annular cavity extending generally along the spray axis 146 from a stop portion 260 to an open end 262. Also in the illustrated embodiment, the spray axis 164 is generally centrally located within the post 240 and disposed at an offset angle relative to the longitudinal axis 94. Additionally, the open end 262 includes a chamfered surface 264 configured to guide the nozzle insert 70 into the nozzle insert cavity 174 during assembly. In other embodiments, other configurations are possible. For example, in some embodiments, a non-cylindrical or asymmetrical profile is possible as is a different (e.g., non-chamfered) configuration at the open end 262. An asymmetrical profile may be useful, for example, to enable the use of a wide-angle insert to provide a wide-angle spray for a foaming cleaner or other product.

[0043] For purposes of describing features relating to or contained within the nozzle insert cavity 174 herein, use of the terms "axial," "radial," and "circumferential" (as well as variations thereof) are based on a reference axis corresponding to the chamber axis 172. In this regard, for example, the nozzle insert cavity 174 includes a radially outer surface 266 that extends as a generally circumferential barrel around the nozzle insert cavity 174 and defines an outer diameter 268 of the nozzle insert cavity 174. Similarly, the post 240 within the nozzle insert cavity 174 extends generally axially from a base near the stop portion 260 to a distal end 270 of the post 240 that is spaced a distance 272 from the open end 262 of the nozzle insert cavity 174. The post 240 further defines a post diameter 274, and the insert cavity 174 is further defined by an insert cavity length 276.

[0044] Generally, the shape and contour defined by the post 240 and by the nozzle insert cavity 174 are configured to generally fit over one or more portions of the nozzle insert 70 to facilitate receipt and retention of the nozzle insert 70 within the nozzle insert cavity 174. In the illustrated embodiment, for example, the post 240 and the nozzle insert cavity 174 define a generally cylindrical shape configured to engage a corresponding cylindrical (or other) feature on the nozzle insert 70. In other embodiments, for example, the post 240 and / or the nozzle insert cavity 174 may define different shapes to facilitate receipt and retention of particular nozzle inserts of other shapes and sizes.

[0045] 24, the vertical conduit 136 defines a generally round bore extending generally axially along the longitudinal axis 94. In other embodiments, for example, the vertical conduit 136 may define another cross-sectional shape, such as a rectangle, an oval, or a polygon. The fluid passage 134 includes an inlet orifice 170 and an outlet in a nozzle conduit 242. The valve seat 92 is configured to slidably receive at least a portion of the valve stem 86 therein. Referring again to FIG. 23, the nozzle conduit 242 is disposed at a second end of the inlet fluid passage 134 downstream of the valve seat 92 and configured to provide fluid communication between the inlet orifice 170 and the nozzle conduit 242.

[0046] 24, the valve seat 92 defines an inner diameter 280 that is generally larger than the diameter of the vertical conduit 136 to engage and actuate the valve stem 86. The valve seat also defines a height 282. In operation, for example, the actuator assembly 64 can be manually or automatically displaced to force engagement between the valve stem 86 and a portion of the valve seat 92. As described above, a user can press the button 130 to disengage the actuator 68 from the transportation locks 190, 192, thereby fully seating the valve seat 92 on the valve stem 86. Upon actuation of the actuator assembly 64, the engagement between the valve stem 86 and a portion of the valve seat 92 displaces the valve stem 86 such that the valve assembly opens and allows product to flow from the container 62 through the valve stem 86 and into the fluid passageway 134.

[0047] 25-29, the nozzle insert 70 is shown in greater detail. The nozzle insert 70 is configured to be at least partially inserted into the nozzle insert cavity 174, thereby promoting the dispensing of the product in the container 62 to the surroundings with proper fluid flow characteristics. In some embodiments, the nozzle insert 70 may be manufactured from a plastic material. In some embodiments, for example, the nozzle insert 70 may be manufactured from an acetal, i.e., polyoxymethylene material. In some embodiments, for example, the nozzle insert 70 may be manufactured from polypropylene, propylene, HDPE, nylon, or other copolymers or homopolymers.

[0048] The nozzle insert 70 includes a nozzle rim 290 and a nozzle body 292 extending from the nozzle rim 290. The nozzle body 292 defines a generally annular cylinder extending generally axially between the nozzle rim 290 and a generally open insert inlet end 294. The nozzle rim 290 and the nozzle body 292 are connected at a first step 296. The nozzle body 292 defines a front or first portion 298 and an aft or second portion 300 separated by a second or chamfered step 302. In other embodiments, for example, the nozzle body 292 may define other shapes, such as rectangular, elliptical, polygonal, tapered, or other shapes, as desired. Additionally, as described below, the inlet end 294 of the nozzle insert 70 may provide access to a nozzle interior cavity 304 to allow the post 240 to be slidably received within the interior cavity 304. The nozzle rim 290 further defines a nozzle front wall or rim wall 306 that defines the nozzle orifice 176 .

[0049] 27, the nozzle body 292 defines an aft portion 300 and a front portion 298 separated from one another by a chamfered step 302. A recess 310 is disposed within a portion of the nozzle rim 290, and the exit orifice 176 is disposed within a front wall 306 of the nozzle insert 70. With particular reference to FIGS. 27 and 28, the nozzle insert 70 defines a rim diameter 312, a first portion diameter 314, and a second portion diameter 316, where the rim diameter 312 is larger than the front portion diameter 314, which is larger than the aft portion diameter 316. Additionally, the rim 290 defines a rim depth 318, the front portion 298 defines a front depth 320, and the nozzle body 292 defines a body depth 322. Additionally, the aft chamfer edge 324 of the nozzle insert 70 defines a first chamfer angle 326, and the chamfer step 302 defines a second chamfer angle 328. In other embodiments, other configurations are possible.

[0050] In general, the stepped profile of the nozzle body 292 is designed to interact with the nozzle conduit 242 of the actuator 68 to provide engagement and prevent over-insertion of the nozzle body 292 into the nozzle insert cavity 174. In the illustrated embodiment, for example, the nozzle rim 290 of the nozzle insert 70 includes a stepped configuration that defines a first insert stop surface 330 that defines a radially extending surface. The first insert stop surface 330 extends generally radially inward between a rim outer surface 332 that defines the rim diameter 312 and a front surface 334 that defines the front diameter 314. The rear portion 300 also defines an aft surface 336 that is stepped further inwardly via a chamfered step 302.

[0051] As shown in FIGS. 25 and 26, the rim wall 306 includes a nozzle orifice 176 extending therethrough to provide fluid communication between the internal cavity 304 of the nozzle insert 70 and the atmosphere. With reference to FIG. 28, the orifice 176 extends through the rim wall 306 from a radially extending inner rim surface 340 to a radially extending outer rim surface 342. In some embodiments, for example, the orifice diameter 344 or other aspects of the orifice 176 can be designed to achieve a desired flow pattern and / or atomization of the fluid flowing therethrough. For example, as described below, varying the orifice diameter 344 can provide different effects or impacts that can benefit the nozzle insert 70 used with the actuator assembly 64. In the illustrated embodiment, the orifice 176 is disposed along the atomization axis 146 defined by the nozzle insert 70. In some embodiments, for example, the orifice 176 may be eccentrically positioned on the insert outlet end to provide a desired flow pattern and / or atomization of the fluid flow through the orifice 176. In some embodiments, multiple outlet orifices may be provided.

[0052] As shown in FIG. 28, the outer rim surface 342 defines a depression or recess 310 generally concentrically disposed with the orifice 176. The recess 310 defines a generally frustoconical recess in the outer rim surface 342, decreasing in diameter (relative to the spray axis 146) as the recess extends axially toward the inner rim surface 340. The recess 310 extends axially from the rim wall 306 to the outlet 350 of the orifice 176 at a location between the outer rim surface 342 and the inner rim surface 340. In other embodiments, for example, the outer rim surface 342 may define a generally flat profile with no recesses, or may define a profile with convexities, or may include multiple recesses or convexities, or recesses having a different profile than that shown. Similarly, in other embodiments, the nozzle assembly may exhibit other configurations for imparting desired flow characteristics to the product stream. For example, in some embodiments, the actuator may include various grooves or channels that lead to an outlet swirl chamber from which fluid may flow to the orifices 176 for dispersion, as described below.

[0053] 28, in particular, the radially inner surface 352 of the nozzle body 292, which partially defines the internal cavity 304 of the nozzle body 292, defines an inner diameter 354 that is generally constant along the internal cavity 194 between the inner rim surface 340 and the insert inlet end 294. In the illustrated embodiment, a plurality of ribs 356 extend generally radially inwardly from the inner surface 352 of the nozzle body 292, providing local deviations from the diameter 354 along the ribs 356. In the illustrated embodiment, the nozzle insert 70 includes four ribs 356 arranged circumferentially about the inner surface 352 in approximately 90 degree increments. In other embodiments, for example, the nozzle insert 70 can include more or fewer ribs or can include flats, any of which can be arranged circumferentially at any increment around the inner surface 352, as desired.

[0054] In the illustrated embodiment, each of the plurality of ribs 356 includes a ramp portion 358 and a spacer portion 360. Each of the plurality of ribs 356 extends axially along the inner surface 160 from between the insert inlet end 294 and the inner rim surface 340. Moving from the insert inlet end 294 toward the rim wall 306, i.e., in a direction opposite to the insertion direction, each of the plurality of ribs 356 begins with a ramp portion 358. At the junction between the ramp portion 358 and the spacer portion 360, the radially inward taper of the ramp portion 358 is discontinuous, and the spacer portion 360 extends axially to the inner rim surface 340 with a generally constant radial thickness. Additionally, as described below, the ribs 356 are configured to centrally engage or otherwise align the posts 240 of the nozzle insert cavity 174 to secure the nozzle insert 70 within the nozzle insert cavity 174.

[0055] 28 and 29, the inner rim surface 340 of the insert 70 defines a central recess 364 and a plurality of radially extending channels 366 extending from the rim wall 306 and disposed between four radially disposed swirl features 368 that are integral with the rim wall 306. The central recess 364 in combination with the channels 366 operates as a swirl chamber that operates to generate a swirl of the composition centrally at the location of the orifice 176. In the illustrated embodiment, the distribution chamber 370 of the nozzle insert defines a channel distance 372 between the parallel channels 366 and a height 374 between the ribs 356. In some embodiments, the height 374 between the ribs 356 can be designed to provide a desired swirl (or other) flow pattern such that the fluid flow is appropriately distributed around the post 240 and within the nozzle insert 70. The channels also define a channel thickness 376.

[0056] 28, a cross-sectional view of the nozzle insert 70 is shown in detail. During assembly, the post 240 of the actuator 68 is received within the internal cavity 304 of the nozzle insert 70. The post 240 engages one or more of a plurality of ribs 356 on the inner surface 160 of the nozzle insert 70. Due to the taper of the ramp portion 358, the plurality of ribs 356 are configured to guide the post 240 into a desired alignment within the internal cavity 304 (or correspondingly, to guide the nozzle insert 70 into proper alignment with the post 240 and the nozzle insert cavity 174). As the post 240 passes the junction between the ramp portion 358 and the spacer portion 360, the spacer portion 360 acts to set the alignment of the post 240 within the internal cavity 194, and correspondingly, to set the alignment of the nozzle insert 70 with the post 240 and the nozzle insert cavity 174. In the illustrated embodiment, the nozzle insert 70 is generally coaxially aligned with the nozzle insert cavity 174 after assembly. In some embodiments, the nozzle insert 70 may alternatively be aligned with the nozzle insert cavity 174 (e.g., eccentrically positioned within the nozzle insert cavity 174) after assembly.

[0057] In other embodiments, other configurations are possible. For example, the channel for product flow to one or more exit orifices of the nozzle insert can be formed on the distal end of a post similar to post 240, or in addition to, instead of being formed on an inner wall of the nozzle insert, such as rim wall 306, on other similar features. In some embodiments, a particular flow path for the product can be defined by a ridge or other protruding feature rather than a recessed channel. In some embodiments, the exit swirl chamber can have a different geometry than the swirl chamber, such as circular or other shape, and the flow path leading to the exit swirl chamber, such as channel 366, can define a curved or other flow path. In some embodiments, the exit swirl chamber can have a stepped or curved wall leading to one or more exit orifices.

[0058] Advantages of the dispensing system 60 disclosed herein will now be described with reference to FIGS. 30-39. With specific reference to FIG. 30, a first image of a sequence comparing the spray distribution patterns of the dispensing system of FIG. 1 and the prior art dispensing system is shown, FIG. 31 is a second image of the sequence, and FIG. 32 is a third image of the sequence. FIG. 30 shows a null state, i.e., a state before the actuation systems of the various dispensing systems are actuated. FIG. 31 shows a first state showing a first spray pattern 400, a second spray pattern 402, and a third spray pattern 404. The first spray pattern 400 reflects the spray pattern generated by the dispensing system 60 disclosed herein, while the second spray pattern 402 and the third spray pattern 404 show the spray patterns of the prior art sprays. The spray patterns 400, 402, 406 are further shown in a second state in FIG. 32, which occurs after the first state.

[0059] The images in the sequence of Figures 30-32 were taken at the same time in the spraying process, and thus the spray patterns 400, 402, 406 show various sprays at the same point in time after the initial actuation of the various actuators of the product dispensing system. As shown in the figures, the first spray pattern 400 and the second spray pattern 402 both dispense the spray at an angle above the horizontal (the product dispensing system 60 sprays at an angle of about 22° above the horizontal or 68° from the vertical), while the third spray pattern 404 dispenses the spray in a direction generally perpendicular to the horizontal. To achieve a preferred descent, it has been determined that having an angle greater than 0 degrees from the horizontal is beneficial, as discussed above with respect to the various preferred ranges. Additionally, as shown in Figure 32, in the second state, the first spray pattern 400 includes droplets dispensed relatively farther than the droplets of the second spray pattern 402. The increased distance is due, at least in part, to the use of compressed gas, modified composition, and increased pressure within the container 62, as disclosed herein. The increased throw distance of the dispenser 60 provides a reduced drop, as shown in the graphs and tables provided below.

[0060] With reference to Table 1 below, various aerosol sprays were simulated in a 6' x 9' bathroom to determine the perceptible fragrance coverage after 10 minutes. The simulations were performed using a full can of aerosol fragrance and a 25% full can. Thus, the two simulations test the perceptible fragrance coverage at the beginning and end of each aerosol can's life. As shown in Table 1 below, the aerosol of the dispensing system 60 outperformed other prior art aerosols in perceptible fragrance coverage for both the full can and the 25% full can. In particular, after 10 minutes, the aerosol of the dispensing system 60 filled about 96% of the bathroom when the full can was used and filled about 92% of the bathroom when the 25% full can was used. Thus, the aerosol of the dispensing system 60 has better fragrance reach than the prior art aerosols. [Table 1]

[0061] FIG. 33 is a graph showing a comparison of perceptible fragrance coverage at 100% for the dispensing system 60 of FIG. 1 using nozzle inserts 70 with various orifice diameters 344, as well as a prior art dispensing system. The data reflecting 90PP, 102PP, and 110PP show better fragrance coverage over time than Febreze®, Glade® 1, and Glade® 2. The 90PP, 102PP, and 110PP comprise dispensing systems 60, the only difference being the use of nozzle inserts 70 with various orifice diameters. The 90PP dispenser included the smallest orifice diameter 344, and the 110PP dispenser included the largest orifice diameter 344. As shown in FIG. 33, the orifice diameter 344 of the nozzle insert 70 helps to increase fragrance coverage. Additionally, all three of the data shown for the product dispensing system 60 provide increased fragrance coverage when compared to the prior art dispensing system. To that end, it has been determined that the nozzle insert 70 disclosed herein, in combination with other aspects of the product dispensing system 60 disclosed herein, is beneficial in providing increased fragrance coverage and thereby reducing dropout, and more specifically, a particular spray orifice diameter 344 has been found to provide increased coverage and reduce dropout. The spray orifice diameter 344 may be from about 0.310 mm to about 0.410 mm, or from about 0.335 mm to about 0.385 mm, or from about 0.350 mm to about 0.370 mm, or about 0.360 mm.

[0062] FIG. 34 is another graph showing a comparison of perceptible fragrance coverage for dispensing system 60 and prior art dispensing systems, but at 25%. The graph in FIG. 34 shows data reflecting the same dispensing system as FIG. 33, without the addition of the Glade® 2 dispensing system. Similar to the fragrance coverage of the dispensing system starting with a full container shown in FIG. 33, the data in FIG. 34 reflecting 90PP, 102PP, and 110PP show better fragrance coverage over time than Febreze® and Glade® 1. The 90PP, 102PP, and 110PP included dispensing system 60, with the only difference being the use of nozzle inserts 70 with various orifice diameters. The 90PP dispenser included the smallest orifice diameter 344, and the 110PP dispenser included the largest orifice diameter 344. As shown in Figure 34, the orifice diameter 344 of the nozzle insert 70 helps to increase fragrance coverage. Additionally, all three of the data presented for the product dispensing system 60 provide increased fragrance coverage when compared to prior art dispensing systems. To that end, it has been determined that the nozzle insert 70 disclosed herein, in combination with other aspects of the product dispensing system 60 disclosed herein, is beneficial in increasing fragrance coverage and thereby reducing dropoff, even when there is little product in the container, i.e., nearing the end of life (EOL) of the product dispensing system.

[0063] Figure 35 is a graph showing a comparison of the rate of drop from various spray heights for the dispensing system of Figure 1 and prior art dispensing systems. The data from Figure 35 is further illustrated in Tables 2 and 3 below, which show experimental results from percent drop tests conducted at two different heights, namely, 4 feet (122 cm) and 5 feet (152 cm), using the dispensing system 60 shown in Figure 1 and various prior art dispensing systems. [Table 2] [Table 3]

[0064] As described herein, the rate of fall test measures the amount of aerosol liquid that falls to the ground after being sprayed into the air. To perform this test, a three by six (3x6) array of scales was placed on the ground and a substrate was placed on the scale to define the spray surface. Before testing each product, the product was weighed to determine the initial weight (Wi). The product was then sprayed for five seconds in the direction of the substrate and scale at a specific height, i.e., four feet or five feet. After the aerosol spray had settled, the weight of the liquid or fallout on the substrate (Ws) was recorded and the product was weighed again to determine the final weight (Wf). The difference between the initial weight (Wi) and the final weight (Wf) and the weight of the liquid on the substrate (Ws) was used to determine the rate of fall (see formula below). After the rate of fall was measured, the substrate was replaced and the test was repeated three times for each product at each height. The rate of fall data shown in Tables 2 and 3 above is the average of three tests performed for each product at each height.

number

[0065] As shown in Tables 2 and 3 above, the dispensing system 60 produced the least amount of drop rate compared to other prior art products. In some examples, the drop rate of the dispensing system 60 assembly was generally half that of the prior art examples. Thus, the dispensing system 60 shown in FIG. 1 allows a higher percentage of the aerosol fragrance to remain suspended in the air rather than falling to the ground. Thus, the consumer can spray less product to produce the desired intensity of fragrance, thereby extending the life of the product. In some embodiments, the drop rate of the dispensing system 60 at 4 feet (122 cm) may be about 10% to about 50%, or about 15% to about 40%, or about 23% to about 36%, or about 28%, or at least 10%, or at least 15%, or at least 23%, or at least 28%. Additionally, the descent rate of the dispensing system 60 at 5 feet (152 cm) may be between about 10% and about 50%, or between about 15% and about 40%, or between about 22% and about 33%, or about 26%, or at least 10%, or at least 15%, or at least 22%, or at least 26%.

[0066] 36 and 37, graphs are shown illustrating a comparison of total drop mass of 100% and 25%, respectively, for the dispensing system of FIG. 1 and the prior art dispensing system. The graphs of FIGS. 36 and 37 show simulations of the drop mass, i.e., the drop mass that occurs during spraying of the various dispensing systems after each dispensing system has been in operation for 10 minutes. The graphs of FIGS. 36 and 37 provide further data to demonstrate that the dispensing system 60 achieves reduced drop when tested under identical conditions against the prior art dispensing system. Additionally, although different versions of the nozzle insert 70 having different orifice diameters 344 were utilized, all three of the nozzle inserts 70 performed better and produced reduced drop than the prior art.

[0067] 38 is a graph showing a comparison of the average spray pattern diameter compared to the percentage of product remaining in the container for the dispensing system of FIG. 1 and the prior art dispensing system. The data in graph 38 shows that the dispensing system 60 disclosed herein maintains a consistent average spray diameter throughout the life of the dispensing system 60, while the prior art dispensers have spray patterns that decrease in diameter over time. To that end, another advantage of the dispensing system 60 disclosed herein is that it maintains a relatively constant spray diameter over the life of the dispensing system 60, which provides a consistent user experience and the user does not have to change the amount of spray to achieve a desired fragrance coverage as the amount of product in the dispenser is reduced.

[0068] Accordingly, embodiments of the present disclosure provide an actuator assembly or nozzle insert for a product dispensing system. In some embodiments, the improved actuator assembly or nozzle insert can provide improved manufacturability and reduce defects resulting during assembly (or use) from over-compression of the nozzle insert. For example, some embodiments of the present invention provide a nozzle insert and a corresponding nozzle insert cavity in an actuator of an actuator assembly, where the first and second stop portions can mitigate the effects of over-compression of the nozzle insert. This can, for example, correspondingly reduce (e.g., eliminate) the possibility of forming defects in the actuator assembly during assembly.

[0069] In alternative embodiments, the composition may include an insecticide disposed in a carrier liquid, a deodorant liquid, and the like. The composition may also include other actives, such as fungicides, mold or mildew inhibitors, insect repellents, and / or the like. In alternative embodiments, it is contemplated that the container 62 may contain any type of pressurized product and / or mixtures thereof, and thus the product dispensing system 60 may be adapted to dispense any number of different products. In some embodiments, the container 62 may contain a liquefied, non-liquefied, or dissolved compressed gas, including one or more of the compressed gases listed above. In some embodiments, the container 62 may contain one or more of a hydrocarbon gas or hydrocarbon derivative, including acetylene, methane, propane, butane, isobutene, halogenated hydrocarbons, ethers, a mixture of butane and propane (also known as liquid petroleum gas or LPG), and / or mixtures thereof.

[0070] While the invention has been described above with reference to specific embodiments and examples, it will be understood by those skilled in the art that the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications, and departures from the embodiments are intended to be encompassed by the claims appended hereto. The entire disclosures of each patent and publication cited herein are incorporated by reference herein, as if each such patent or publication was individually incorporated by reference herein.

[0071] Any of the embodiments described herein can be modified to include any of the structures or methods disclosed in connection with the different embodiments. Furthermore, the disclosure is not limited to the types of aerosol containers specifically shown. Furthermore, the overcap of any of the embodiments disclosed herein can be modified to function with any type of aerosol or non-aerosol container. [Industrial Applicability]

[0072] In view of the foregoing description, numerous modifications to the present disclosure will be apparent to those skilled in the art. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling any person skilled in the art to make and use the present disclosure. The exclusive rights to all modifications that come within the scope of the appended claims are reserved.

Claims

1. A container having a body that defines an internal pressure, in which a composition is contained, and the pressure is at least 930 kPa; and An actuator assembly attached to the container, The actuator assembly includes A housing, An actuator disposed within the housing and having a fluid passage in fluid communication with the composition; and A nozzle insert disposed within the fluid passage and having an orifice diameter of from about 0.335 mm to about 0.385 mm and defining a nozzle orifice, The composition includes a compressed gas and from about 5 vol% to about 10 vol% ethanol, The container is configured to spray the composition with a projection distance of from 68.6 cm to 114 cm and a spray diameter of from 127 mm to 241 mm when the composition is filled from 100% to 25%, The composition is sprayed at a spray rate of from 1.2 g / s to 2.0 g / s when the container is filled from 100% to 25% with the composition, A dispensing system containing a composition comprising one or more of a deodorizing composition, an aromatic composition, and a cleaning composition.

2. The composition includes from 8 vol% to 10 vol% ethanol, The dispensing system according to claim 1.

3. The body has an outer wall that defines a thickness, and the thickness is greater than 0.50 mm, The dispensing system according to claim 1.

4. The pressure is at least 1050 kPa, The dispensing system according to claim 1.

5. The housing includes an outer wall, an upper wall, and an inner wall extending downward from the upper wall, and an internal cavity is defined between the inner wall and the outer wall, The dispensing system according to claim 1.

6. The housing further includes a first retaining arm and a second retaining arm, each of the retaining arms hanging downward from the inner wall of the housing and being integral with the inner wall of the housing, The dispensing system according to claim 5.

7. Each of the retaining arms includes a catch disposed on the inside, and the catches of the first and second retaining arms are configured to prevent over-actuation of the actuator, The dispensing system according to claim 6.

8. The actuator includes a left arm and a right arm, and the left arm and the right arm are respectively disposed in the internal cavity of the housing. The dispensing system according to claim 5.

9. The dispensing system has a spray height of 122 cm to 152 cm and a drop rate of 25% to 30%. The dispensing system according to claim 1.

10. The insert includes a central recess and a plurality of radially extending channels that are arranged radially and are disposed between four spiral shapes. The dispensing system according to claim 1.

11. Prepare a container having a body and configured to have pressure inside, and in which a composition is contained so that the pressure is at least 930 kPa. Attach an actuator assembly to the container, where the actuator assembly includes: a housing; an actuator disposed in the housing and having a fluid passage in fluid communication with the composition; a nozzle insert disposed in the fluid passage. When the container is filled with the composition in the range of 100% to 25%, it includes spraying at a projection distance of 68.6 cm to 114 cm, a spray diameter of 127 mm to 241 mm, and a spray rate of 1.2 g / s to 2.0 g / s. When the composition is sprayed from a spray height of 122 cm to 152 cm, it has a drop rate of 25% to 30%. A method of dispensing a composition comprising one or more of a deodorant composition, an aromatic composition, and a cleaning composition.

12. The valve stem of the container defines a longitudinal axis. The spray axis of the nozzle insert is offset 60° to 70° from the longitudinal axis. The method of dispensing a composition according to claim 11.

13. The composition includes a compressed gas and 5% to 10% by volume of ethanol. The method of dispensing a composition according to claim 11.

14. The insert includes a central recess and a plurality of radially extending channels disposed between four spiral mechanisms. The method of dispensing a composition according to claim 11.

15. The pressure is at least 1050 kPa. The method of dispensing a composition according to claim 11.

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