Aerosol dispensing systems

Abstract

A dispensing system for dispensing an aerosol spray of air freshening product includes a housing, a container coupled to the housing and containing the air freshening product, a nozzle defining an outlet, an actuator coupled to the housing and configured to dispense the air freshening product from the container through the outlet to form the aerosol spray, and a fan coupled to the housing and configured to generate airflow that moves toward the aerosol spray to move the aerosol spray away from the housing.

Description

AEROSOL DISPENSING SYSTEMSCROSS-REFERENCE TO RELATED PATENT APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Application No. 63 / 621,064, filed on January 15, 2024, the entire disclosure of which is hereby incorporated by reference herein.BACKGROUND

[0002] The present disclosure relates generally to air freshener aerosol sprays, methods of generating such aerosol sprays, and systems for dispensing such aerosol sprays.

[0003] Aerosol sprays are used to provide many consumer products, including air fresheners, deodorizers, disinfectants, insecticides, and cleaners. To provide such aerosol sprays, different types of dispensing systems have been developed. Some aerosol spray dispensing systems have or are connected to a power source causing the system to automatically dispense the sprays. Other types of aerosol dispensing systems are provided in containers that are actuated by a user on demand.

[0004] Even with the wide variety of dispensing systems and dispensing system configurations, for some products it can be difficult to generate an aerosol spray having desired properties. For example, in the case of air freshening products, the goal is for the system to provide the product such that a sufficient amount of fragrance experience is achieved soon after the dispensing, but also such that there is longevity in the fragrance experience. To achieve this, it is often important that the size of the particles in the aerosol spray be in a certain range, and that the particles do not greatly deviate from certain sizes. It is also often important that particles in an air freshening spray do not fall to the ground too quickly after the spray is dispensed and that the particles are discharged a sufficient distance from the dispensing system.

[0005] Many aerosol dispensing systems include a container that holds a product with liquid and gas parts. The gas included with the liquid product acts as a propellant to discharge the liquid product from the container when the system is actuated. The propellant pressurizes the container holding the liquid composition and provides a force to expel the liquid composition from the container when the system is actuated. For such systems, thereare two main types of propellants: (1) liquefied gas propellants (LPGs), such as hydrocarbon and hydro fluorocarbon (HFC) propellants, and (2) compressed gas propellants (CGAs), such as carbon dioxide and nitrogen. Generally speaking, as compared to CGA propellant systems, aerosol dispensing systems that use LPG propellants are able to produce smaller, more consistent sized particles in sprays. Thus, from a performance standpoint, systems using LPG propellants are often superior to systems using CGAs as propellants. However, LPG propellants include a high amount of volatile organic compounds (VOCs), thereby making their use subject to various regulations.SUMMARY

[0006] At least one embodiment relates to a dispensing system for dispensing an aerosol spray of an air freshening product. The dispensing system includes a housing, a container coupled to the housing and containing the air freshening product, a nozzle defining an outlet, an actuator coupled to the housing and configured to dispense an air freshening product from the container through the outlet to form the aerosol spray, and a fan coupled to the housing and configured to generate airflow that moves toward the aerosol spray to move the aerosol spray away from the housing.

[0007] Another embodiment relates to an automatic dispenser for dispensing a material. The automatic dispenser includes a housing and a volatilization unit coupled to the housing. The volatilization unit includes a container containing a volume of the material and an actuator coupled to the container and configured to form a spray of the material that extends above the housing. The automatic dispenser further includes a fan coupled to the housing and configured to generate airflow directing the spray away from the housing and a controller operatively coupled to the actuator and the fan and configured to perform a dispensing process at regular intervals. The dispensing process includes controlling the actuator to form the spray of the material and at least one of (a) controlling the fan to generate the airflow for a first period of time that ends when the actuator forms the spray of the material or (b) controlling the fan to generate the airflow for a second period of time that starts when the actuator forms the spray of the material.

[0008] Another embodiment relates to a dispensing system for dispensing an aerosol spray of a product. The dispensing system includes a housing defining an air inlet, an annular air outlet, and a ventilation passage extending from the air inlet to the annular air outlet, a fancoupled to the housing and configured to generate airflow along the ventilation passage, a container coupled to the housing and containing the product, a nozzle defining an outlet, an actuator coupled to the housing and configured to dispense the product from the container through the outlet to form the aerosol spray along a spray axis that extends upward from the nozzle and passes through the annular air outlet, a flow diverter positioned to divert a first portion of the airflow toward the spray axis and permit a second portion of the airflow to exit the ventilation passage through the annular air outlet, a heater configured to supply thermal energy to at least one of (a) the nozzle, (b) the container, or (c) the airflow within the ventilation passage, and a controller operatively coupled to the fan and the actuator. The controller is configured to control the fan to operate at a first fan speed while controlling the actuator to dispense the product from the container and control the fan to operate at a second fan speed greater than the first fan speed while the actuator is not dispensing the product from the container

[0009] This summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements.BRIEF DESCRIPTION OF THE FIGURES

[0010] The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:

[0011] FIG. 1 is an exploded view of a spray nozzle, according to an exemplary embodiment.

[0012] FIG. 2 is a top view of a membrane of the spray nozzle of FIG. 1 including a series of micropores, according to an exemplary embodiment.

[0013] FIG. 3 is a top view of a membrane of the spray nozzle of FIG. 1 including a series of micropores, according to another exemplary embodiment.

[0014] FIG. 4 is a side view of the spray nozzle of FIG. 1 forming an aerosol spray.

[0015] FIG. 5 is a perspective view of an aerosol dispensing cartridge including the spray nozzle of FIG. 1 , according to an exemplary embodiment.

[0016] FIG. 6 is a schematic view of the aerosol dispensing cartridge of FIG. 5.

[0017] FIG. 7 is a section view of an automatic dispenser including the aerosol dispensing cartridge of FIG. 5, according to an exemplary embodiment.

[0018] FIG. 8 is a block diagram of the automatic dispenser of FIG. 7.

[0019] FIG. 9 is a front perspective view of a configuration of the automatic dispenser of FIG. 7, according to an exemplary embodiment.

[0020] FIG. 10 is a top perspective view of the automatic dispenser of FIG. 9.

[0021] FIG. 11 is a bottom perspective view of a stop of the automatic dispenser of FIG.9.

[0022] FIG. 12 is a top perspective view of the automatic dispenser of FIG. 9 with the stop removed.

[0023] FIG. 13 is a front perspective view of the automatic dispenser of FIG. 9 with a cartridge partially removed.

[0024] FIG. 14 is a top perspective view of the automatic dispenser of FIG. 9 with the cartridge and the stop removed.

[0025] FIG. 15 is a front view of the automatic dispenser of FIG. 9 with a housing shown as being transparent.

[0026] FIG. 16 is a right side view of the automatic dispenser of FIG. 9 with the housing shown as being transparent.

[0027] FIG. 17 is a rear view of the automatic dispenser of FIG. 9 with the housing shown as being transparent.

[0028] FIG. 18 is a section view showing an arrangement of a fan and the spray nozzle of the automatic dispenser of FIG. 7, according to an exemplary embodiment.

[0029] FIG. 19 is a diagram showing an arrangement of a fan and the spray nozzle of the automatic dispenser of FIG. 7, according to another exemplary embodiment.

[0030] FIG. 20 is a section view showing an arrangement of a fan and the spray nozzle of the automatic dispenser of FIG. 7, according to another exemplary embodiment.

[0031] FIG. 21 is a front view of a nozzle cleaner and the cartridge of the automatic dispenser of FIG. 7, according to an exemplary embodiment.

[0032] FIGS. 22 and 23 are front views of a nozzle cleaner and the cartridge of the automatic dispenser of FIG. 7, according to another exemplary embodiment.

[0033] FIGS. 24-27 are section views of the spray nozzle of FIG. 1, according to various embodiments.

[0034] FIG. 28 is a section view showing an arrangement of a spray passage and the spray nozzle of the automatic dispenser of FIG. 7, according to another exemplary embodiment.

[0035] FIG. 29 is a section view of a piezoelectric dispenser, according to an exemplary embodiment.

[0036] FIG. 30 is a top perspective view of a piezoelectric assembly of the piezoelectric dispenser of FIG. 29, according to an exemplary embodiment.

[0037] FIG. 31 is a section view of the piezoelectric assembly of FIG. 30.

[0038] FIG. 32 is a section view of an automatic dispenser including the piezoelectric dispenser of FIG. 29, according to an exemplary embodiment.

[0039] FIG. 33 is a block diagram of the automatic dispenser of FIG. 32.DETAILED DESCRIPTION

[0040] Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.

[0041] As utilized herein, the term “aerosol spray” means a suspension of particles (solid, liquid, and / or vaporized liquid) in air or another gas. By way of example, an aerosol spray may include a combination of liquid particles and vaporized liquid particles entrained in a gas. In some configurations, the spray is dispensed from a system with the use of a propellant gas. In other configurations, sprays are formed without the use of propellant gases. Thus, as used herein, an aerosol spray may mean a collection of particles suspended in normal air with or without a further propellant gas. The aerosol spray may include a fragrance compound(s) to provide an air freshening product.Spray Nozzle

[0042] A nozzle assembly or spray nozzle unit, shown as spray nozzle 100, is shown according to various embodiments in Figures 1-3. The spray nozzle 100 may be used, for example, in automatic aerosol dispensing systems. By way of another example, the spray nozzle 100 may be used in manually-actuated aerosol dispensing systems. A spray nozzle 100 may be used to generate aerosol sprays described herein by passing a product forming the aerosol spray through the spray nozzle 100. The spray nozzle 100 may utilize the structure and have similar performance characteristics to the spray nozzles shown and described in PCT Publication No. WO2022 / 152921, which is hereby incorporated by reference in its entirety.

[0043] Referring to FIG. 1, the spray nozzle 100 includes an outlet portion, shown as plastic cap structure 102, a membrane 104, and fdters 106 for catching large particles before the particles reach the membrane 104. As shown, product enters the spray nozzle 100 through an inlet 110 positioned upstream of the fdters 106. The product passes through the fdters 106, then the membrane 104, and finally through the plastic cap structure 102 before leaving the spray nozzle 100. The product exits the spray nozzle 100 through an aperture, shown as outlet 112, defined by the plastic cap structure 102.

[0044] As shown in FIG. 2, the membrane 104 defines a series of apertures, shown as micropores 120, that are arranged in three concentric circles. One of the micropores 120, shown as micropore 122, is positioned at the center of the circles. The corresponding dispensing system in which the spray nozzle 100 is used is configured such that the product to be dispensed travels through the micropores 108 in the membrane. As a result of the product passing through the micropores in the membrane, the product emanates from thespray nozzle 100 in Rayleigh jets that subsequently break up into the aerosol particles making up the spray. Rayleigh jets are a phenomenon that occurs when discharging a liquid from a nozzle at a large velocity such that a continuous jet is formed. Due to capillary forces, the Rayleigh jets break up into droplets soon after exiting the spray nozzle 100. This results an aerosol spray having many outstanding properties, as described herein.

[0045] In some embodiments, the membrane 104 is a silicon wafer chip that may be created using manufacturing techniques that are used to produce semiconductors. Examples of such silicon wafer chips and their manufacture can be seen in U.S. Patent No. 8,936,160, No. 8,814,059, No. 9,566,398, and No. 10,632,265, which are hereby incorporated by reference in their entireties.

[0046] It should be noted that the spray nozzle 100 is not limited to the configuration depicted in FIG. 1. By way of example, filtering may be performed prior to the product entering the nozzle structure. Thus, the spray nozzle 100 may not include the filters 105 and 106.

[0047] The layout and number of the micropores 108 in the membrane 104 is not limited to the configuration shown in FIG. 1. By way of example, FIG. 3 shows an alternative configuration of the membrane 104. In this embodiment, the membrane 104 includes two concentric circles of micropores 108. In other embodiments, the micropores 108 are not positioned in circles. For example, in other embodiments, the micropores 108 are laid out in other symmetrical geometries, such as a square or star shape. Still further, in other embodiments, multiple membranes 104 are included in one spray nozzle 100, with the micropores 108 in each of the multiple membranes 104 providing parts of the total output spray from the spray nozzle 100.

[0048] One design parameter for the spray nozzle 100 is the total number of micropores 108 in the membrane 104 (z.e., the number of micropores in the spray nozzle 100). In some embodiments, the number of micropores 108 for a spray nozzle 100 ranges from 40 to 125. Other design parameters of the spray nozzle 100 are the diameter of the micropores 108 in the membrane 104 and the cone angle of the spray emanating from the micropores 108. In some embodiments, the diameters of the micropores 108 range from about 4 pm to about 10 pm. In some such embodiments, the diameters of the micropores 108 range from about 4pm to about 8 gm. In some such embodiments, the diameters of the micropores 108 range from about 4 pm to about 7 pm.

[0049] Another design parameter the spray nozzle 100 is the open area in the membrane 104 that is provided by the micropores 108 (i.e., the cross-sectional area of a micropore 108 on the surface of the membrane 104 multiplied by the number of pores). By way of example, the membrane 104 may have eighty-two micropores 108 each having a diameter of 6 pm, for a total open area of about 2318 pm2. In some embodiments, the total open area on the surface of the membrane 104 provided by the micropores 108 membranes is from about 1100 pm2to about 6150 pm2. In some such embodiments, the total open area on the surface of the membrane provided by the pores is from about 1100 pm2to about 3200 pm2. The open area for the spray nozzle 100 may be related to operating conditions for the dispensing system, particularly the means for generating the force that pushes the formulated product through the membrane. For example, in embodiments that use a pump mechanism (e.g., the pump 220), the open area provided by the pores of the membrane 104 may be correlated to the pressure force that the pump generates to cause the formulated product to move through the membrane.

[0050] Referring to FIG. 4, the spray nozzle 100 is shown producing an aerosol spray S along a spray axis SA. The aerosol spray S has a cone angle a, which is the angle of the aerosol spray S produced by the spray nozzle 100 relative to the spray axis SA. In some embodiments, the cone angle a ranges from about 0° to about 15°. In some such embodiments, the cone angle a ranges from about 5° to about 10°.Spray Nozzle Performance

[0051] Due to various structural features of the spray nozzle 100, such as inclusion of the membrane 104, the spray nozzle 100 is capable of producing aerosol sprays having properties that make the sprays useful for air freshening products. These beneficial properties may advantageously be achieved without the use of a propellant gas. One such property is the size of the particles in the spray. The particle size may be characterized by the Dv(50) of the particles, which is the diameter for which 50% of the total spray volume is made up of droplets of equal or lesser diameter. In some embodiments in which the aerosol spray is an air freshening product, the particles range in Dv(50) size from about 20 pm to about 70 pm. In some such embodiments, the particles range in Dv(50) size from about 20iim to about 45 gm. In some such embodiments, the particles range in Dv(50) size from about 20 pm to about 30 pm.

[0052] Another advantageous property of aerosol sprays produced by the spray nozzle 100 is the distribution of the sizes of the particles in the sprays. The size distribution can be quantified as the span factor, which is defined by the following equation:Dr(90) - Dv(10) Span Factor — - — — — -' Dv(50) where Dv(10) is the diameter for which 10% of the total spray volume is made of droplets of equal or lesser diameter, Dv(50) is the diameter for which 50% of the total spray volume is made of droplets of equal or lesser diameter, and Dv(90) is the diameter for which 90% of the total spray volume is made of droplets of equal or lesser diameter. In some embodiments, the span factor may range from about 0.75 to about 1.25. In some such embodiments that utilize air freshening compounds with a water formulation, the span factor for the particles may range from about 0.75 to about 1.0. In other embodiments using air freshening compounds in a solvent-based formulation, the span factor for the particles in the aerosol spray may range from about 0.80 to about 1.1.

[0053] Still other advantageous properties of aerosol sprays produced by the spray nozzle 100 are the distance that the spray particles travel from the spray nozzle 100, the low amount of fallout of the particles from the spray in the air onto the ground, and the longevity of spray particles in the air over time. Methods for determining these properties are described in PCT Publication No. WO2022 / 152921, which is hereby incorporated by reference in its entirety.

[0054] A spray experience factor is defined by the combination of spray efficacy and the negative of the span factor of the particles, where spray efficacy is defined as the negative of the product of the percent fallout and spray distance. Those skilled in the art will appreciate that the spray experience factor is indicative of the performance of an aerosol spray in a product such as an air freshener. In some embodiments where air freshening sprays are produced by the spray nozzle 100, the spray experience factor has a (negative) spray efficacy of about 0 up to about -3300 and a (negative) span factor of up to about - 1.25. In some such embodiment utilizing a water-based formulation, the spray experience factor has a spray efficacy of about 0 to about -400 and a (negative) span factor of about -0.75 to about -1.0. In other embodiments utilizing a solvent-based formulation, the spray experience factor has a spray efficacy of about -950 to about -3300 and a (negative) span factor of about -0.80 to about -1.1.

[0055] Another combination of properties of sprays that is indicative of performance is a particle quality factor, which is defined herein by the negative Dv(90) particle size for the spray and the negative of the span factor for the spray particles. As will be appreciated by those skilled in the art, Dv(90) particle size is indicative of the amount of larger size particles in a spray, e.g., a lower Dv(90) indicates a lower amount of large particles. A lower number of large particles usually equates to less fallout of the spray. In some embodiments, sprays produced by the spray nozzle 100 have a particle quality factor having a (negative) Dv(90) of up to about -90 pm and a (negative) span factor of up to about -1.25. In some such embodiments providing air freshening sprays with a water-based formulation, the particle quality factor has a (negative) Dv(90) of about -50 pm to about -65 pm and a (negative) span factor of about -0.75 to about -1.0. In other such embodiments providing air freshening sprays with a solvent-based formulation, the particle quality factor has a (negative) Dv(90) of about -40 pm to about -65 pm and a (negative) span factor of about - 0.8 to about -1.1.Aerosol Dispensing Cartridge

[0056] Referring to FIGS. 5 and 6, an aerosol dispensing system, base-container aerosol dispensing system, aerosol dispenser, handheld dispenser, automatic dispenser refill, or aerosol dispensing cartridge is shown as cartridge 200 according to an exemplary embodiment. The cartridge 200 contains a volume of product P and is configured to dispense the product P as an aerosol spray S when actuated. The cartridge 200 includes the spray nozzle 100 and may utilize the spray nozzle 100 to produce the aerosol spray S. In some embodiments, the cartridge 200 includes multiple spray nozzles 100 (e.g., facing in opposing directions). In some embodiments, the cartridge 200 is configured to be mounted within an automatic dispenser (e.g., the automatic dispenser 300). In some such embodiments, the automatic dispenser actuates the cartridge 200 to produce the aerosol spray (e.g., by depressing, rotating, or moving a portion of the cartridge 200). In some embodiments, the cartridge 200 is configured to be handheld and actuated on demand by auser (e.g., by manually depressing, rotating, or otherwise moving a portion of the cartridge 200).

[0057] The cartridge 200 includes a container (e.g., a vessel, a holder, a canister, a tank, a bottle, etc.), shown as bottle 210, that defines a storage volume 212 containing a volume of the product P. In some embodiments, the storage volume 212 is sized to contain about 30 mL of the product P. In other embodiments, the storage volume 212 is sized to contain more of the product P or less of the product P. In some embodiments, the cartridge 200 includes a conduit (e.g., a tube, a hose, a pipe, etc.), shown as dip tube 214, that extends into the bottle 210 to a bottom portion of the storage volume 212. The dip tube 214 may facilitate retrieving the product P from the bottom of the storage volume 212 (e.g., after a portion of the product P has been dispensed from the cartridge 200).

[0058] The cartridge 200 further includes an actuator, shown as pump 220, that is fluidly coupled to the bottle 210. The pump 220 may be configured to provide a flow of pressurized product P. Specifically, the pump 220 may draw the product P from the bottle 210 (e.g., through the dip tube 214) and supply the product P to the spray nozzle 100. In some embodiments, the pump 220 is configured to be actuated by an external force (e.g., applied by an external actuator, manually applied by a user, etc.).

[0059] In some embodiments, the pump 220 is a positive displacement pump, such as a reciprocating pump. For example, as a reciprocating pump, the pump can include a piston, plunger, diaphragm, or other structure that functions to provide the force that drives the product P out of the bottle 210. In other embodiments, the pump 220 is another type of positive displacement pump, such as a rotary pump. A rotary pump may include gears, lobes, screws, vanes, and / or cams that rotate to generate the force to discharge the product P from the bottle 210.

[0060] As shown, the pump 220 includes a first portion, member, or component, shown as bottle portion 222, and a second portion, member, or component, shown as nozzle portion 224. The bottle portion 222 is fixedly coupled to (e.g., adhered to, pressed onto, integrally formed with, etc.) the bottle 210. The nozzle portion 224 is fixedly coupled to the spray nozzle 100. The nozzle portion 224 is slidably coupled to the bottle portion 222, such that the nozzle portion 224 is movable relative to the bottle portion 222 along a pump axis PA of the pump 220. The pump 220 further includes a biasing element or resilient member,shown as pump spring 226, that is configured to apply a biasing force to bias the nozzle portion 224 away from the bottle portion 222. As shown, the bottle portion 222 includes a series of radial protrusions, shown as locking protrusions 228, that are angularly offset from one another along a circumference of the bottle portion 222. The locking protrusions 228 may facilitate mounting the cartridge 200 (e.g., to the automatic dispenser 300).

[0061] In operation, an external force may be applied to the pump 220 to move the nozzle portion 224 toward the bottle portion 222, positioning the pump 220 into a compressed configuration. When this external force is removed, the pump spring 226 may move the nozzle portion 224 away from the bottle portion 222, returning the pump 220 to an extended configuration (e.g., as shown in FIG. 5). The compression and extension of the pump 220 may cause the pump 220 draw the product P out of the bottle 210 and supply the product P at an elevated pressure downstream.

[0062] The cartridge 200 further includes a flow control valve, shown as precompression valve 240, that fluidly coupled to an inlet of the spray nozzle 100 and to an outlet of the pump 220. The precompression valve 240 may fluidly decouple the pump 220 from the spray nozzle 100 until a threshold pressure is achieved upstream of the precompression valve 240. When a pressure at an inlet to the precompression valve 240 (e.g., the pressure at the outlet of the pump 220) meets or exceeds the threshold pressure, the precompression valve 240 permits the product to flow from the pump 220, through the precompression valve 240, and out through the spray nozzle 100. In this way, the precompression valve 240 provides a highly linear delivery of pressure, which results in a consistent flow of the product P out of the system.

[0063] In some embodiments, the spray axis SA is oriented such that the cartridge 200 sprays upward (e.g., the spray axis SA is vertical). In some such embodiments, the spray axis SA is aligned with the pump axis PA. In other embodiments, the spray axis SA extends laterally, such that the cartridge 200 sprays laterally outward. By way of example, the spray axis SA may be oriented horizontally and perpendicular to the pump axis PA. By way of another example, the spray axis SA may be oriented upward and laterally outward (e.g., between 0 degrees and 90 degrees from vertical).Composition of Dispensed Product

[0064] Different formulations are used in a myriad of commercial products to deliver fragrance in the air. Single phase base-container CGA aerosol dispensing systems tend to have water-based formulations that typically include water, emulsifier, and fragrance. At other times, water-based formulations are used in conjunction with an LPG to create a dual phase formulation. In such cases, the product is shaken to disperse the LPG within the water formulations. Automatic aerosol dispensing systems often rely on the LPG propellant as a co-solvent for the fragrance. In such automatic devices the fragrance is dissolved in an organic solvent and is blended with the LPG to create a single-phase formulation. Diffusing systems use fragrance oil that usually consist of aroma chemicals mixed with various solvents.

[0065] In some embodiments, the product P dispensed by the cartridge 200 is an air freshener composition, air freshening compound, or air freshening formulation. In some such embodiments, the product P is an air freshening computing having a water-based formulation comprising water, emulsifier, and fragrance oil, as follows:

[0066] In other embodiments, product P is an air freshening compound having a solventbased formulation having a co-solvent, such as an alcohol, to facilitate the solubilization of the ingredients. Preferably, the co-solvent is a low molecular weight monohydric C alcohol, such as ethanol, propanol, isopropanol, butanol, or isobutanol. Other co-solvents, such as acetone, may also be included in the aerosol composition. In a general embodiment, an emulsifier may be present as set forth above. If the co-solvent is present in the composition in an amount that is insufficient to form an emulsion without the presence of the emulsifier, the emulsifier can be present in such instance in an amount ranging from about 0.4 to about 4 wt.%. Additional adjuvants, such as fragrances, corrosion inhibitors, pH adjustors, antimicrobials, preservatives, and the like, may also be included. Preferred individualranges for the above-listed adjuvants are from 0 to about 5 wt.%, more preferably from 0 to about 2 wt.%.

[0067] In another embodiment, the aerosol composition could consist of just the fragrance oils that are developed by Givaudan Company of Vernier, Switzerland, Takasago International Corporation of Tokyo, Japan, and Surmise AG of Holzminden, Germany. Such products are typically used in plug in scented oils or diffusers. Additionally, the fragrance oil could be added to a solvent such as low vapor pressure solvent such as DPMA (dipropylene glycol ether acetate), Isopar™ M (by ExxonMobil Chemical Company of Irving, Texas), DPM (dipropylene glycol monomethyl ether), ethanol, and combinations thereof, can be used to add vapor pressure to enhance the fragrance experience and less fallout. Additionally, low-VOC formulations could be created using low-VOC solvents. For low-VOC formulations, a class of materials includes acetone, dimethyl carbonate, methyl acetate, parachlorobenzotrifluoride (sold under the brand name OXSOL® 100 by Mana of New York, New York), tert-butyl acetate, and propylene carbonate. For solventbased formulations, the air freshening composition may be as follows:

[0068] Due to the inclusion of the pump 220, the cartridge 200 is capable of producing the aerosol sprays S without a propellant gas. Because the propellant gas is neither required nor included, the cartridge 200 will not be subject to the regulations associated with systems using VOC-containing propellant gases, such as LPGs. However, due to the structure of the spray nozzle 100, the cartridge 200 may still provide product sprays having equivalent or better properties to sprays generated in LPG systems. Moreover, the sprays from the cartridge 200 may be superior to sprays generated from other types of systems that do not use VOC-containing propellant gases, such as CGAs.Automatic Dispenser

[0069] Referring to FIGS. 7 and 8, an automatic aerosol dispensing system or stationary aerosol dispenser is shown as automatic dispenser 300, according to an exemplaryembodiment. In some embodiments, the automatic dispenser 300 controls the cartridge 200 to release the product. The automatic dispenser 300 provides a metered spray over an extended period of time, such as several weeks. By way of example, the automatic dispenser 300 may automatically (e.g., without a user input) control the cartridge 200 to dispense an aerosol spray S at regular intervals.

[0070] The automatic dispenser 300 includes a chassis, frame, enclosure, or housing, shown as housing 310. As shown, the housing 310 includes a first wall or inner wall, shown as interior wall 312, and a second wall or outer wall, shown as exterior wall 314, that is fixedly coupled to the interior wall 312. In other embodiments, the housing 310 includes more or fewer walls or other support structures. In some embodiments, the housing 310 is substantially cylindrical. In other embodiments, the housing 310 is otherwise shaped.

[0071] The housing 310 may support and / or contain (e.g., enclose) the other components of the automatic dispenser 300. As shown, the interior wall 312 of the housing 310 defines a recess or volume, shown as cartridge receptacle 320, that receives the cartridge 200. The housing 310 further includes a protrusion, shown as stop 322, positioned along the cartridge receptacle 320. The stop 322 is positioned to limit movement of the cartridge 200 out of the cartridge receptacle 320 (e.g., upward movement of the cartridge 200). In some embodiments, the stop 322 is removably coupled to the interior wall 312. By removing the stop 322, the housing 310 may permit removal of the cartridge 200 from the cartridge receptacle 320 (e.g., when the product P has been emptied from the cartridge 200). The cartridge 200 may be replaced with a new cartridge 200 or refilled. The filled cartridge 200 may be placed within the cartridge receptacle 320, and the stop 322 may be coupled to the interior wall 312.

[0072] In some embodiments, the housing 310 defines a passage or pathway, shown as spray passage 330, within the interior wall 312. As shown, the spray passage 330 is in fluid communication with the spray nozzle 100. The spray nozzle 100 introduces the aerosol spray S into the spray passage 330, and the aerosol spray S passes through the spray passage 330 before exiting the housing 310 into the surrounding atmosphere. In other embodiments, spray passage 330 is omitted, and the spray nozzle 100 introduces the aerosol spray S directly into the surrounding atmosphere.

[0073] As shown in FIG. 7, the housing 310 defines one or more passages or pathways, shown as ventilation passage 340. The ventilation passage 340 facilitates directing air through the housing 310. As shown, the ventilation passage 340 extends between the interior wall 312 and the exterior wall 314 (e.g., such that at least a portion of the ventilation passage 340 is annular). The housing 310 defines a series of apertures or inlets, shown as air inlets 342, in fluid communication with (e.g., fluidly coupled to) the ventilation passage 340. The air inlets 342 may be positioned to introduce air from the surrounding atmosphere into the ventilation passage 340. The housing 310 defines one or more apertures or outlets, shown as nozzle ventilation outlets 344, in fluid communication with the ventilation passage 340. The nozzle ventilation outlets 344 may be positioned to direct air from the ventilation passage 340 toward the spray nozzle 100. By way of example, the nozzle ventilation outlets 344 may be in fluid communication with the spray passage 330. The housing 310 defines one or more apertures or outlets, shown as air outlet 346, in fluid communication with the ventilation passage 340. The air outlet 346 may be positioned to direct air from the ventilation passage 340 toward the aerosol spray S. By way of example, the air outlet 346 may direct air upward.

[0074] Referring to FIGS. 7 and 8, the automatic dispenser 300 includes one or more deflectors or diverters (e.g., panels, scoops, etc.), shown as flow diverters 350, coupled to the housing 310. The flow diverters 350 may control the flow of air to the nozzle ventilation outlet 344 and the air outlet 346. By way of example, the flow diverters 350 may extend into the ventilation passage 340 to redirect a portion of the airflow through the ventilation passage 340 (e.g., toward the spray nozzle 100). The flow diverters 350 may permit the remaining airflow to continue along the ventilation passage 340 and exit through the air outlet 346. In some embodiments, the flow diverters 350 are static (e.g., have a fixed position relative to the housing 310). In other embodiments, the flow diverters 350 are repositionable relative to the housing 310 (e.g., manually, by an actuator, etc.). In some such embodiments, the automatic dispenser 300 includes flow diverter actuators 352 that are configured to reposition the flow diverters 350 relative to the housing 310. The flow diverters 350 may be repositionable to variably control the airflow through the ventilation passage 340. By way of example, a flow diverter 350 may be repositioned to extend further into the ventilation passage 340 to direct a greater portion of the airflow to a particular outlet. By way of another example, a flow diverter 350 may be repositioned to block an outlet and prevent air from passing through the outlet.

[0075] Referring to FIGS. 7 and 8, the automatic dispenser 300 further includes one or more blowers or ventilators, shown as fans 360. The fans 360 are configured to generate airflow to facilitate operation of the automatic dispenser 300. As shown in FIG. 7, a fan 360 is coupled to the housing 310 and positioned within the ventilation passage 340.During operation, the fan 360 draws in air through the air inlets 342 and directs the air toward the nozzle ventilation outlets 344 and the air outlet 346. FIG. 7 illustrates various possible airflow paths AF through the ventilation passage 340. In some embodiments, the fan 360 provides a positive pressure within the housing 310 (e.g., within the ventilation passage 340, within the spray passage 330, etc.). In other embodiments, the fan 360 provides a negative pressure within the housing 310 (e.g., to draw product out of the housing 310 or off of the spray nozzle 100). In some embodiments, airflow from the fan 360 cools various components of the automatic dispenser (e.g., actuators, the controller 450, etc.).

[0076] As shown in FIG. 7, the fan 360 includes a series of impellers, propellers, or vanes, shown as fan blades 362, and an actuator (e.g., an electric motor), shown as fan motor 364. The fan motor 364 is coupled to the housing 310. The fan motor 364 may be configured to drive rotation of the fan blades 362 to operate the fan 360. In other embodiments, the fan motor 364 is omitted, and the fan 360 is otherwise powered. By way of example, the fan 360 may be powered by a motor of another component (e.g., the motor 372 of the pump actuator 370). By way of another example, the fan 360 may be coupled to the cartridge 200 such that the fan 360 is powered by motion of the cartridge 200.

[0077] Referring to FIGS. 7 and 8, the automatic dispenser 300 further includes an actuating mechanism, shown as pump actuator 370, that is configured to actuate the pump 220 of the cartridge 200. The pump actuator 370 may be coupled to the housing 310. As shown, the pump actuator 370 is positioned below the cartridge 200. In some embodiments, the pump actuator 370 is otherwise positioned.

[0078] As shown, the pump actuator 370 includes an actuator (e.g., an electric motor), shown as motor 372, and a cartridge interface or interface member, shown as cam 374. The motor 372 is configured to drive movement of the cam 374. Specifically, the motor 372 causes the cam 374 to rotate about an axis of rotation 376 (e.g., a horizontal axis, a lateral axis, etc.). As the cam 374 rotates, the cam 374 applies an upward force on the bottle 210of the cartridge 200. This upward force is resisted by the stop 322, compressing the pump 220. As the cam 374 continues to rotate, the cam 374 moves downward, away from the stop 322 and permits the pump 220 to expand. Accordingly, each rotation of the cam 374 completes one actuation cycle of the pump 220. In other embodiments, the pump actuator 370 is another type of actuator that controls actuation of the pump 220 (e.g., a screw-based linear actuator, a solenoid, a motor directly coupled to the pump 220 and configured to actuate an impeller or other element within the pump 220, etc.).

[0079] The automatic dispenser 300 further includes a sensor, shown as pump actuator sensor 378, that is configured to provide sensor data relating to operation of the pump actuator 370. In some embodiments, the pump actuator sensor 378 includes a position sensor (e.g., an angular position sensor, such as an optical encoder or potentiometer) that is configured to indicate a current position of the cam 374. In some embodiments, the pump actuator sensor 378 includes a current sensor that indicates an electrical current being delivered to the motor 372 of the pump actuator 370. A correlation between the force applied to the cartridge 200 by the pump actuator 370 and the current may be predetermined (e.g., and stored in the memory 454), such that the current indicates the force on the cartridge 200. In some embodiments, the pump actuator sensor 378 includes a force sensor (e.g., a load cell or strain gauge) that measures the force directly.

[0080] Referring to FIG. 7, the automatic dispenser 300 further includes a pair of biasing elements or resilient members (e.g., springs, dampers, combination spring / dampers, etc.), shown as compressible member 380 and compressible member 382. The compressible member 380 extends between the stop 322 and the nozzle portion 224 of the pump 220. The compressible member 382 extends between the bottle 210 and the pump actuator 370. Accordingly, the compressive force of the pump actuator 370 is applied to the cartridge 200 through the compressible members 380 and 382, and the compressible members 380 and 382 are compressed when the pump actuator 370 is cycled.

[0081] The compressible members 380 and 382 are each compressible but apply a resistive force or biasing force that resists the compression. By way of example, the compressible member 380 may act as a spring, applying a resistive force that opposes compression and varies based on the degree to which the compressible member 380 is compressed (e.g., proportionally to the compression distance). By way of another example,the compressible member 380 may act as a damper, applying a resistive force that opposes compression and varies based on the speed of compression (e.g., proportionally to the speed of compression). In some embodiments, the compressible member 380 acts as both a spring and a damper. By way of example, the damping properties may resist fast compression of the compressible member 380, and the spring properties may facilitate returning the compressible member 380 to the original (i.e., uncompressed) configuration at the end of the pumping cycle. The compressible member 382 may function similarly to the compressible member 380.

[0082] In some embodiments, the compressible members 380 and 382 are formed from a flexible material such as rubber or plastic (e.g., polypropylene). In some embodiments, the compressible members 380 and 382 are formed from material in a configuration that facilitates compression (e.g., in a coiled configuration, in a corrugated configuration, etc.). By way of example, the compressible members 380 and 382 may be formed from cardboard. In some such embodiments, the carboard is corrugated to facilitate compression. By way of another example, the compressible members 380 and 382 may each be formed from a rubber O-ring or packing. The annular shape of the O-ring may be desirable for the compressible member 380, as it may permit the spray nozzle 100 to pass through the compressible member.

[0083] In some embodiments, the compressible member 380 is omitted, and the nozzle portion 224 of the pump 220 directly engages the stop 322. In some embodiments, the compressible member 382 is omitted, and the pump actuator 370 directly engages the bottle 210. In some embodiments, both the compressible member 380 and the compressible member 382 are omitted.

[0084] Referring to FIGS. 7 and 8, the automatic dispenser 300 includes a series of thermal management units or thermal management devices (e.g., heaters, heating elements, coolers, etc.), shown as heaters 390. The heaters 390 are configured to provide thermal energy to heat various parts of the automatic dispenser 300. By way of example, the heaters 390 may be resistive heaters that supply thermal energy in response to receiving electrical energy. As shown, a first heater 390 is coupled to the spray nozzle 100 and configured to heat the spray nozzle 100. A second heater 390 is coupled to the bottle 210 and configured to heat the bottle 210 and the product P within the bottle 210. A third heater 390 ispositioned within the ventilation passage 340 and configured to heat the air that is directed by the fan 360. This heated air may flow throughout the automatic dispenser 300, such that this heater 390 indirectly heats multiple components of the automatic dispenser 300. In some embodiments, one or more of these heaters 390 are omitted, or other heaters 390 are added. In some embodiments, a single heater 390 directly heats multiple components. By way of example, a heater 390 may be positioned to heat both the bottle 210 and the spray nozzle 100.

[0085] Referring still to FIGS. 7 and 8, the automatic dispenser 300 further includes a cleaning assembly, shown as nozzle cleaner 400, coupled to the housing 310. The nozzle cleaner 400 is configured to remove undesirable or obstructive material, such as dispensed product or debris (e.g., dust, dirt, etc.) from the spray nozzle 100. The nozzle cleaner 400 includes a cleaning element (e.g., a wiper, an adsorber, an absorber, etc.), shown as cleaning element 402. The cleaning element 402 is configured to engage and remove the material from the spray nozzle 100. In some embodiments, the cleaning element 402 includes a wiper (e.g., a squeegee) that moves the obstructive material across and off of the spray nozzle 100. In some embodiments, the cleaning element 402 includes an absorbent material that absorbs the obstructive material into the cleaning element 402. In some embodiments, the cleaning element 402 includes an adsorbent material that adsorbs the obstructive material onto the surface of the cleaning element 402. In some embodiments, the obstructive material evaporates from the cleaning element 402 over time. In some embodiments, the cleaning element 402 is removal to facilitate cleaning or replacement.

[0086] In some embodiments, the nozzle cleaner 400 includes an actuator, shown as cleaner actuator 404, that is configured to move the cleaning element 402 relative to the spray nozzle 100. The cleaner actuator 404 may move the cleaning element 402 onto the spray nozzle 100 for cleaning, then away from the spray nozzle 100 to prevent the cleaning element 402 from obstructing the spray nozzle 100. In some embodiments, the cleaner actuator 404 includes an electric motor. In some embodiments, the cleaner actuator 404 is omitted, and the cleaning element 402 is passively repositioned (e.g., based on movement of the cartridge 200, as shown in FIGS. 22 and 23).

[0087] Referring to FIG. 8, the automatic dispenser 300 includes a vibratory actuator or vibrator, shown as agitator 410. The agitator 410 may be configured to cause the housing310 to shake or vibrate. By way of example, the agitator 410 may include an eccentric rotating mass that is rotated by an electric motor. By vibrating the housing 310, the agitator 410 may also cause other components coupled to the housing 310 to vibrate.

[0088] Referring to FIG. 8, the automatic dispenser 300 includes a control circuit, shown as controller 450, that is configured to control operation of the automatic dispenser 300. The controller 450 includes a processing circuit, shown as processor 452, and a memory device, shown as memory 454. The memory 454 may store one or more instructions that, when executed by the processor 452, cause the automatic dispenser 300 to perform the functions described herein. As shown in FIG. 8, the controller 450 is operatively coupled to the flow diverter actuators 352, the fans 360, the pump actuator 370, the pump actuator sensor 378, the heaters 390, the nozzle cleaner 400, and the agitator 410. The controller 450 may receive information (e.g., data, electrical signals, etc.) from and / or provide commands (e.g., data, electrical signals, etc.) to the flow diverter actuators 352, the fans 360, the pump actuator 370, the pump actuator sensor 378, the heaters 390, the nozzle cleaner 400, and the agitator 410.

[0089] The automatic dispenser 300 includes an input / output device, shown as user interface 456, operatively coupled to the controller 450. The user interface 456 may include one or more output devices (e.g., lights, buttons, speakers, screens, haptic feedback devices, etc.) that provide information to a user. The user interface 456 may include one or more input devices (e.g., buttons, switches, knobs, touch screens, microphones, etc.) that receive information (e.g., commands) from a user.

[0090] The automatic dispenser 300 includes one or more first electrical energy supplies or energy storage devices (e.g., batteries, capacitors, etc.), shown as batteries 460. The batteries 460 store electrical energy. The batteries 460 provide the stored electrical energy to the other components of the automatic dispenser 300 to power the automatic dispenser 300.

[0091] The automatic dispenser 300 includes a second electrical energy supply or external electrical energy source, shown as power connector 462. The power connector 462 is configured to electrically couple to an external source of electrical energy (e.g., a USB power supply, a household power outlet, a power grid, a solar panel, a generator, etc.). The power connector 462 may receive electrical energy from the external source and supply theelectrical energy to the other components of the automatic dispenser 300. By way of example, the power connector 462 may be used to charge the batteries 460. In some embodiments, the batteries 460 are omitted, and the automatic dispenser 300 is powered solely through the power connector 462. In some embodiments, the power connector 462 is omitted, and the automatic dispenser 300 is powered solely by the batteries 460. In such an embodiment, the batteries 460 may be removable for charging or disposal.

[0092] In operation, the controller 450 is configured to control the automatic dispenser 300 to automatically dispense product (e.g., perform a dispensing process) at regular intervals (e.g., hourly, once every ten minutes, once per minute, etc.). In some embodiments, the controller 450 controls the automatic dispenser 300 to automatically dispense the product according to a predetermined schedule (e.g., set by a user). The controller 450 may initiate a dispensing event by controlling the pump actuator 370 to cycle the pump 220 one time (e.g., compressing and expanding the pump 220). In some embodiments, each dispensing cycle releases less than 50 uL of product. In some such embodiments, each dispensing event releases approximately 30pL of product.Advantageously, the automatic dispenser 300 may have similar or better fragrance delivery performance than CGA propellant systems that require 60-65 LIL of product per dispensing event.

[0093] The delay between dispensing events may be selected by a user (e.g., through the user interface 456). The delay may control an intensity level of a fragrance delivered by the automatic dispenser 300. By way of example, increasing the delay may decrease the fragrance intensity, as the product has more time to dissipate between dispensing events. In some embodiments, the delay is one of 10 minutes, 15 minutes, 20 minutes, 30 minutes, or 40 minutes. In some such embodiments, the controller 450 permits the user to select from between two or more of these delays. During testing, a delay of 15 minutes was found to be optimal for a room of 1500 ft2.

[0094] Referring to FIGS. 9-17, an automatic dispenser 500 is shown according to an exemplary embodiment. The automatic dispenser 500 of FIGS. 9-17 represents one possible configuration of the automatic dispenser 300 shown in FIGS. 7 and 8. As such, any description with respect to the automatic dispenser 300 of FIGS. 7 and 8 may also apply to the automatic dispenser 500, except as otherwise specified herein.

[0095] The automatic dispenser 500 includes a stop 322 that is removably coupled to the interior wall 312 of the housing 310. The stop 322 defines an aperture, shown as nozzle aperture 502, through which the spray nozzle 100 is exposed. The spray passage 330 may be omitted, such that the spray nozzle 100 dispenses the aerosol spray S directly into the surrounding atmosphere. The stop 322 includes a first series of radial protrusions, shown as locking protrusions 510, that extend radially outward from a circumference of the stop 322. The locking protrusions 510 are each angularly offset from one another. The housing 310 includes a second series of radial protrusions, shown as locking protrusions 512, that extend radially inward from the interior wall 312 of the housing 310. The locking protrusions 512 are each angularly offset from one another.

[0096] FIGS. 10-14 illustrate a method of removing the cartridge 200 from the automatic dispenser 500, according to an exemplary embodiment. In FIG. 10, the stop 322 is an installed configuration within the housing 310. In the installed configuration, the locking protrusions 510 each engage one of the locking protrusions 512, preventing removal of the stop 322. To free the stop 322, the stop 322 is rotated until the locking protrusions 510 disengage from the locking protrusions 512, and the stop 322 can be freely removed. As shown in FIG. 13, the cartridge 200 can be lifted out of the cartridge receptacle 320 and replaced or refilled. This process can be followed in reverse with a filled cartridge 200 to prepare the automatic dispenser 500 for operation.

[0097] FIGS. 9 and 17 illustrate the user interface 456 of the automatic dispenser 500. The user interface 456 includes a pair of input devices, shown as touch buttons 520, and an output device, shown as intensity indicator 522. The touch buttons 520 and the intensity indicator 522 may facilitate a user selecting an intensity setting for the automatic dispenser 500. The intensity setting may represent a fragrance intensity provided by the automatic dispenser 500. By way of example, the controller 450 may use the intensity setting to select an interval between dispensing events. In response to a user pressing a first touch button 520, the controller 450 may increase the intensity setting. In response to the user pressing a second touch button 520, the controller 450 may decrease the intensity setting.

[0098] The intensity indicator 522 may include a series of light sources (e.g., LED indicators). The controller 450 may use the intensity indicator 522 to indicate various information to a user (e.g., by changing which of the light sources are illuminated, bychanging a color of the light sources, by changing a brightness of the light sources, by flashing the light sources at a given frequency, etc.). By way of example, the controller 450 may control the intensity indicator 522 to indicate the current intensity setting to a user (e.g., by controlling how many of the light sources are illuminated). By way of another example, the controller 450 may control the intensity indicator 522 to indicate a fill level of the cartridge 200 (e.g., that the cartridge 200 should be replaced or refilled). By way of another example, the controller 450 may control the intensity indicator 522 to indicate a charge level of the batteries 460.

[0099] The user interface 456 further includes a sliding switch, shown as mode selector 524. The mode selector 524 may be used to select an operating mode of the automatic dispenser 500. Based on the position of the mode selector 524, the controller 450 may change between (a) an off position in which the automatic dispenser 500 is powered off, (b) a 24 hour mode in which the automatic dispenser 500 operates consistently through the entire day, and (c) a day / night mode in which intensity setting of the automatic dispenser 500 decreases at night.

[0100] FIGS. 15-17 illustrate the pump actuator 370 of the automatic dispenser 500. The pump actuator 370 includes a power transmission, shown as gearbox 530, that couples the motor 372 to the cam 374. The gearbox 530 may provide a gear reduction that decreases the speed and increases the torque applied to the cam 374 relative to the speed and torque of the motor 372.

[0101] The pump actuator 370 further includes a sliding element or support (e.g., a platform, a plunger, etc.), shown as plunger 532, that is slidably coupled to the housing 310 and the gearbox 530. The housing 310 and the gearbox 530 may constrain motion of the plunger 532 to solely vertical motion (e.g., upward and downward motion). The plunger 532 is positioned beneath the cartridge 200 such that the plunger 532 contacts a bottom surface of the cartridge 200. The plunger 532 extends between the cartridge 200 and the cam 374. The plunger 532 may transfer upward force from the cam 374 to the cartridge 200, distributing the upward force of the cam 374 along the bottom surface of the cartridge 200.

[0102] As shown in FIG. 15, the pump actuator sensor 378 is positioned to engage the pump actuator sensor 378 when the plunger 532 is in a lowermost position. As the plunger532 is lifted by the cam 374, the plunger 532 may disengage from the pump actuator sensor 378. The pump actuator sensor 378 may indicate whether or not the plunger 532 is currently engaging the pump actuator sensor 378 to provide the controller 450 with an indication of a current position of the plunger 532.Features for Reducing Fallout and Spitting

[0103] Unlike handheld dispensing systems that are transported by a user during operation, the automatic dispenser 300 may remain in a given place for an extended period of time. By way of example, a user may place the automatic dispenser 300 on a table, shelf, or counter. The automatic dispenser 300 may remain there, undisturbed, until the user has to recharge the batteries 460 or replace the cartridge 200. Throughout this period of time, the automatic dispenser 300 may complete many operation cycles and may dispense a significant volume of product. As the aerosol spray is directed in the same way each time, any product that falls nearby the automatic dispenser 300 may collect on the nearby surfaces. This collected product may be visible to a user, leading to poor user satisfaction. Accordingly, it is advantageous for the product to be moved far from the automatic dispenser 300 and dispersed throughout the surrounding room. This dispersion also improves the air freshening performance of the product. If this cannot be achieved, it is secondarily advantageous to capture any fallen product within the automatic dispenser 300 instead of on the surrounding surfaces.

[0104] Some particles are not successfully dispersed due to product fallout. Product fallout occurs when the product is successfully sprayed into the surrounding air, but the product falls to the ground nearby the automatic dispenser 300 before it is successfully dispersed (e.g., due to the large size of the particles).

[0105] Other particles are not successfully dispersed due to spitting. Spitting occurs when particles of product combine to form large droplets. In some embodiments, the droplets produced during spitting are about 1 mm in diameter, which is significantly larger than the particles of about 37 pm that a produced during a successful dispersal. These large droplets struggle to leave the spray nozzle 100 and often immediately fall to the ground. One known source of spitting is when product from a prior dispensing event pools on or around the outlet 112 of the spray nozzle 100. This obstructive material then obstructs the productleaving the spray nozzle 100 in subsequent dispensing events, robbing the subsequent sprays of kinetic energy and forming large droplets.

[0106] The automatic dispenser 300 includes various features that are intended to prevent or remediate product fallout and spitting. Although these features may be discussed separately, it should be understood that the automatic dispenser 300 may utilize any of these features separately or any combination of these features to optimally prevent or remediate product fallout and spitting.Airflow Control to Address Fallout

[0107] In some embodiments, the automatic dispenser 300 includes one or more fans 360 positioned to direct airflow toward the aerosol spray S. The airflow catches the particles within the aerosol spray and directs them away from the automatic dispenser 300. Directing particles upward (e.g., through an upward-facing fan 360) may increase the distance between the particles and the ground, giving the particles more time to disperse throughout the air. Directing the particles horizontally (e.g., through a horizontally- facing fan 360) may distribute the particles over a larger area, reducing the fallout density of the product that still experiences fallout (i.e., the amount of product fallout within a given area). The inclusion of the fan 360 arranged to direct airflow toward the aerosol spray S may decrease the amount of time required distribute the product throughout a room. Through experimental testing, the inclusion of a fan 360 arranged to direct airflow toward the aerosol spray S has proven to significantly decrease product fallout.

[0108] FIGS. 7, 18, and 19 illustrate various configurations of the fan 360 that direct airflow toward the aerosol spray S. Referring to FIG. 7, the fan 360 is positioned below the spray nozzle 100 and directed upward. The ventilation passage 340 is shaped such that airflow leaves the air outlet 346 in an upward direction (e.g., vertically) along a fan axis FA. In the embodiment of FIG. 7, the fan axis FA is aligned with the spray axis SA. The airflow leaving the air outlet 346 has an annular shape (e.g., an annular column) surrounding the spray S. This annular shape may discourage lateral movement of the product that would otherwise cause the product to escape the annular airflow. The airflow that exits through the nozzle ventilation outlets 344 may pass through the center of the spray S, further encouraging movement of the product along the fan axis FA.

[0109] Referring to FIG. 18, an alternative fan configuration of the automatic dispenser 300 is shown according to an exemplary embodiment. This configuration may be substantially similar to the configuration of FIG. 7, except as otherwise stated. In the configuration of FIG. 18, the fan 360 is arranged above spray nozzle 100 and positioned to direct airflow laterally, toward the spray axis SA. The ventilation passage 340 redirects the airflow from the fan 360 upward, and the airflow leaves the air outlet 346 in an upward direction (e.g., vertically) along a fan axis FA. The fan axis FA may represent the general direction of the airflow after leaving the automatic dispenser 300. In the embodiment of FIG. 18, the fan axis FA is aligned with the spray axis SA. The airflow leaving the air outlet 346 has an annular shape surrounding the spray S. A bottom portion of the spray passage 330 is exposed to the surrounding atmosphere. The annular shape of the airflow leaving the air outlet 346 entrains air from the surrounding environment through the spray passage 330, which further encourages movement of the product along the fan axis FA. Accordingly, the total airflow along the fan axis FA is greater than the airflow leaving the fan 360.

[0110] In some embodiments, the portion of the housing 310 shown in FIG. 18 is otherwise oriented relative to the spray axis SA of the spray nozzle 100. By way of example, an angle between the fan axis FA and the spray axis SA may be greater than 0 degrees (e.g., greater than 0 degrees and less than or equal to 90 degrees). In such an arrangement, the airflow along the fan axis FA causes the product from the aerosol spray S to move laterally.

[0111] Referring to FIG. 19, an alternative fan configuration of the automatic dispenser 300 is shown according to an exemplary embodiment. In this embodiment, the ventilation passage 340 is omitted, and airflow from the fan 360 is directly exposed to the aerosol spray S. Airflow leaves the fan 360 along a fan axis FA. The fan axis FA is arranged at an angle 0 relative to the spray axis SA. In some embodiments, the angle 0 is 0 degrees, and the airflow directs the product upward, along the spray axis SA. In some embodiments, the angle 0 is 90 degrees, and the airflow directs the product horizontally, perpendicular to the spray axis SA. In some embodiments, the angle 0 is between 0 and 90 degrees, and the airflow directs the product both upward and horizontally.

[0112] In some embodiments, the controller 450 controls the operation of the fans 360 to minimize fallout. The controller 450 may control a fan 360 to operate for a period of time (i.e., a fan operation period) before and / or after to dispensing the aerosol spray S. In some embodiments, the fan operation period includes a period of time before dispensing the aerosol spray S. This may facilitate the airflow through the automatic dispenser 300 reaching a steady state condition prior to dispensing, which may prevent fallout. In some embodiments, the controller 450 activates the fan 360 for a period of time (e.g., at least 2 seconds) prior to dispensing the aerosol spray S. In some embodiments, the fan operation period includes a period of time after dispensing the aerosol spray S (e.g., after the dispensing has ceased). This may facilitate moving the product away from automatic dispenser 300, which may prevent fallout. In some embodiments, the period of time after the dispensing has ceased is longer than the period of time prior to dispensing the aerosol spray S. In some embodiments, the controller 450 continues to operate the fan 360 for at least 5 seconds after the dispensing has concluded or ceased. In some such embodiments, the controller 450 continues to operate the fan 360 for at least 10 seconds after the dispensing has concluded. After conclusion of the fan operation period, the controller 450 may deactivate the fan 360 to conserve energy and reduce noise.

[0113] In some embodiments, the controller 450 operates the fan 360 continuously and at a constant speed throughout the fan operation period. In some embodiments, during the fan operation period, the controller 450 repeatedly pulses the fan 360 by changing a fan speed of the fan 360 from a high speed to a low speed (i.e., decreasing the fan speed), then returning to the high speed (i.e., increasing the fan speed). During the pulse of the fan 360, the controller 450 may briefly stop the supply of electrical energy to the fan 360, which may cause the fan 360 to slow down or stop. Pulsing the fan may introduce turbulence into the airflow, which may reduce fallout. In some embodiments, the pulsing occurs throughout the entire fan operation period. In other embodiments, the pulsing occurs only before the dispensing event, only after the dispensing event, or only during the dispensing event.Airflow Control to Address Spitting

[0114] In some embodiments, the automatic dispenser 300 includes one or more fans 360 positioned to direct airflow toward the spray nozzle 100. In such a configuration, the airflow blows across the outlet 112 of the spray nozzle 100. This airflow may encourageevaporation of obstructive material (e.g., product) that has pooled on the spray nozzle 100. Additionally or alternatively, the airflow may blow the obstructive material off of the spray nozzle 100. By removing the obstructive material from the spray nozzle 100, the fan 360 arranged to direct airflow toward the aerosol spray S may reduce spitting.

[0115] FIGS. 7 and 19 illustrate various configurations of the fan 360 that direct airflow toward the spray nozzle 100. Referring to FIG. 7, the flow diverters 350 direct the airflow that leaves the nozzle ventilation outlets 344 laterally inward, toward the spray nozzle 100. Accordingly, the airflow moves toward the spray axis SA and facilitates clearing the obstructive material from the spray nozzle 100. Referring to FIG. 19, the fan 360 is arranged such that the fan axis FA is not parallel with the spray axis SA. Accordingly, airflow from the fan 360 moves toward the spray axis SA and facilitates clearing the obstructive material from the spray nozzle 100.

[0116] Referring to FIG. 20, an alternative fan configuration of the automatic dispenser 300 is shown according to an exemplary embodiment. In this embodiment, the ventilation passage 340 is includes a narrowed portion or flow restriction, shown as venturi 550, positioned along the length of the ventilation passage 340. The housing 310 further defines an aperture, shown as venturi inlet 552, in fluid communication with the venturi 550. The venturi 550 has a smaller cross-sectional area than a portion of the ventilation passage 340 upstream of the venturi 550 and a portion of the ventilation passage 340 downstream of the venturi 550. The reduction in cross-sectional area creates a low pressure zone at the venturi inlet 552, drawing airflow from the surrounding atmosphere into the venturi inlet 552. The venturi inlet 552 is positioned such that this low pressure draws the airflow across the spray nozzle 100. This arrangement facilitates clearing obstructive material from the spray nozzle 100.

[0117] In some embodiments, the automatic dispenser 300 is reconfigurable between (a) an operating configuration for normal dispensing operation and (b) a purge configuration or cleaning configuration where the controller 450 operates the fans 360 to clear obstructive material from the spray nozzle 100. In some embodiments, the pump actuator 370 is disabled and the automatic dispenser 300 is configured to maximize airflow to the spray nozzle 100 in the cleaning configuration. The controller 450 may enter the cleaning configuration in response to a user input (e.g., through the user interface 456). Thecontroller 450 may enter the cleaning configuration periodically (e.g., hourly, daily, weekly, monthly, etc.).

[0118] One or more of the flow diverters 350 may be repositionable to facilitate diverting additional airflow to the spray nozzle 100. Each flow diverter 350 may have a normal operating position in the operating configuration and a cleaning position in the cleaning configuration. The flow diverters 350 may be positioned to redirect a greater portion of the airflow toward the spray nozzle 100 in the cleaning position than in the normal operating position. Referring to FIGS. 7 and 8, the flow diverters 350 may extend further into the ventilation passage 340 in the cleaning position to direct a greater portion of the airflow toward the spray nozzle 100. In some embodiments, the flow diverters 350 completely block the ventilation passage 340, such that all of the airflow through the ventilation passage 340 is directed toward the spray nozzle 100 (e.g., none of the airflow reaches the air outlet 346). The controller 450 may operate the flow diverter actuators 352 to move the flow diverters 350 between the normal operating position and the cleaning position.

[0119] In some embodiments, the controller 450 controls operation of the fans 360 to maximize airflow to the spray nozzle 100 in the cleaning configuration. By way of example, the fans 360 may have a first fan speed in the operating configuration and a second, higher fan speed in the cleaning configuration. This increased fan speed may result in increased airflow and more effective cleaning of the spray nozzle 100.

[0120] In some embodiments, the automatic dispenser 300 includes multiple fans 360, each positioned to accomplish a different function. By way of example, a primary fan 360 may direct airflow toward the aerosol spray S to reduce fallout, and a secondary fan 360 direct airflow toward the spray nozzle 100 to reduce spitting. By utilizing two separate fans 360, the fans 360 may each be optimally positioned for their designated task. Additionally, the fans 360 may be independently controlled (e.g., to operate at different times, to operate at different speeds, etc.).Controlled Pump Actuation

[0121] Referring to FIGS. 7 and 8, during a dispensing event, the cam 374 of the pump actuator 370 rotates to apply a compressive force on the pump 220. Using feedback from the pump actuator sensor 378, the controller 450 may apply closed- loop control over themotor 372 of the pump actuator 370. By way of example, the controller 450 may utilize a PID control loop to achieve a desired angular position, rotational speed, and / or compressive force of the cam 374 based on sensor data from the pump actuator sensor 378. By controlling the speed with which the pump 220 is compressed and / or the force applied to the pump 220 by the cam 374, the controller 450 may control the characteristics of the aerosol spray S and prevent spitting.

[0122] In some embodiments, the controller 450 controls the pump actuator 370 to cycle the pump 220 according to a desired speed profde (e.g., a mapping of desired compression speed versus time or pump compression). A relationship between the angular position of the cam 374 and the corresponding compression of the pump 220 may be predetermined (e.g., experimentally, mathematically, etc.) and stored in the memory 454. Based on this relationship and feedback from the pump actuator sensor 378, the controller 450 may apply closed-loop control (e.g., PID control) over the compression speed of the pump 220.Through testing, it has been determined that initially compressing the pump 220 slowly, then subsequently increasing the compression speed has shown to reduce spitting relative to a configuration where the compression speed is constant throughout the dispensing cycle. In some embodiments, the compression speed is reduced as the pump 220 approaches maximum compression.

[0123] In some embodiments, a desired range of forces for the compressive force on the pump 220 is predetermined and stored in the memory 454. After the pump 220 reaches maximum compression and begins to expand, the compressive force may be permitted to fall out of the desired range. In some embodiments, the desired range of forces has a minimum desired force. By way of example, the minimum desired force may be based on a minimum force required to actuate the precompression valve 240. In some such embodiments, the minimum desired force is 1 Ibf. In some such embodiments, the minimum desired force is 2 Ibf.

[0124] In some embodiments, the desired range of forces has a maximum desired force. By way of example, the maximum desired force may be based on the maximum force that can be applied to the pump 220 without causing spitting. Exceeding the maximum desired force may cause the aerosol spray S to exhibit undesirable characteristics (e.g., large particles, spitting, etc.). By way of example, exceeding the maximum desired force maycause a portion of the product from the aerosol spray to be left behind and begin pooling on the membrane 104. In some embodiments, the maximum desired force is 10 Ibf. In some such embodiments, the maximum desired force is 8 Ibf.

[0125] In some embodiments, the controller 450 controls the pump actuator 370 maintain the compressive force on the pump 220 within a desired range of forces throughout the compression portion of the dispensing cycle. The controller 450 may apply closed-loop control (e.g., PID control) over the compression force on the pump 220 based on feedback from the pump actuator sensor 378. If the compression force is below the minimum desired force, the controller 450 may increase the speed of the cam 374 and / or increase the torque on the cam 374 (e.g., by varying a voltage applied to the motor 372). If the compression force is above the maximum desired force, the controller 450 may decrease the speed of the cam 374 and / or decrease the torque on the cam 374. In this way, the controller 450 can maintain the force required to actuate the precompression valve 240 without applying so much force that spitting is initiated.Compressible Members

[0126] In some embodiments, the compressible members 380 and 382 prevent spitting. In testing, a compressible member 382 made from cardboard was included in the automatic dispenser 300. Experimental data indicated that the addition of the compressible member 382 significantly decreased spitting relative to operation of the automatic dispenser 300 with the compressible member 382 omitted. In some embodiments, the compressible members 380 and 382 facilitate gradually applying compressive force to the pump 220, which reduces the pooling of product that causes spitting. A damping effect of the compressible members 380 and 382 may reduce the likelihood of overshooting the maximum desired force.Detect Cartridge End of Life

[0127] In some embodiments, the controller 450 is configured to use feedback from the pump actuator sensor 378 to determine that the cartridge 200 is nearing end of life (e.g., is below a threshold fill level) and requires replacement. Through testing, it has been determined that the force required to actuate the pump 220 of the cartridge 200 is generally constant until the fill level falls below a threshold fill level. At this point, air is introducedinto the pump 220 through the dip tube 214, and the force required to actuate the pump 220 decreases. In response to detecting the decrease in force (e.g., as a decrease in the current supplied to the motor 372), the controller 450 may determine that the cartridge 200 requires replacement. In some embodiments, the controller 450 is configured to require that the decrease in force is detected multiple times (e.g., in multiple consecutive dispensing cycles, more than a threshold number or times in a given number of dispensing cycles, more than a threshold number of time in a predetermined time period, etc.) before the controller 450 determines that the cartridge 200 requires replacement. In response, the controller 450 may provide a notification to a user (e.g., through the user interface 456) indicating that the cartridge 200 should be replaced.

[0128] While an aerosol spray may be formed when the cartridge 200 is below the threshold fill level, the introduction of air into the pump 220 may cause the aerosol spray to begin spitting. Accordingly, it may be advantageous to prevent operation of the pump 220 when the cartridge 200 is below the threshold fill level. In response to a determination that the cartridge 200 is below the threshold fill level, the controller 450 may prevent operation of the pump actuator 370. The controller 450 may permit operation of the pump actuator 370 in response to an indication that the cartridge 200 has been replaced (e.g., a user input through the user interface 456).Heaters

[0129] Referring to FIGS. 7 and 8, the controller 450 operates the heaters 390 to improve performance of the automatic dispenser 300. By way of example, the controller 450 may activate the heaters 390 in response to a user input and / or periodically. In some embodiments, the controller 450 activates the heaters 390 as part of the cleaning configuration.

[0130] In some embodiments, activating the heater 390 coupled to the spray nozzle 100 increases a temperature of the spray nozzle 100. This may increase a temperature of any obstructive material on the spray nozzle 100. The increase in temperature may decrease the viscosity of the obstructive material, permitting it to run off of the spray nozzle 100 more easily. The increase in temperature may encourage or otherwise facilitate evaporation of the obstructive material. Accordingly, the heater 390 coupled to the spray nozzle 100 may reduce spitting.

[0131] In some embodiments, activating the heater 390 coupled to the bottle 210 increases a temperature of the product within the bottle 210. The product may have one or more properties that are temperature-dependent. By way of example, a viscosity of the product may decrease as the temperature of the product increases. A decreased viscosity may reduce the occurrence of product fallout (e.g., by facilitating smaller droplet formation). Should product fallout occur, the decreased viscosity may facilitate the product fallout evaporating more quickly (e.g., by permitting the product to spread over a wider area).

[0132] In some embodiments, the product utilizes a DPMA as a solvent. DPMA may have a viscosity of about 5 cP, such that the viscosity of DPMA is slightly higher than that of water. In other embodiments, a different solvent having a lower viscosity is selected, potentially providing similar benefits to the heater 390 coupled to the bottle 210.

[0133] In some embodiments, activating the heater 390 positioned within the ventilation passage 340 heats the air passing through the ventilation passage 340. The air may heat the cartridge 200, providing similar benefits to the other heaters 390. Additionally or alternatively, the heated air may rise above the surrounding air due to convection, carrying the product from the aerosol spray S upward to reduce product fallout. The upward convective airflow from the heater 390 may supplement upward airflow from the fans 360. Alternatively, the fans 360 may be omitted, and the convective airflow from the heater 390 may carry the product upward without airflow from the fans 360.Nozzle Cleaner

[0134] In some embodiments, the nozzle cleaner 400 limits (e.g., prevents) spitting by removing obstructive material from the spray nozzle 100. The nozzle cleaner 400 may move the cleaning element 402 into contact with the spray nozzle 100 (e.g., when the cartridge 200 is not spraying). The cleaning element 402 may wipe the obstructive material off of the spray nozzle 100, absorb the obstructive material, and / or adsorb the obstructive material. After contacting the spray nozzle 100, the nozzle cleaner 400 may move the cleaning element 402 away from the spray nozzle 100 (e.g., to provide clearance relative to the aerosol spray S).

[0135] Referring to FIG. 21, the nozzle cleaner 400 is shown according to an exemplary embodiment. FIG. 21 may illustrate an actively-controlled embodiment of the nozzlecleaner 400. In the embodiment shown, the cleaning element 402 is pivotally coupled to the housing 310 by a support, shown as arm 570. The arm 570 may be rotatable about a substantially horizontal axis. Specifically, the cleaning element 402 is repositionable between a cleaning position (shown in solid lines) where the cleaning element 402 contacts the spray nozzle 100 and a storage position (shown in dashed lines) where the cleaning element 402 is moved away from the spray nozzle 100. As shown, the cleaner actuator 404 is coupled to the arm 570 and configured to reposition the cleaning element 402 (e.g., as commanded by the controller 450).

[0136] Referring to FIGS. 22 and 23, the nozzle cleaner 400 is shown according to another exemplary embodiment. FIGS. 22 and 23 may illustrate a passively-controlled embodiment of the nozzle cleaner 400. As shown, the cleaning element 402 is pivotally coupled to the nozzle portion 224 of the pump 220 by a support, shown as arm 572. A first end portion of the arm 572 is pivotally coupled to the cleaning element 402, and a second end portion of the arm 572 is pivotally coupled to the nozzle portion 224. In some embodiments, the nozzle portion 224 is coupled to the housing 310 such that the arm 572 is indirectly coupled to the housing 310. The arm 572 may be rotatable about a substantially horizontal axis. A linking element, shown as control link 574, has a first end portion that is pivotally coupled to the arm 572. The control link 574 has a second end portion that is pivotally coupled to the bottle 210 and / or the bottle portion 222 of the pump 220.

[0137] The cleaning element 402 is repositionable between a cleaning position (shown in FIG. 22) and a storage position (shown in FIG. 23). Together, the arm 572, the control link 574, the bottle portion 222, and the nozzle portion 224 form a four-bar linkage. During actuation, the bottle portion 222 and the nozzle portion 224 move closer to one another, and the four-bar linkage automatically and passively moves the cleaning element 402 to the cleaning position when the pump 220 nearly fully compressed. As the bottle portion 222 and the nozzle portion 224 move apart, the four-bar linkage automatically and passively moves the cleaning element 402 back to the storage position. Accordingly, the nozzle cleaner 400 operates without the use of the cleaner actuator 404.Spray Nozzle Geometry to Counter Pooling

[0138] Referring to FIG. 24, the spray nozzle 100 is shown according to an exemplary embodiment. As shown, the plastic cap structure 102 has an outer surface 600, along whichthe outlet 112 is defined. The membrane 104 is positioned within the outlet 112, adjacent the outer surface 600. In some embodiment, an outer surface of the membrane 104 extends along and is shaped similarly to the outer surface 600.

[0139] In the embodiment shown in FIG. 24, the outer surface 600 is concave and faces upward. During operation, product P that has not been fully ejected from the spray nozzle 100 may collect on the outer surface 600. Due to the concave shape and upward-facing orientation of the outer surface 600, the product P may pool and cover the membrane 104. This pooling on the membrane 104 may in turn cause spitting for subsequent dispensing events.

[0140] FIGS. 25-27 include various features that prevent pooling of the product P along the membrane 104, thereby preventing the spray nozzle 100 from spitting. In the embodiment of the spray nozzle 100 shown in FIG. 25, the outer surface 600 of the plastic cap structure 102 is convex instead of concave. While the outer surface 600 still faces upward, the convex shape of the outer surface 600 permits gravity to draw the product P away from the membrane 104 along various paths of egress PE that extend along the outer surface 600. Accordingly, the shape of the outer surface 600 prevents pooling of the product P on the membrane 104. In some embodiments, an outer surface of the membrane 104 is also convex (e.g., to match and sit flush with the outer surface 600).

[0001] In the embodiment of the spray nozzle 100 shown in FIG. 26, the outer surface 600 is concave and faces upward. However, the plastic cap structure 102 defines a series of passages or weep holes, shown as drainage passages 602. Each drainage passage 602 has an inlet positioned along the outer surface 600. The drainage passages 602 each extend downward and radially outward and have an outlet along a circumference of the plastic cap structure 102. Each drainage passage 602 defines a path of egress PE, along which gravity can draw the product P away from the membrane 104. Accordingly, the drainage passages 602 prevent pooling of the product P on the membrane 104. As shown, the drainage passages 602 are shown as enclosed conduits. In other embodiments, the drainage passages 602 are exposed grooves extending downward into the plastic cap structure 102.

[0141] The embodiment of the spray nozzle 100 shown in FIG. 27 may be substantially similar to the embodiment of FIG. 24 except for an orientation of the spray nozzle 100. In FIG. 27, the spray axis SA is rotated downward such that the spray axis SA is not vertical.In some embodiments, the spray axis SA is rotated downward between 1 degree and 90 degrees from an upward-facing, vertical orientation. The orientation of the outer surface 600 permits gravity to draw the product P away from the membrane 104 along various paths of egress PE that extend along the outer surface 600. Accordingly, the orientation of the outer surface 600 prevents pooling of the product P on the membrane 104.Spray Passage Shaped to Capture Large Particles

[0142] Referring to FIG. 7, in some embodiments, the spray passage 330 facilitates catching large particles (e.g., particles prone to fallout, large droplets from spitting, etc.). As shown in FIG. 7, the aerosol spray S is introduced into the spray passage 330, and the interior wall 312 surrounds the aerosol spray S. Accordingly, the aerosol spray S may be required to pass through the spray passage 330 prior to exiting the automatic dispenser 300. As the aerosol spray S moves outward, large particles may move toward the interior wall 312. These large particles may contact the interior wall 312 and become caught. Advantageously, this prevents the particles from being dispensed onto the surfaces surrounding the automatic dispenser 300, improving user satisfaction.

[0143] Referring to FIG. 28, the spray passage 330 is shown according to another exemplary embodiment. In the embodiment of FIG. 28, the spray passage 330 follows a curved or tortuous path having one or more curves or bends, shown as bends 620. The particles of the aerosol spray S may be drawn along the spray passage 330 by airflow (e.g., from one or more fans 360). An example of a small particle 622 and a large particle 624 from the aerosol spray S are shown moving along their respective paths. Relatively small particles (e.g., particles which are desirably less prone to fallout), such as the particle 622, have a relatively small mass. The small mass permits the particle 622 to quickly change direction and navigate through the bends 620. Accordingly, the particle 622 freely exits the outlet of the spray passage 330. Relatively large particles (e.g., particles which are prone to fallout or large droplets formed by spitting), such as the particle 624, have a relatively large mass. The large mass resists the particle 624 changing direction. Accordingly, the particle 624 collides with the interior wall 312 and is prevented from exiting the spray passage 330. By eliminating the large particles in this way, the spray passage 330 may reduce fallout and spitting.Vibration

[0144] In some embodiments, the controller 450 utilizes the agitator 410 to limit spitting and / or fallout. By way of example, the controller 450 may control the agitator 410 to vibrate the automatic dispenser 300 before, during, and / or after a dispensing event. The vibration may limit undesirable characteristics of the aerosol spray S. By way of example, the vibration may shake the spray nozzle 100 to remove product that may have pooled there and reduce spitting.Alternative Aerosol Generators

[0145] Referring to FIGS. 5-7, the cartridge 200 is an example of an aerosol generator (e.g., a volatilization engine, a volatilization unit, etc.) for use with the automatic dispenser 300. An aerosol generator may be any mechanism that produces an aerosol spray including a suspension of particles (solid or liquid) in air or a gas. An aerosol generator or volatilization unit may include a container (e.g., the bottle 210) containing a material to be dispensed (e.g., the product P, a volatile, etc.), an actuator (e.g., the pump 220, a piezoelectric element, a heater, etc.) that causes the material to be dispensed, and a nozzle (e.g., the spray nozzle 100) defining an outlet through which an aerosol spray of the material is released. The aerosol generator or volatilization unit may additionally include one or more components of the automatic dispenser 300 that actuate the aerosol generator (e.g., the pump actuator 370, the compressible member 380, the compressible members 382, the stop 322, etc.).

[0146] The automatic dispenser 300 may be usable with other types of aerosol generators or volatilization units. By way of example, the automatic dispenser 300 may be usable with a diffuser that utilizes a piezoelectric element to dispense material (e.g., the piezoelectric dispenser 700). By way of another example, the automatic dispenser 300 may be usable with a scented oil heater or wax melter (e.g., a heater 390) that utilizes a heating element to heat a container of material (e.g., scented oils, wax, etc.) and release the material into the surrounding air. In one such example, the heater 390 of FIG. 7 heats the bottle 210 to release the product P directly into the surrounding air (e.g., omitting the pump 220 such that the product P is exposed to the surrounding air). These other types of aerosol generators or volatilization units may benefit from features of the automatic dispenser 300 that reducespitting, reduce fallout, and / or facilitate dispersion of material throughout a room or other space.Piezoelectric Dispenser

[0147] Referring to FIGS. 29-33, an aerosol generator, volatilization engine, volatilization unit, dispenser, diffuser, aerosol dispensing system, base-container aerosol dispensing system, aerosol dispenser, handheld dispenser, automatic dispenser refdl, or aerosol dispensing cartridge is shown as piezoelectric dispenser 700 according to an exemplary embodiment. The piezoelectric dispenser 700 may represent an alternative aerosol generator for use with the automatic dispenser 300. Accordingly, the piezoelectric dispenser 700 may be used in place of any of the cartridges 200 shown or described herein. The piezoelectric dispenser 700 may be substantially similar to the cartridge 200 except as otherwise specified.

[0148] The piezoelectric dispenser 700 may utilize the structure and have similar performance characteristics to the volatile material dispensers or diffusers shown and described in U.S. Patent No. 11,407,000, which is hereby incorporated by reference in its entirety.

[0149] The piezoelectric dispenser 700 includes a container (e.g., a vessel, a holder, a canister, a tank, a bottle, etc.), shown as bottle 710, that defines a storage volume 712 containing a volume of the product P. The piezoelectric dispenser 700 includes a conduit, shown as wick 714, that is coupled to a neck 716 of the bottle 710. A lower end of the wick 714 extends into the storage volume 712 to contact the product P, and an upper end of the wick 714 extends out of the bottle 710 through the neck 716. The wick 714 may be made of extruded fibers or other material that wicks (e.g., through capillary action and / or absorbency of the material) the product P upward to the upper end. By way of example, the wick 714 may include rope, sponge, or one or more cotton cords. In some embodiments, the bottle 710 and the wick 714 are removable from the piezoelectric dispenser 700 and replaceable to refill the piezoelectric dispenser 700 when the product P has been exhausted.

[0150] The piezoelectric dispenser 700 includes an actuator, shown as piezoelectric assembly 720, in contact with the upper end of the wick 714. The piezoelectric assembly 720 includes an annular piezoelectric element 722 defining a circular rim of thepiezoelectric assembly 720. The annular piezoelectric element 722 defines a central aperture 724 through which the product from the bottle 710 is dispensed when the piezoelectric dispenser 700 is activated.

[0151] The neck 716 of the bottle 710 is coupled to a support, manifold, housing, stop, or cap, shown as bottle mount 730. The bottle 710 may be removably coupled to the bottle mount 730 (e.g., through a threaded connection) to facilitate replacing the bottle 710 with a refill. The bottle mount 730 defines an aperture, shown as outlet 732, through which the spray S exits the piezoelectric dispenser 700. A biasing element, shown as spring 734, extends between the bottle mount 730 and the piezoelectric assembly 720. The spring 734 may apply a biasing force onto the piezoelectric assembly 720 to force the piezoelectric assembly 720 toward the wick 714, maintaining engagement between the wick 714 and the piezoelectric assembly 720. The bottle 710, the wick 714, the piezoelectric assembly 720, the outlet 732, and the spring 734 are aligned along the spray axis SA.

[0152] Referring to FIGS. 30 and 31, the piezoelectric assembly 720 is shown according to an exemplary embodiment. The piezoelectric assembly 720 includes a piezoelectric plate 740 having an upper surface 742. The annular piezoelectric element 722 is coupled to the piezoelectric plate 740 and circumscribes the upper surface 742, such that the upper surface 742 is exposed through the central aperture 724. A lower surface of the piezoelectric plate 740 contacts the wick 714. A series of apertures or passages, shown as orifices 744, extend through the piezoelectric plate 740, fluidly coupling the central aperture 724 to the wick 714. In some embodiments, the annular piezoelectric element 722 is made from a ceramic, and the piezoelectric plate 740 is made from stainless steel (e.g., SUS 316L steel). In other embodiments, the piezoelectric dispenser 700 includes another type of piezoelectric actuator, such as a piezoelectric vibrating mesh actuator, a piezoelectric standing wave actuator, or a piezoelectric vibrating needle.

[0153] Referring to FIGS. 32 and 33, the piezoelectric dispenser 700 is included in the automatic dispenser 300 in place of the cartridge 200, according to an exemplary embodiment. The piezoelectric dispenser 700 is positioned within the interior wall 312 and centered such that the spray axis SA is aligned with the fan axis FA. The bottle mount 730 extends radially outward to engage the interior wall 312 and fixedly couple the piezoelectric dispenser 700 to the housing 310. A heater 390 is coupled to the bottle 710 to heat theproduct P within the storage volume 712. The piezoelectric assembly 720 is operatively coupled to the controller 450, such that the controller 450 may control operation of the piezoelectric assembly 720.

[0154] Referring to FIGS. 29-33, that the controller 450 may supply electrical energy (e.g., from the batteries 460 or the power connector 462) to the annular piezoelectric element 722 to activate the piezoelectric assembly 720. When the annular piezoelectric element 722 receives the electrical energy, the annular piezoelectric element 722 activates, causing the piezoelectric plate 740 to expand and contract in a radial direction (e.g., perpendicular to the spray axis SA). This expansion and contraction causes the annular piezoelectric element 722 to vibrate in an axial direction (e.g., along the spray axis SA), forcing product retained within the orifices 744 of the annular piezoelectric element 722 away from the piezoelectric assembly 720 and forming the spray S. The spray passes through the annular piezoelectric element 722, the outlet 732, and the housing 310, such that each of the annular piezoelectric element 722, the bottle mount 730, and the housing 310 may act as a nozzle defining an outlet for the spray. The orifices 744 may be refilled with product P from the bottle 710 through repeated contact with the wick 714. The piezoelectric dispenser 700 and the resultant spray S may benefit from the fallout reduction, spitting reduction, and enhanced dispersion features of the automatic dispenser 300 described herein with reference to the cartridge 200.

[0155] As utilized herein with respect to numerical ranges, the terms “approximately,” “about,” “substantially,” and similar terms generally mean + / - 10% of the disclosed values. When the terms “approximately,” “about,” “substantially,” and similar terms are applied to a structural feature (e.g., to describe its shape, size, orientation, direction, etc.), these terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.

[0156] It should be noted that the term “exemplary” and variations thereof, as used herein to describe various embodiments, are intended to indicate that such embodiments are possible examples, representations, or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

[0157] The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

[0158] References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

[0159] The hardware and data processing components used to implement the various processes, operations, illustrative logics, logical blocks, modules and circuits described in connection with the embodiments disclosed herein may be implemented or performed with a general purpose single- or multi-chip processor, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. A general purpose processor may be a microprocessor, or, any conventionalprocessor, controller, microcontroller, or state machine. A processor also may be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, particular processes and methods may be performed by circuitry that is specific to a given function. The memory (e.g., memory, memory unit, storage device) may include one or more devices (e.g., RAM, ROM, Flash memory, hard disk storage) for storing data and / or computer code for completing or facilitating the various processes, layers and modules described in the present disclosure. The memory may be or include volatile memory or non-volatile memory, and may include database components, object code components, script components, or any other type of information structure for supporting the various activities and information structures described in the present disclosure. According to an exemplary embodiment, the memory is communicably connected to the processor via a processing circuit and includes computer code for executing (e.g., by the processing circuit or the processor) the one or more processes described herein.

[0160] The present disclosure contemplates methods, systems and program products on any machine-readable media for accomplishing various operations. The embodiments of the present disclosure may be implemented using existing computer processors, or by a special purpose computer processor for an appropriate system, incorporated for this or another purpose, or by a hardwired system. Embodiments within the scope of the present disclosure include program products comprising machine-readable media for carrying or having machine-executable instructions or data structures stored thereon. Such machine- readable media can be any available media that can be accessed by a general purpose or special purpose computer or other machine with a processor. By way of example, such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code in the form of machine-executable instructions or data structures and which can be accessed by a general purpose or special purpose computer or other machine with a processor. Combinations of the above are also included within the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing machines to perform a certain function or group of functions.

[0161] Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above. Such variation may depend, for example, on the software and hardware systems chosen and on designer choice. All such variations are within the scope of the disclosure. Likewise, software implementations of the described methods could be accomplished with standard programming techniques with rulebased logic and other logic to accomplish the various connection steps, processing steps, comparison steps, and decision steps.

[0162] It is important to note that the construction and arrangement of the automatic dispenser 300 as shown in the various exemplary embodiments is illustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. For example, the venturi 550 of the exemplary embodiment shown in at least FIG. 20 may be incorporated in the automatic dispenser 300 of the exemplary embodiment shown in at least FIG. 7. Although only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein.

Claims

WHAT IS CLAIMED IS:

1. A dispensing system for dispensing an aerosol spray of an air freshening product, the dispensing system comprising: a housing; a container coupled to the housing and containing the air freshening product; a nozzle defining an outlet; an actuator coupled to the housing and configured to dispense the air freshening product from the container through the outlet to form an aerosol spray; and a fan coupled to the housing and configured to generate airflow that moves toward the aerosol spray to move the aerosol spray away from the housing.

2. The dispensing system of Claim 1, wherein the actuator is configured to dispense the air freshening product along a spray axis that extends upward from the nozzle, and wherein the airflow moves upward toward the aerosol spray to move the aerosol spray upward and away from the housing.

3. The dispensing system of Claim 2, wherein the housing defines an air outlet and a ventilation passage extending between the fan and the air outlet, and wherein the housing is configured to direct the airflow along the ventilation passage and through the air outlet.

4. The dispensing system of Claim 3, wherein the air outlet is annular and surrounds the spray axis.

5. The dispensing system of Claim 1, wherein the actuator is configured to dispense the air freshening product along a spray axis that extends upward from the nozzle, and wherein the airflow moves laterally toward the spray axis and across the outlet.

6. The dispensing system of Claim 1, further comprising a flow diverter coupled to the housing, wherein the actuator is configured to dispense the air freshening product along a spray axis that extends upward from the nozzle, and wherein the flow diverter is configured to direct a first portion of the airflow laterally toward the spray axis, and wherein the flow diverter is configured to permit a second portion of the airflow to move upward along the spray axis.

7. The dispensing system of Claim 1, further comprising a controller operatively coupled to the fan and the actuator, wherein the controller is configured to: control the fan to generate the airflow for a period of time prior to operation of the actuator; and at an end of the period of time, control the actuator to dispense the air freshening product from the container.

8. The dispensing system of Claim 7, wherein the period of time is a first period of time, and wherein the controller is configured to: control the actuator to cease dispensing of the air freshening product from the container; and control the fan to continue generating the airflow for a second period of time after the actuator ceases dispensing of the air freshening product.

9. The dispensing system of Claim 8, wherein the second period of time is longer than the first period of time.

10. The dispensing system of Claim 1, further comprising a controller operatively coupled to the fan and configured to control the fan to repeatedly increase and decrease a fan speed of the fan while generating the airflow.

11. The dispensing system of Claim 1, further comprising a controller operatively coupled to the fan and the actuator, wherein the controller is configured to: control the fan to operate at a first fan speed while controlling the actuator to dispense the air freshening product from the container; and perform a cleaning operation by controlling the fan to operate at a second fan speed greater than the first fan speed while the actuator is not dispensing the air freshening product from the container.

12. The dispensing system of Claim 1, further comprising a flow diverter coupled to the housing and a controller operatively coupled to the actuator, wherein the controller is configured to: control the flow diverter to divert a first portion of the airflow toward the nozzle while controlling the actuator to dispense the air freshening product from the container; and perform a cleaning operation by controlling the flow diverter to divert a second portion of the airflow toward the nozzle while the actuator is not dispensing the air freshening product from the container, the second portion of the airflow being greater than the first portion.

13. The dispensing system of Claim 1, further comprising a heater configured to supply thermal energy to at least one of the nozzle or the container containing the air freshening product.

14. The dispensing system of Claim 1, further comprising a heater coupled to the housing, wherein the housing defines an air outlet and a ventilation passage extending between the fan and the air outlet, wherein the housing is configured to direct the airflow along the ventilation passage and through the air outlet, and wherein the heater is positioned to supply thermal energy to the airflow within the ventilation passage.

15. The dispensing system of Claim 1, wherein the actuator is a piezoelectric element that is configured to vibrate to dispense the air freshening product from the container through the outlet to form the aerosol spray.

16. The dispensing system of Claim 1, further comprising a pump fluidly coupled to the container, wherein the nozzle is a spray nozzle including a membrane having micropores configured to allow the air freshening product to pass through the membrane; wherein the pump is configured to move the air freshening product through the membrane to form the aerosol spray; and wherein the actuator is configured to apply a compressive force to the pump to dispense the air freshening product from the container.

17. An automatic dispenser for dispensing a material, the automatic dispenser comprising: a housing; a volatilization unit coupled to the housing, the volatilization unit including: a container containing a volume of the material; and an actuator coupled to the container and configured to form a spray of the material that extends above the housing; a fan coupled to the housing and configured to generate airflow directing the spray away from the housing; and a controller operatively coupled to the actuator and the fan and configured to perform a dispensing process at regular intervals, the dispensing process including: controlling the actuator to form the spray of the material; and at least one of (a) controlling the fan to generate the airflow for a first period of time that ends when the actuator forms the spray of the material or (b) controlling the fan to generate the airflow for a second period of time that starts when the actuator forms the spray of the material.

18. The automatic dispenser of Claim 17, wherein the housing defines an air inlet, an air outlet, and a ventilation passage extending between the air inlet and the air outlet, and wherein the fan is positioned to direct the airflow along the ventilation passage, and wherein the air outlet is annular and extends around the spray of the material.

19. The automatic dispenser of Claim 18, wherein the actuator includes a heater configured to supply thermal energy to the material to form the spray of the material.

20. A dispensing system for dispensing an aerosol spray of a product, the dispensing system comprising: a housing defining an air inlet, an annular air outlet, and a ventilation passage extending from the air inlet to the annular air outlet; a fan coupled to the housing and configured to generate airflow along the ventilation passage; a container coupled to the housing and containing the product; a nozzle defining an outlet; an actuator coupled to the housing and configured to dispense the product from the container through the outlet to form the aerosol spray along a spray axis that extends upward from the nozzle and passes through the annular air outlet; a flow diverter positioned to divert a first portion of the airflow toward the spray axis and permit a second portion of the airflow to exit the ventilation passage through the annular air outlet; a heater configured to supply thermal energy to at least one of (a) the nozzle, (b) the container, or (c) the airflow within the ventilation passage; and a controller operatively coupled to the fan and the actuator and configured to: control the fan to operate at a first fan speed while controlling the actuator to dispense the product from the container; and control the fan to operate at a second fan speed greater than the first fan speed while the actuator is not dispensing the product from the container.

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