Spray dispenser with reusable phase change substance

Abstract

A spray dispenser (300) comprising at least one air chamber (309) for containing pressurised air and at least one formulation chamber (310) for containing pressurised formulation, wherein when the spray dispenser (300) is actuated, pressurised air from the air chamber (309) is delivered to a mixing chamber (102) at a desired air working pressure, and pressurised formulation from the formulation chamber (310) is delivered to the mixing chamber (102) at a desired formulation working pressure; wherein: the pressurised air and pressurised formulation are combined in the mixing chamber (102) and dispensed therefrom; the air chamber (309) is a container of changeable volume; the air chamber (309) comprises an air working surface (315), the air working surface (315) being configured to act upon the air chamber (309) to pressurise it; and the spray dispenser (300) comprises a sealed container (330) of changeable volume filled with a substance that undergoes a reversible phase change; wherein the change in volume of the sealed container (330) drives movement of the air working surface (315) thereby changing the volume of the air chamber (309) and the pressure of the air contained in the air chamber (309).

Description

[0001] SPRAY DISPENSER WITH REUSABLE PHASE CHANGE SUBSTANCE

[0002] Field of the Invention

[0003] The present invention relates to a spray dispenser for delivering a combination of air and formulation when the spray dispenser is actuated.

[0004] Background of the Invention

[0005] Spray dispensers are used to deliver an aerosolised formulation when the spray dispenser is actuated by a user. In order to propel the formulation out of the dispenser when it is actuated, the formulation in a traditional spray dispenser typically contains a liquefied propellant. This liquefied propellant provides a near constant vapour pressure during use until the dispenser is emptied, therefore providing a consistent delivery of product at a constant flow rate over the lifetime of the dispenser. These liquefied propellants are released to the environment as the formulation is dispensed. These liquefied propellants may have detrimental impacts on the environment.

[0006] In order to contain the liquefied propellant, these dispensers need to be sturdy and are therefore often made from metals, such as aluminium or steel. Once all the formulation has been dispensed, the canister is often not recycled by the user which can result in a significant amount of waste material.

[0007] Attempts have been made to prevent the liquid propellant being released into the atmosphere, however the resulting products typically exhibit a poor user satisfaction relative to traditional liquid propellant products.

[0008] The present invention has been devised in light of the above considerations. of the Invention

[0009] According to the present invention there is provided a spray dispenser comprising at least one air chamber for containing pressurised air and at least one formulation chamber for containing pressurised formulation, wherein when the spray dispenser is actuated, pressurised air from the air chamber is delivered to a mixing chamber at a desired air working pressure, and pressurised formulation from the formulation chamber is delivered to the mixing chamber at a desired formulation working pressure; wherein: the pressurised air and pressurised formulation are combined in the mixing chamber and dispensed therefrom; the air chamber is a container of changeable volume; the air chamber comprises an air working surface, the air working surface being configured to act upon the air chamber to pressurise it; and the spray dispenser comprises a sealed container of changeable volume filled with a substance that undergoes a reversible phase change; wherein the change in volume of the sealed container drives movement of the air working surface thereby changing the volume of the air chamber and the pressure of the air contained in the air chamber.

[0010] In this way, the present invention provides a spray dispenser for delivering an aerosolised spray of formulation when actuated by a user. The spray dispenser does not release propellant into the atmosphere like traditional spray dispensers. Instead, a mixture of pressurised formulation and pressurised air is dispensed. The pressure in the air chamber is driven by a sealed container of a phase change substance that is never released from the dispenser but can be reused over the lifetime of the dispenser. Embodiments of the present invention may be used to dispense a variety of formulations from across the Beauty and Personal Care industry, such as hairsprays, dry shampoos, deodorants and anti-perspirants. Embodiments of the present invention may also be found in other industries such as Homecare, such as fabric or air fresheners.

[0011] The formulation may, for example, be a hairspray and the pressurised air and pressurised formulation may create a spray that is dispensed with similar performance to a traditional propellant-based hairspray in terms of various parameters such as flow rate and particle size. By pressurising and atomising the formulation with air, it is no longer necessary to release a propellant into the atmosphere while dispensing formulation.

[0012] Optionally, the reversible phase change is from a liquid to a vapour. Alternatively, the phase change may be from a solid to a liquid or a solid to a vapour.

[0013] Optionally, the sealed container is a balloon or bag disposed inside the air chamber, wherein the air working surface is the surface of the balloon or bag. In another embodiment, the sealed container is a bellow acting upon the air chamber, wherein the air working surface is the surface disposed between the bellow and the air chamber. Optionally, the formulation chamber is a container of changeable volume; and the formulation chamber comprises a formulation working surface, the formulation working surface being configured to act upon the formulation chamber to pressurise it.

[0014] Optionally, pressurised air from the air chamber acts upon the formulation working surface. The formulation working surface can take the form of one or more of: a piston, a bladder, a balloon and / or a bag, or a part of one or more of a piston, a bladder, a balloon and / or a bag.

[0015] Optionally, the compression mechanism is driven by an electric motor, for example a DC brushless motor. Alternatively, the compression mechanism may be operated manually. Optionally, the compression mechanism rotates the sealed container to compress it. In some embodiments the compression mechanism reduces the height of the sealed container to compress it. In some embodiments, the compression mechanism fills the air chamber with pressurised air to compress the sealed container. The compression mechanism may employ one or more of: a geared drive, a leadscrew, a cable and / or a drum.

[0016] Optionally, the substance that undergoes a reversible phase change is a liquefied gas, such as those used in traditional aerosol cans. The substance is never released from the spray dispenser into the atmosphere. Preferred substances are selected from hydrofluorocarbons (for example hydrofluorocarbon 152A), dimethylether, hydrocarbons such as propane, isobutane, butane and mixtures thereof.

[0017] Optionally, an air compressor provides pressurised air to the air chamber.

[0018] Optionally, the air compressor is contained in a dock separate to the spray dispenser, wherein the spray dispenser is removably attached to the dock to refill with pressurised air.

[0019] Optionally, the formulation chamber is replaceable or refillable. The formulation chamber may be removed and completely replaced by a new formulation chamber filled with formulation. Alternatively, the formulation chamber may have an inlet through which the formulation can be refilled. Refilling the formulation chamber may be done when the spray dispenser is placed in the dock.

[0020] Optionally, the formulation chamber is filled with a defined dose of formulation at the desired formulation working pressure and a second formulation chamber is filled with unpressurised formulation; and wherein the second formulation chamber supplies the formulation chamber with formulation when the formulation chamber is emptied.

[0021] Optionally, the spray dispenser further comprises a pressure maintenance mechanism which acts upon one or both of the air chamber and formulation chamber to maintain at least their respective desired working pressures during containment of air in the air chamber and formulation in the formulation chamber, and also dispensing of the combined air and formulation.

[0022] Optionally, the air chamber is pressurised to a pressure above the desired air working pressure, and the desired air working pressure and desired formulation working pressure are maintained during dispensing of the combined air and formulation, by one or more pressure control valves. The air chamber may be repressurised when pressure drops below the desired air working pressure.

[0023] Implementations are envisaged that encompass the combination of the aspects, embodiments and / or preferred features described above except where such a combination is clearly impermissible or expressly avoided.

[0024] Summary of the Figures

[0025] Embodiments and experiments illustrating the principles of the invention will now be discussed with reference to the accompanying figures in which:

[0026] Figure 1 shows an embodiment of the spray dispenser using a reusable phase change substance contained in a bellow that acts on the air chamber to pressurise the air chamber.

[0027] Figure 2 shows an embodiment of the spray dispenser using a reusable phase change substance contained in a bag within the air chamber to pressurise the air chamber.

[0028] Figure 3 shows an embodiment of the spray dispenser with a bag of a reusable phase change substance placed on a dock that provides compressed air to the air chamber with an air compressor. Detailed Description of the Invention

[0029] Aspects and embodiments of the present invention will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art. All documents mentioned in this text are incorporated herein by reference.

[0030] A spray dispenser 300 according to an embodiment of the present invention is described below with reference to Figure 1. The spray dispenser 300 has at least one air chamber 309. The air chamber 309 is for containing pressurised air. That is to say, the pressure of air in the air chamber can be retained at pressures greater than the pressure of air at ambient room condition. The air chamber 309 may be made from, for example polypropylene (PP), high density polyethylene (HDPE), low density polyethylene (LDPE), silicone, nitrile, perfluoroelastomer (FFKM), or any rigid body such as polyoxymethylene (POM) or aluminium, with an elastomer bung. In one example, the air chamber 309 has a volume of 460ml with a diameter of 56mm and a height of 214mm in its fully expanded state. In some examples, the volume is between 50ml and 1000ml. More preferably, the volume is between 200ml and 750ml. Even more preferably, the volume is between 400ml and 500ml. In some examples, the diameter is between 10mm and 80mm. More preferably, the diameter is between 30mm and 70mm. Even more preferably, the diameter is between 50mm and 60mm. In some examples, the height is between 40mm and 400mm. More preferably, the height is between 100mm and 300mm. Even more preferably, the height is between 200mm and 250mm.

[0031] The spray dispenser further comprises a formulation chamber 310. The formulation chamber 310 may be made from, for example an elastomer such as silicone, nitrile or FFKM, a soft plastic such as polyvinyl chloride (PVC) or polyurethane (Pll), or any rigid body such as POM or aluminium, with an elastomer bung. In one example, the formulation chamber 310 has a volume of 85ml with a diameter of 50mm and a height of 43mm in its fully expanded state. In some examples, the volume is between 5ml and 500ml. More preferably, the volume is between 10ml and 200ml. Even more preferably, the volume is between 50ml and 100ml. In some examples, the diameter is between 10mm and 80mm. More preferably, the diameter is between 30mm and 70mm. Even more preferably, the diameter is between 40mm and 60mm. In some examples, the height is between 5mm and 200mm. More preferably, the height is between 10mm and 100mm. Even more preferably, the height is between 40mm and 60mm. The formulation chamber 310 may be disposed inside the air chamber 309. When the spray dispenser 300 is actuated, for example by a user pushing a button or actuator on the exterior of the spray dispenser 300 (not shown), pressurised air travels from air chamber 309 along air outlet pathway 103 to the mixing chamber 102 where it is delivered at a desired air working pressure, and pressurised formulation travels from formulation chamber 310 along formulation outlet pathway 106 to the mixing chamber 102 where it is delivered at a desired formulation working pressure. Typically, both the desired air working pressure and desired formulation working pressures are greater than their respective pressures would be at ambient conditions. Mixing chamber 102 may take one of various forms known in the art, for example, an internal mixing chamber or a swirl chamber.

[0032] The air and formulation are mixed together in mixing chamber 102 and then dispensed from the spray dispenser. The air and formulation may be dispensed through a nozzle 101 which may take one of various forms known in the art, for example a mechanical break-up unit.

[0033] A sealed container of changeable volume 330, filled with a substance that undergoes a reversible phase change from a liquid to a vapour may pressurise the air chamber.

[0034] Optionally, the substance that undergoes a reversible phase change is a liquefied gas. The substance is never released from the spray dispenser into the atmosphere. Preferred substances are selected from hydrofluorocarbons (for example hydrofluorocarbon 152A), dimethylether, hydrocarbons such as propane, isobutane, butane and mixtures thereof.

[0035] The sealed container 330 may comprise one or more bellow(s) filled with a reuseable phase change substance acting upon the air chamber 309, wherein the air working surface 315 is the surface disposed between the bellow(s) 330 and the air chamber 309. In one example, the sealed container has a volume of 350ml with a diameter of 50mm and a height of 180mm. In some examples, the volume is between 10ml and 500ml. More preferably, the volume is between 10ml and 200ml. Even more preferably, the volume is between 50ml and 100ml. In some examples, the diameter is between 20mm and 80mm. More preferably, the diameter is between 30mm and 70mm. Even more preferably, the diameter is between 40mm and 60mm. In some examples, the height is between 5mm and 200mm. More preferably, the height is between 10mm and 100mm. Even more preferably, the height is between 40mm and 60mm. The sealed container may be made from, for example, PP, HDPE, silicone, PVC, Pll, LDPE or any rigid body with an eleastomer bung. As the spray dispenser 300 is actuated and air and formulation are dispensed, the vapour fraction within the sealed container 330 increases to maintain pressure equilibrium across the sealed container 330 and the air chamber 309 which causes the sealed container 330 to increase in volume. As the sealed container 330 expands, it acts on the air working surface 315 which causes the volume of the air chamber 309 to reduce and the pressure inside to increase. The air chamber 309 may comprise one or more bellow(s) with side walls that adapt in length depending on the force applied by the sealed container 330.

[0036] The formulation chamber 310 may be disposed inside the air chamber 309 so that the formulation working surface 310 is the surface of the formulation chamber 310 which the air inside the air chamber 309 acts directly on to pressurise the formulation contained within. The formulation chamber 310 may be a container of changeable volume that takes the form of a bladder, a balloon, a bag and / or a rigid body with a piston, made from, for example, silicone, PVC, Pll, LDPE, a rigid body such as POM or aluminium with an elastomer bung. The formulation refill inlet pathway 113 and formulation outlet pathway 106 are connected to the formulation chamber 310 via a connector, for example a rigid connector which may be plastically welded. The formulation chamber 310 may be disposed at the opposite end of the air chamber 309 to the air working surface 315 acted on by the sealed container 330.

[0037] It may be appreciated that the formulation chamber 310 may contain a dose of formulation and there may be a second unpressurised formulation chamber (not shown) disposed outside the air chamber 309, which supplies the dose formulation chamber 310 with formulation when the dose formulation chamber 310 is emptied.

[0038] Optionally, the pressurised air prior to actuation has a desired air working gauge pressure of between 0 and 14 bar measured at standard temperature and pressure (STP), which is known in the art to be 0 degrees Celsius and 1 atmosphere (atm) of pressure, or an absolute pressure of between 1 and 15 bar. More preferably, the desired air working gauge pressure is between 0.1 and 9 bar measured at STP or an absolute pressure of between 1.1 and 10 bar. Even more preferably, the desired air working gauge pressure is between 0.2 and 4 bar measured at STP or an absolute pressure of between 1.2 and 5 bar. Optionally, the pressurised formulation prior to actuation has a desired formulation gauge pressure of between 0 and 14 bar measured at STP or an absolute pressure of between 1 and 15 bar. More preferably, the desired formulation gauge pressure is between 0.1 and 9 bar measured at STP or an absolute pressure of between 1.1 and 10 bar. Even more preferably, the desired formulation gauge pressure is between 0.2 and 4 bar measured at STP or an absolute pressure of between 1.2 and 5 bar. An upper limit of 5 bar on the absolute pressure of the air and formulation working pressures may be advantageous for safety considerations.

[0039] Optionally, the air flow rate is between 0 and 1g / s. More preferably, the air flow rate is between 0.01 and 0.5 g / s. Even more preferably, the air flow rate is between 0.05 and 0.1g / s. Optionally, the formulation flow rate is between 0 and 2g / s. More preferably, the formulation flow rate is between 0.1 and 1g / s. Even more preferably, the formulation flow rate is between 0.18 and 0.4g / s. Optionally, the ratio of formulation:air in the dispensed mixture is from 1:2 to 10:1. More preferably, the ratio of formulatiomair is from 1 :1 to 8:1. Optionally, the length of one spray is between 1 and 10 seconds in duration. More preferably, the length of one spray is between 2 and 8 seconds in duration. Even more preferably, the length of one spray is between 4.5 and 5 seconds in duration.

[0040] Optionally, the particles produced have a volume-weighted mean diameter (D43) of between 10 and 250 microns. More preferably, the particles produced have a volume- weighted mean diameter (D43) of between 20 and 120 microns. Even more preferably, the particles produced have a volume-weighted mean diameter (D43) of between 40 and 100 microns.

[0041] The air working pressure of the air delivered to the mixing chamber may, optionally, be controlled by an air outlet pressure regulator 104. The formulation working pressure of the formulation delivered to the mixing chamber may, optionally, be controlled by formulation outlet pressure regulator 107. Air pressure regulator 104 and formulation pressure regulator 107 may allow the spray dispenser to dispense sprays at different pressures, depending on the desired spray performance.

[0042] Air outlet one-way valve 105 may optionally be disposed in air outlet pathway 103 only to allow air to pass in one direction from the air chamber 309 to the mixing chamber 102. Formulation outlet one-way valve 108 may optionally be disposed in formulation outlet pathway 106 to only allow formulation to pass in one direction from the formulation chamber 310 to the mixing chamber 102.

[0043] The formulation chamber 310 may be refillable through formulation refill inlet pathway 113 via a one-way valve 114. As formulation chamber 310 is filed with formulation, the formulation working surface expands to allow the formulation chamber 310 volume to expand. The formulation in any embodiment described herein may be considered a base formulation that does not contain any liquefied propellant. The base formulation may, for example, be one of the formulations contained in tables 1 to 8 below. Table 1

[0044] Table 2

[0045] Table 3

[0046] Table 4

[0047] Table 5 Table 6

[0048] Table 7 Table 8

[0049] In some embodiments, the product is a hairstyling formulation. In some embodiments, the product is a deodorant or antiperspirant formulation.

[0050] In some embodiments, the product comprises a hairstyling formulation comprising a hair styling polymer and a neutraliser. In some embodiments the formulation is an aqueous composition. In some instances, alcohol-based hairstyling formulations can lead to perceived negative performance by the consumer such as hair dryness. Thus, in some applications it may be preferable to use a water-based formulation in the invention.

[0051] In an alternative embodiment, the formulation is an alcohol-based composition. In some instances, water-based hairstyling formulations can lead to perceived negative performance by the consumer such as curl droop, long drying times and stickiness on the hair. Therefore, in some embodiments it may be preferable to use an alcohol-based formulation.

[0052] A hairstyling polymer is present preferably in an amount of from 1.0 to 10 wt %, preferably from 1.0 to 8.0 wt %, most preferably from 2 to 7 wt % by total weight of the hairstyling formulation.

[0053] The hairstyling polymer may be selected from a VA / Crotonates / Vinyl Neodecanoate Copolymer , Polyurethane-14 (and) AMP-Acrylates Copolymer (for example, DynamX available from AzkoNoble), Butyl Ester of PVM / MA Copolymer (for example, Gantrez available from Ashland), Polyester-5, Octylacrylamide / Acrylates / Butylaminoethyl Methacrylate Copolymer, imidized isobutylene / maleic anhydride copolymer (for example, Aquaflex™ FX-64 available from Ashland), Polyvinylpyrrolidone, Acrylates / Hydroxyesters Acrylates Copolymer (for example, Acudyne 180 available from DOW), Polyurethane-6, Acrylates / Octylacrylamide Copolymer and Acrylates Copolymer (for example, Balance CR available from AkzoNoble and Luvimer 100 P available from BASF), and more preferably from VA / CrotonatesA / inyl Neodecanoate Copolymer (for example, Resyn 28-2930 available from AkzoNoble) and Octylacrylamide / Acrylates / Butylaminoethyl Methacrylate Copolymer (for example, Amphomer available from AkzoNoble).

[0054] Preferably the styling resin comprises VA / Crotonates / Vinyl Neodecanoate Copolymer (for example, Resyn 28-2930 available from AkzoNoble) and Octylacrylamide / Acrylates / Butylaminoethyl Methacrylate Copolymer (for example, Amphomer available from AkzoNoble).

[0055] The neutralizer provides an alkaline base. The neutralizer is preferably selected from potassium hydroxide, sodium hydroxide, triisopropanolamine, 2-aminobutanol, 2-aminomethyl propanol, aminoethylpropandiol, dimethyl stearamine, sodium silicate, tetrahydroxypropyl ethylenediamine, ammonia, triethanolamine, trimethylamine, aminomerhylpropandiol, and more preferably 2-aminomethyl propanol, dimethyl stearamine and 2-aminobutanol and mixtures thereof.

[0056] The alcohol is preferably selected from ethanol, isopropyl alcohol, butanol, most preferably ethanol.

[0057] The alcohol is preferably present in an amount of from 30 to 99 wt % by total weight of the formulation, preferably from 35 to 98 wt %, more preferably from 35 to 95 wt %, most preferably from 50 to 95 wt %, by total weight of the formulation.

[0058] In some embodiments, the formulation is preferably substantially free of water. In embodiments when the formulation is free of water it preferably comprises less than 2 wt % water, by total weight of the hairstyling formulation. In at least one embodiment, the hairstyling formulation comprises 0.001 to 1.8 wt %, or 0.001 to 1.5 wt %, or 0.001 to 1 wt % water by total weight of the formulation. In some embodiments, the formulation is anhydrous.

[0059] In some alternative embodiments, water is present in an amount of from 20 wt % to 75 wt % by total weight of the formulation, preferably from 30 wt % to 70 wt %, more preferably from 35 wt % to 60 wt %, most preferably from 35 wt % to 55 wt %, by total weight of the formulation. When the formulation contains water, the formulation preferably contains less than 60wt% alcohol, more preferably less than 55 wt% alcohol, such as less than 20 wt % alcohol, more preferably less than 10 wt %, even more preferably 5 wt % and most preferably is substantially free of alcohol.

[0060] The formulation may also comprise other adjuncts commonly used in hair sprays. Preferably perfume, silicone (for example phenyl trimethicone, cyclopentylsiloxane, PEG / PPG-20 / 15 Dimethicone), emotives, corrosion inhibitors, emollients, UV absorbers (for example benzopheonone-4, ethyl hexyl methoxy cinnamate) and mixtures thereof.

[0061] In some embodiments, the formulation comprises one or more cosmetic actives.

[0062] The cosmetic active may be any of those known in the art that is suitable for spray application. Preferred cosmetic actives include deodorant actives, i.e. actives that can reduces body odour or at least the perception thereof. Preferred deodorant actives are organic in nature, to aid with their ethanol solubility.

[0063] Herein, “organic” deodorant actives should be understood to refer to actives comprising carbon and hydrogen. Such actives may also comprise other elements, including metals. Herein, deodorant actives comprising carbon, hydrogen and metal are termed organometallic deodorant actives.

[0064] Suitable organic deodorant actives for use in the present invention include 2-methyl-5- cyclohexylpentanol (SymDeo B125), butyloctanoic acid, dipropylene glycol, DTPA, ethylhexyl glycerol (Sensiva SC50), glyceryl laurate, lactic acid, menthyl lactate (Freshcolat ML), Octenidine hydrochloride (TPI 2007; Sensidin DO); pentylene glycol, piroctone olamine (Octopirox); poly(hexamethylenebiguanide) hydrochloride (Cosmocil CQ); polyquaternium-6 (Merquat 100); propanediol; propylene glycol; triclosan; triethyl citrate (Hydragen CAT); zinc neodecanoate; zinc phenol sulphonate; and zinc ricinoleate.

[0065] Organometallic deodorant actives are a preferred group of cosmetic actives for use in the invention since they typically have low volatility and good ethanol solubility. They can also have extremely good efficacy when delivered in accordance with the invention. Amongst such actives, zinc carboxylates salts are particularly preferred, these actives typically being zinc dicarboxylates, reflecting the stoichiometry of salts formed between divalent zinc ions and monovalent carboxylates. Herein, references to zinc carboxylates also include zinc dicarboxylates.

[0066] Preferred zinc carboxylates salts are salts of a fatty acid having from 6 to 18 carbon atoms. Such salts are relative hydrophobic in nature, enhancing the ease with which they can be formulated with ethanolic base compositions.

[0067] Preferred zinc carboxylate salts are salts of a fatty acid having from 8 to 14 carbon atoms, particularly 8 to 12 carbon atoms.

[0068] Preferred zinc carboxylate salts are salts of a saturated fatty acid, in particular salts of a saturated branched chain fatty acid having from 8 to 12 carbon atoms and more.

[0069] Other suitable deodorant actives for use include polyquaternium compounds, such as those disclosed in WO 16 / 012417 A1 (Beiersdorf, 2016) and WO 16 / 012420 A1 (Beiersdorf, 2016).

[0070] When employed, preferred PQ compounds may be selected from a list consisting of PQ-5, PQ-6, PQ-7, PQ-10, PQ-11, PQ-16, PQ-22, PQ-28, PQ-37 and mixtures thereof. Particularly preferred PQ compounds are PQ-6, PQ-16, PQ-22 and PQ-37; especially preferred are PQ-6, PQ-16 and PQ-22 and most preferred is PQ-6.

[0071] Herein, PQ-6, i.e. polyquaternium-6, is polymeric quaternary ammonium salt of diallyldimethylammonium chloride.

[0072] The cosmetic active is typically included in the formulation at a level of from 0.01 to 10%, preferably at from 0.05 % to 7.5% and most preferably at from 0.1% to 5%. These levels are of particular relevance when the cosmetic active is a deodorant active.

[0073] A preferred additional component in compositions used in the invention is a fragrance or fragrance oil, sometimes alternatively called a perfume (oil). The fragrance oil may comprise a single fragrance or component more commonly a plurality of fragrance components. Herein, fragrance oils impart an odour, preferably a pleasant odour, to the composition. Preferably, the fragrance oil imparts a pleasant odour to the surface of the human body the composition is applied to. The fragrance may be “free”, herein simply termed “fragrance” and / or it may be encapsulated by methods known in the art, in order to delay its release. Often, the delayed release of the fragrance is triggered by contact with moisture or, preferably, by friction. In preferred embodiments, compositions of the invention comprise both free and encapsulated fragrance.

[0074] The amount of fragrance oil in the formulation is preferably up to 20%, advantageously is at least 0.01% and particularly from 1% to 8%.

[0075] In some embodiments, the formulation comprises an emulsion such as an oil-in-water emulsion or a water-in-oil emulsion.

[0076] For example, in the water-in-oil emulsions, the continuous phase may comprise formulations such as the continuous phase may comprise a concentrate comprising one or more emollients. In some cases, the product comprises a composition comprising a water-in-oil emulsion comprising a continuous phase, wherein the continuous phase comprises a concentrate comprising at least about 10%, by weight of the mixture, of one or more water-insoluble emollients.

[0077] The air chamber 309 may be refillable through air inlet pathway 111 via a one-way valve 112.

[0078] When spray dispenser 300 is actuated, air from air chamber 309 travels to mixing chamber 102 and formulation from formulation chamber 310 travels to mixing chamber 102. In order to maintain vapour pressure, more of the liquid contained in sealed container 330 will convert to a vapour and therefore increase the volume of sealed container 330. This causes sealed container 330 to act on air working surface 315 to reduce the volume of air chamber 309 and maintain pressure as air is dispensed. This reduction in volume maintains the pressure of the air contained in the air chamber 309. When the spray is operated in the region of normal room temperatures which is expected in regular use. As pressure is maintained in air chamber 309, pressure is also maintained in formulation chamber 310 disposed within air chamber 309. The sealed container 330 of phase change substance therefore may act as a pressure maintenance mechanism.

[0079] In order to reuse the spray dispenser 300, a compression mechanism acts on a working surface 331 of the sealed container 330 to force the substance contained within to undergo a reverse phase change from a vapour to a liquid. This causes the sealed container 330 to decrease in volume, causing air chamber 309 to expand and draw in air through inlet 111. The compression mechanism may be driven by an electric motor 317 powered by battery 318 which acts on the bellows 330 to compress them. For example, the electric motor 317 may rotate a mechanical actuator, such as a leadscrew, (not shown) which working surface 331 is threaded onto such that the rotation of the leadscrew causes the working surface to move linearly to compress the bellows of the sealed container 330. Alternatively, the electric motor 317 could twist the sealed container 330 in the form of a bag or balloon. Alternatively, the electric motor could drive a cam, a wedge, a pul ly system, a rack and pinion or a scissor platform which act to compress the sealed container 330. Battery 318 may be replaceable or rechargeable. The electric motor 317 and battery 318 may be disposed at the bottom of the spray dispenser 300 below the air chamber 309 and the sealed container 330.

[0080] Once the air chamber 309 has been refilled, the torque acting on the sealed container 330 is released causing a proportion of the substance contained within to evaporate and expand, thereby driving air working surface 315 to reduce the volume of air chamber 309 and pressurise the air contained within. Consequently, the pressurised air acts on the surface of formulation chamber 310 to compress it and therefore reduce the volume of formulation chamber 310 and pressurise the formulation contained within. This utilises the properties of liquefied propellants currently used in traditional spray dispensers but does not release the propellant into the atmosphere.

[0081] A further embodiment of a spray dispenser 400 according to the present invention is described below with reference to Figure 2 where like reference numerals correspond to features described in relation to previous embodiments. In the embodiment of Figure 2, the sealed container 430 may take the form of a bag, bellows or a bladder disposed within the air chamber 409 made from, for example, PP, HDPE, silicone, PVC, Pll or LDPE. The air working surface is the surface of the sealed container 430 which acts directly on the air within the air chamber 409. The air chamber 409 may take the form of a rigid, cylindrical structure made from, for example, POM or aluminium.

[0082] As the spray dispenser 400 is actuated and the vapour fraction of the phase changes substance contained in sealed container 430 increases, the sealed container expands therefore decreasing the volume of the air chamber 409 and pressuring the air contained within. As the sealed container 430 expands, a mesh or grill 432, made from, for example, stainless steel or aluminium, may be disposed in the air chamber to prevent the sealed container 430 acting on the formulation chamber 310 directly. The pressurised air contained in air chamber 409 acts on the formulation chamber 310 to pressurise it. The sealed container 430 is compressed for reuse by motor 417 powered by battery 418 acting on the working surface 431 .

[0083] A further embodiment of a spray dispenser 500 according to the present invention is described below with reference to Figure 3 where like reference numerals correspond to features described in relation to previous embodiments. In the embodiment shown in Figure 3, the air chamber 409 is refilled with pressurised air provided by an air compressor 533 that takes in air from inlet 534. The air compressor 533 is contained within a dock 536 powered by mains power source 535 which is separate to the spray dispenser 500, wherein the spray dispenser 500 may be removably attached to the dock 536 by placing the spray dispenser on the dock 536. The dock 536 may also comprise motor 417 so that when the spray dispenser 500 is connected to the dock 536, the motor 417 can act on the sealed container 430 via working surface 431. Housing the air compressor 533 and / or motor 417 in a dock 536 makes the spray dispenser 500 more compact, lightweight and portable as less components are contained in the spray dispenser 500 and an up to 25% smaller air chamber 409 can be used. The formulation chamber 310 may also be refilled with formulation via a connection to the dock 536.

[0084] Air compressor 533 may provide enough compressed air to pressurise the air chamber 409 above the desired air working pressure and thereby pressurise the formulation chamber 310 above the desired formulation working pressure. A pressure maintenance mechanism may then be provided by an air pressure control valve 104 and a formulation pressure control valve 107 which maintain air and formulation being delivered to the mixing chamber 102 at least at their respective desired working pressures. This means a compression mechanism may not be required to compress the phase change substance in sealed container 430 and repressurise the air chamber 409 as the sealed container 430 will be compressed by pressurised air filling the air chamber 409.

[0085] The dock 536 may be used in combination with any of the other embodiments of spray dispenser described to provide compressed air to the air chamber and, optionally, provide the electric motor.

[0086] The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

[0087] While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.

[0088] For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

[0089] Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

[0090] Throughout this specification, including the claims which follow, unless the context requires otherwise, the word “comprise” and “include”, and variations such as “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

[0091] It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means for example + / - 10%.

Claims

1. Claims1. A spray dispenser comprising at least one air chamber for containing pressurised air and at least one formulation chamber for containing pressurised formulation, wherein when the spray dispenser is actuated, pressurised air from the air chamber is delivered to a mixing chamber at a desired air working pressure, and pressurised formulation from the formulation chamber is delivered to the mixing chamber at a desired formulation working pressure; wherein: the pressurised air and pressurised formulation are combined in the mixing chamber and dispensed therefrom; the air chamber is a container of changeable volume; the air chamber comprises an air working surface, the air working surface being configured to act upon the air chamber to pressurise it; and the spray dispenser comprises a sealed container of changeable volume filled with a substance that undergoes a reversible phase change; wherein the change in volume of the sealed container drives movement of the air working surface thereby changing the volume of the air chamber and the pressure of the air contained in the air chamber.

2. The spray dispenser of claim 1, wherein the reversible phase change is from a liquid to a vapour.

3. The spray dispenser of any one of claims 1 to 2, wherein the formulation chamber is a container of changeable volume; and wherein the formulation chamber comprises a formulation working surface, the formulation working surface being configured to act upon the formulation chamber to pressurise it.

4. The spray dispenser of claim 3, wherein pressurised air from the air chamber acts upon the formulation working surface.

5. The spray dispenser any one of the preceding claims, wherein to refill the air chamber with air, a compression mechanism acts upon the sealed container of changeable volume to force the substance contained within to undergo a reverse phase change.

6. The spray dispenser of claim 5, wherein the compression mechanism is driven by an electric motor.

7. The spray dispenser of any one of the preceding claims, wherein the substance that undergoes a reversible phase change is a liquefied gas.

8. The spray dispenser of any one of the preceding claims, wherein an air compressor provides pressurised air to the air chamber.

9. The spray dispenser of claim 8, wherein the air compressor is contained in a dock separate to the spray dispenser, wherein the spray dispenser is removably attached to the dock to refill with pressurised air.

10. The spray dispenser of any one of the preceding claims, wherein the formulation chamber is replaceable or refillable.

11. The spray dispenser of any one of the preceding claims, wherein the formulation chamber is filled with a defined dose of formulation at the desired formulation working pressure and a second formulation chamber is filled with unpressurised formulation; and wherein the second formulation chamber supplies the formulation chamber with formulation when the formulation chamber is emptied.

12. The spray dispenser of any of the preceding claims, wherein the spray dispenser further comprises a pressure maintenance mechanism which acts upon one or both of the air chamber and formulation chamber to maintain at least their respective desired working pressures during containment of air in the air chamber and formulation in the formulation chamber, and also dispensing of the combined air and formulation.

13. The spray dispenser of any one of the preceding claims, wherein the air chamber is pressurised to a pressure above the desired air working pressure, and the desired air working pressure and desired formulation working pressure are maintained during dispensing of the combined air and formulation, by one or more pressure control valves.

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