Component for an actuator, combinations with the component, and method of making the same

Abstract

A component (18, 18A, 18B, 18C) for an actuator (20, 120) on a container (24) of a fluent substance includes a unitary thermoplastic body (40, 40A, 40B, 40C) having a screen (42, 42A, 42B, 42C) defining an inlet side (44, 44A, 44B, 44C) for facing an interior of the actuator (20, 120) and an outlet side (46, 46A, 46B, 46C) for facing an exterior of the actuator (20, 120). The screen (42, 42A, 42B, 42C) includes a plurality of apertures (48, 48A, 48B, 48C) and is configured to receive a fluent substance from a dispensing flow path (22, 122) of the actuator (20, 122) and is configured to form a foam from the fluent substance on the outlet side (46, 46A, 46B, 46C) of the screen (42, 42A, 42B, 42C). In some forms, the component (18, 18A, 18B, 18C) is used with a mechanical breakup unit (60) installed on the inlet side (44, 44A, 44B, 44C) of the component (18, 18A, 18B, 18C). In other forms, the component (18, 18A, 18B, 18C) is integrally formed with the actuator (20, 120).

Description

SEA04401P00271PC (CRY-033)-1-COMPONENT FOR AN ACTUATOR, COMBINATIONS WITH THE COMPONENT,AND METHOD OF MAKING THE SAMEPRIORITY

[0001] This application claims priority of U. S. Provisional Patent Application No.63 / 749,514, filed January 25, 2025, the entire contents of which is incorporated herein by reference.TECHNICAL FIELD

[0002] The present invention relates generally to hand-held dispensing packages for dispensing a fluent substance, typically in the form of a spray or foam, from a container. A finger-operable actuator is used in such dispensing packages to actuate a valve or pump to dispense the fluent substance from the interior of the container. The invention more particularly relates to dispensing packages having an actuator that provides a foaming transformation of the fluent substance.BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE PRIOR ART

[0003] Finger-operable actuators are typically adapted to be incorporated in dispensing systems mounted on hand-held containers that are commonly used for fluent substances. Some actuators are designed for use with a valve assembly and have a suitable discharge structure to produce a foam, mousse, or atomized spray. A dispensing system including such a valve assembly and cooperating actuator is typically used for dispensing household fluent substances or products, such as cleaning products, deodorizers, insecticide; and other fluent products, such as cosmetic products or otherSEA04401P00271PC (CRY-033)-2-personal care products such as shaving cream or shaving foam, hair mousse, sun care products, etc., as well as other institutional and industrial products.

[0004] Dispensing systems having a valve assembly and cooperating actuator are typically mounted at the top or opening of a container, such as a metal can or polyethylene terephthalate (“PET”) bottle containing a pressurized fluent substance. The container, the product and any propellant in the container, the valve assembly, and the actuator all together make up a dispensing package. The actuator typically includes a component that is connected to the valve assembly external of the container and that provides a dispensing flow path or passage from the valve assembly and through which the product can be dispensed to a target area.

[0005] For some types of fluent products, the dispensing system may be provided with a structure in the actuator to direct or shape the spray pattern of the fluent product as it is dispensed from the actuator. In current systems, this structure is provided in the form of a nozzle insert having special configurations in the orifice or orifices of the insert that provide the spray pattern. U. S. Patent No. 7,510,131 B2 shows some examples of such nozzle inserts and U. S. Patent No. 10,112,767 B2 illustrates such actuators, each reference being incorporated in its entirety as if fully set forth herein.

[0006] While current actuators may work well for their intended purpose of facilitating the movement of a fluent product from the container to the exterior of the actuator, the inventor has found such current actuators may require complicated and expensive composite structures to transform the fluent product from a liquid to a foam.

[0007] There exists a need for a feasible, cost-effective, solution for improved dispensing, particularly with respect to the formation of foams from liquid products.

[0008] The inventor of the present invention has discovered that, in at least some applications, it would be desirable to provide a component for use in an actuator, particularly suitable for use with generating a foam from a liquid product, which can be more easily manufactured, assembled, and / or recycled compared to the prior art.SEA04401P00271PC (CRY-033)-3-

[0009] The inventor of the present invention has also determined that it would be desirable to provide, at least for some applications, a component for an actuator that can exhibit improved dispensing across a wide variety of fluent substances having different formulations.

[0010] The inventor of the present invention has also discovered that it would be desirable to provide, at least for some applications, an improved actuator component that can be manufactured and / or assembled as a unitary thermoplastic construction at a relatively low cost, and can accommodate manufacture of the actuator by means of efficient, high-quality, large-volume techniques, and that can facilitate the minimization of plastic and part weight.

[0011] The inventor of the present invention has discovered how to provide such a component for an actuator, and assemblies and combinations thereof with an actuator and other structures, which includes novel, advantageous features not heretofore taught or contemplated by the prior art, and which can accommodate designs having one or more of the above-discussed benefits or features.SUMMARY OF THE INVENTION

[0012] In accordance with one broad form of the invention, a component is provided for an actuator for use with a container of a fluent substance, the actuator being of the type having a dispensing flow path to direct a fluent substance from an interior of the container to an exterior of the actuator. The component has a unitary thermoplastic body having a screen defining an inlet side for facing an interior of an actuator and an outlet side for facing an exterior of the actuator. The screen defines a plurality of apertures and is configured to receive a fluent substance from a dispensing flow path of the actuator and is further configured to form a foam from the fluent substance on the outlet side of the screen.SEA04401P00271PC (CRY-033)-4-

[0013] In one form of the present invention, the body is unitarily molded from a single polymer.

[0014] In another form of the present invention, the screen has an arcuate inlet surface that is located on the inlet side of the screen.

[0015] According to one aspect of the present invention, the includes an outlet surface that is located on the outlet side and that is substantially flat.

[0016] In one form of the present invention, the plurality of apertures in the screen are square.

[0017] According to one form of the present invention, the body further has an annular wall extending inwardly from the inlet side for engaging a portion of an actuator to retain the component at a dispensing flow path of the actuator.

[0018] In another form of the present invention, the body includes a nozzle extending outwardly from the outlet side.

[0019] In one form of the present invention, the body includes a flange extending laterally outwardly of, and surrounding, the screen.

[0020] In still another form of the present invention, the component is provided in combination with an actuator, wherein the component is retained at a dispensing flow path of the actuator. Preferably, the combination is further provided with a mechanical breakup unit insert that is retained with the actuator at a location on the inlet side of the component.

[0021] According to one form of the present invention, the component is unitarily formed with an actuator.

[0022] According to another aspect of the present invention, the component is provided in combination with an actuator and a container of a fluent substance--all together defining a package.SEA04401P00271PC (CRY-033)-5-

[0023] In accordance with another broad form of the present invention, a method of manufacturing an actuator for use with a container of a fluent substance includes the step of obtaining an actuator. The actuator has a dispensing flow path to direct a fluent substance from an interior of the container to an exterior of the actuator. The method includes the step of obtaining a component that has a unitary thermoplastic body having a screen defining an inlet side for facing an interior of an actuator and an outlet side for facing an exterior of the actuator. The screen defines a plurality of apertures and is configured to receive a fluent substance from a dispensing flow path of the actuator and is further configured to form a foam from the fluent substance on the outlet side of the screen. The method includes the step of retaining the component with the actuator at the dispensing flow path to locate the inlet side of the component to face the interior of the actuator. Preferably, the method includes the further steps of obtaining a mechanical breakup unit insert and retaining the mechanical breakup unit insert at the dispensing flow path at a location on the inlet side of the component.

[0024] Other objects, features, and advantages of the invention will become apparent from a review of the entire specification, including the appended claims and drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0025] FIG. 1 is an isometric, cross-sectional view from the front and right side of a first embodiment of a component according to the present invention for use in an actuator (not illustrated in FIG. 1) for being installed on a container of pressurized fluent substance (not illustrated in FIG. 1 );

[0026] FIG. 2 is an isometric view from the front, top, and right side of the component of FIG. 1;

[0027] FIG. 3 is an isometric view from the rear, top, and right side of the component of FIG. 1;SEA04401P00271PC (CRY-033)-6-

[0028] FIG. 4 is an isometric view from the front, top, and right side of a second embodiment of a component according to the present invention for use in an actuator (not illustrated in FIG. 4) for installation on a container of pressurized fluent substance (not illustrated in FIG. 4);

[0029] FIG. 5 is an isometric, exploded view from the front, top, and right side of another embodiment of a component according to the present invention in combination with an actuator and a mechanical breakup unit;

[0030] FIG. 6 is a cross-sectional view of the assembled component, actuator, and mechanical breakup unit of FIG. 5, taken along a vertical plane through the center of the flow path of the actuator;

[0031] FIG. 7 is an isometric, exploded view from the front, top, and right side of yet another embodiment of a component according to the present invention for use with a spray manifold type actuator for being installed on a container of pressurized fluent substance (not illustrated in FIG. 7);

[0032] FIG. 8 is an isometric view from the rear and right side of the component of FIG. 7, and FIG. 8 shows the inlet side of the component;

[0033] FIG. 9 is an isometric view from the front and right side of the component of FIG. 7, and FIG. 9 shows the outlet side of the component;

[0034] FIG. 10 is a front elevation view of the component of FIG. 7;

[0035] FIG. 11 is a cross-sectional view of the component of FIG. 7, taken along the view plane 11-11 in FIG. 10;

[0036] FIG. 12 is a rear elevation view of the component of FIG. 7; and

[0037] FIG. 13 is an isometric view from above of a fragmentary upper portion of a container and a spray valve.DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] While this invention is susceptible of embodiment in many different forms, this specification and the accompanying drawings disclose only some specific forms asSEA04401P00271PC (CRY-033)-7-examples of the invention. The invention is not intended to be limited to the embodiments so described, however. The scope of the invention is pointed out in the appended claims.

[0039] For ease of description, the components and assemblies of this invention are described in a typical (upright) position, and terms such as upper, lower, radial, axial, above, below, etc., are used with reference to this position that the components would have when installed upon an upright container of a fluent substance or product (the upper portion of a container being only partially illustrated in FIG. 13). It will be understood, however, that the components embodying this invention may be manufactured, stored, transported, used, and sold in an orientation other than the position described.

[0040] Figures illustrating the components of this invention may omit the valve or pump and the container (with the exception of FIG. 13), which are conventional mechanical elements that are known and that will be recognized by one skilled in the art. The detailed descriptions of such cooperating elements are not necessary to an understanding of the invention, and accordingly, are herein presented only to the degree necessary to facilitate an understanding of the novel features of the present invention.

[0041] As will be further described in detail, the present invention is directed to a component for an actuator that is used for dispensing a fluent material or product (and is especially suitable for dispensing a pressurized liquid to be transformed into a foam). The inventive component, when used within an actuator, can dispense types of fluent materials or substances in a manner that minimizes or at least reduces the number, cost, and / or manufacturing complexity of components of the actuator.

[0042] FIGS. 1-3 illustrate a first embodiment of a component 18 according to the present invention for use with an actuator (such as the actuator 20 shown in FIGS. 5 and 6) having a dispensing flow path (e.g., the flow path 22 in FIG. 6), and such an actuator 20 is suitable for use in a hand-held dispensing package including a pressurized container (e.g., 24 in FIG. 13) containing a fluent substance, and a pump (not illustrated) or dispensing valve in the form of an aerosol dispensing valve (e.g., 28 in FIG. 13) or other conventional valve.SEA04401P00271PC (CRY-033)-8-

[0043] It should be understood that the actuator 20, the container 24, and / or the valve 28 can be of any conventional, known construction, and accordingly will only be briefly described herein. The container 24 is typically a metal can having an upper edge rolled into a mounting bead surrounding a container opening. The container 24 could be a plastic (e.g., PET) bottle. The container 24 is adapted to hold the fluent substance (e.g., a liquid) and pressurized gas below the valve 28.

[0044] With reference to FIG. 13, the valve 28 may be of any suitable conventional or special type. The dispensing valve 28 will typically include a body, and the valve body contains the working components of the valve, with the bottom end of the body being attached to a conventional dip tube (not visible) that directs the fluent product from the container 24 and into the valve body to be dispensed from the container 24. The upper end of the valve body typically has a valve stem 29 that projects above the top of the container 24 to be actuated from a closed position (wherein fluent product is not dispensed through the valve 28) to an open position (wherein the fluent product is dispensed through the valve 28 via the valve stem 29). Typically, the valve stem 29 is biased to the closed position, such as by a spring (not visible) contained in the valve body, so that the valve 28 is normally closed unless forced to the open position by the actuator 20 as it is actuated by a user. After the dispensing valve 28 is actuated to dispense product, such as an atomized spray or a foaming liquid, the user terminates the actuation operation so that the valve stem 29 is returned by the spring to the closed position condition wherein the valve 28 is closed.

[0045] The dispensing valve 28 may be mounted to the container 24 by any suitable means, one such suitable means being a conventional valve mounting cup which has a mounting flange with an outer peripheral portion that can be crimped about the container mounting bead to provide a secure and sealed attachment of the mounting cup to the container 24 at the container opening. The mounting cup includes an annular inner wall which defines an opening through which a portion of the valve body projects, with a portion of the annular inner wall crimped to the exterior of the valve body to provide aSEA04401P00271PC (CRY-033)-9-secure and sealed attachment of the valve body to the mounting cup. U. S. Application Publication Number 2008 / 0210710 A1, and U. S. Patent Numbers 7,249,692 and 7,861,894 each show and describe in further detail other suitable forms of dispensing valves 28 that can be employed in connection with the present invention.

[0046] It will be appreciated that the particular type of the dispensing valve 28 may be of any suitable design for dispensing a product from the container 24 (with or without a dip tube) out through the valve stem 29. The detailed design and construction of the dispensing valve 28 per se forms no part of the present invention. It should be understood that while the preferred embodiments of the actuator 20 are shown herein in connection with a dispensing valve 28, in some applications it may be desirable to utilize an actuator according to the invention with other types of dispensing devices, such as a hand-powered or finger-operated pump or other dispensing systems or devices.

[0047] As best seen in FIG. 1, the component 18 of the present invention includes a body 40 that has a unitary thermoplastic construction such as a polypropylene or a polyethylene. The body 40 may be preferably molded or formed from a single polymer categorized in a single recycling identification number (“RIN”) for single stream recycling capability. The body 40 includes an integral screen 42 that defines or separates an inlet side 44 for facing the interior of the actuator 20 (visible in FIGS. 5 and 6) and an outlet side 46 for facing the exterior (e.g., ambient) environment of the actuator 20. The screen 42 defines a plurality of apertures 48 to permit flow of a fluent substance therethrough. The screen 42 is configured to receive a fluent substance such as a liquid from a dispensing flow path 22 (visible in FIG. 6) of the actuator 20 and transforms the fluent substance into a foam on the outlet side 46 of the screen 42. It can be seen that the screen 42 includes an inlet surface 50 located on the inlet side 44. The inlet surface 50 is tapered in the direction moving away from the screen 42 (i.e., in the upstream direction away from the direction of flow) and has an arcuate shape when viewed in cross-section (as shown in FIG. 1 ) in a vertical plane extending along the center of the flow path. The screen 42 further has an outlet surface 52 that is substantially or approximately flat.SEA04401P00271PC (CRY-033)-10-

[0048] With reference to FIG. 1, it can be seen that the apertures 48 are predominantly square in shape, with the exception of some of the apertures 48 located toward the perimeter of the screen 42, which may have truncated square shapes with a circular side. It will be understood that, while the preferred embodiment defines the apertures 48 as squares of generally equal sizes for producing a desirable foam from a liquid fluent substance, the shape, number, size, and arrangement of the apertures 48 could be modified for other applications. For example, the number, size, shape, and arrangement of the apertures 48 could be modified to control the foam characteristics such as foam density, projection, spray rate, bubble size, etc. The apertures 48 might be circular, oval, polygonal, or irregularly shaped.

[0049] Referring now to FIGS. 1 and 3, the body 40 of the component 18 includes an annular wall 54 that extends inwardly (in the upstream flow direction) away from the screen 42 on the inlet side 44. The annular wall 54 includes a plurality of projections and recesses therebetween to assist in engaging a portion of the actuator 20 to retain the component 18 in the dispensing flow path 22 of the actuator 20 (FIG. 6). While the preferred, illustrated first embodiment of the component 18 is especially suitable for being mechanically retained within the dispensing flow path 22 of the actuator by means of friction fit, it will be understood that other means may be employed, such as welding, heating, gluing, or bi-injection molding, etc. of the component 18 with the actuator 20. In such cases, the annular wall 54 and inlet side 44 may be re-configured to accommodate different mating surfaces and / or structures of the actuator 20.

[0050] Referring now to FIGS. 1 and 2, the body 40 of the component 18 includes a nozzle 56 that extends outwardly (in the downstream flow direction) away from the screen 42 on the outlet side 46. The nozzle 56 expands laterally outwardly, relative to the central axis 57 of the flow path 22 to assist in the management and projection of the foam created by impingement of the fluent substance against the screen 42. The interior surfaces of the nozzle 56 include a first portion, proximate to the screen 42, that is angled less than about 45 degrees, relative to a vertical plane that extends in a perpendicularSEA04401P00271PC (CRY-033)-11-direction to the direction of flow, and a second portion, distal to the screen 42, that is between about 70 degrees and about 90 degrees, relative to a vertical plane that extends in a perpendicular direction to the direction of flow. While the preferred, first illustrated embodiment of the component 18 is especially suitable for dispensing a fluent substance in the form of a foam created from a pressurized liquid, it will be understood that the shape and / or angle of the nozzle 56 may be modified for other applications. For example, the nozzle 56 may have a non-linear, arcuate interior surface or irregular, faceted surface.

[0051] Still referring to FIGS. 1 and 2, the body 40 of the component 18 includes a flange 58 that extends laterally outwardly of, and surrounding the screen 42. The flange 58 has a circular, disc-like shape with an axially inwardly extending annular wall located at its laterally distal end.

[0052] In the presently preferred form of the present invention, the component 18 is a separately molded component from the actuator 20, such that the component 18 is retained with the actuator 20 by the aforementioned means (e.g., friction, weld, adhesive, etc.) in the dispensing flow path 22 to locate the inlet side 44 of the component 18 toward the interior of the actuator 20. However, it will be understood that in some applications, the component 18 may be unitarily molded or otherwise formed with the actuator 20 such that no assembly is required.

[0053] The component 18 may also be advantageously utilized with a spray insert or mechanical breakup unit insert (“MBU”) (such as the MBU 60 shown in FIGS. 5 and 6) that is retained in the actuator 20 at a location in the dispensing flow path 22 on the inlet side 44 (i.e., upstream) of the component 18. A variety of MBU geometries and assemblies with an actuator are disclosed in International Patent Application Publication No. WO 2013 / 055323 A1 for providing a desired spray pattern or profile, and this reference is incorporated by reference herein in its entirety.

[0054] With reference to FIG. 6, the actuator 20 has a body or base 62 that may be installed atop a portion of a pump (not illustrated) or, alternatively, a portion of a valve 28 (shown in FIG. 13 only), and / or a portion of the container 24 (illustrated in FIG. 13SEA04401P00271PC (CRY-033)-12-only). The base 62 has a deflectable actuator button 64 that is movable relative to the remainder of the base 62. It should be appreciated that there are many possible forms for the base 62 and the actuator button 64 depending on the intended application of the actuator 20. The base 62 includes a downwardly extending, internal stem pocket 72 to securely receive the valve stem 29 (illustrated in FIG. 13 only) at the opening of the container 24 (illustrated in FIG. 13 only). The flow passage or path 22 extends through the base 62 to direct fluent product from the valve stem 29 to the exterior of the actuator 20. The button 64 is located laterally rearwardly of the stem pocket 72 and flow path 22 defined therein. The button 64 is deflectable or movable between (i) a neutral, nonactuating position wherein the stem pocket 72 is located so as not to actuate the valve 28, and (ii) an actuating position wherein the stem pocket 72 is located to move the valve stem 29 to actuate the valve 28 to dispense a fluent product. The button 64 is biased to the neutral position, which in the illustrated embodiment is the as-molded condition or as-formed condition of base 62. In some embodiments of the invention, the base 62 may be attached only to the valve, or to an aluminum can shoulder.

[0055] The flow path 22 proximate to the component 18 is centered on, and defines, a central axis 57. The screen 42 of the component 18 is generally centered on the central axis 57, such that the tapered inlet surface 50 impinges the fluent substance traveling through the flow path 22 (visible in FIG. 6) in a uniform and symmetrical manner.

[0056] The inventor has discovered that the component 18 may provide a suitable foam formation mechanism that is able to be constructed in a manner that minimizes, or at least reduces, the cost and complexity of such mechanisms compared to the prior art. Currently, such screens are formed from a metal woven mesh that must be trim-punched and welded, mechanically, or adhesively held in place in the actuator. These prior art designs are not amenable to recycling and greatly increase the manufacturing and assembly costs of the components and actuator. It is currently believed the mesh size and shape, which can be controlled by the injection molding tooling, offers better controlSEA04401P00271PC (CRY-033)-13-of the mesh opening size and shape, thus resulting in more consistent foam properties compared to the prior art metal screens.

[0057] It should be understood that while some preferred embodiments are shown, these embodiments are illustrative of the concepts of the invention and that there are many possible forms for the component, actuator, spray insert, valve or pump, and container that are within the scope of the invention. For example, the size, shape, and arrangement of the apertures, the size and shape of the nozzle, and the inlet and outlet surface geometry of the screen can be modified from those illustrated to achieve different foam spray characteristics and / or to accommodate different fluent products and / or different dispensing pressures.

[0058] As yet a further example, while the portion of the flow path proximate to the screen extends horizontally when the actuator is installed on an upright container, any other orientation is possible within the scope of the invention and other orientations may be more desirable depending upon the requirements of each application. For example, in some applications it may be desirable for the axis to extend at an angle relative to the horizontal plane, such as, for example vertically, or as a further example, at a 45 degree angle relative to horizontal. Furthermore, while all of the illustrated embodiments show a single flow path, it may be desirable to provide multiple such flow paths in a single actuator. As an even further example, while the flow channels and screens in the illustrated embodiments are shown centered on the longitudinal axis, it may be desirable in some applications for the flow channel and / or screen to be offset relative to the longitudinal axis.

[0059] A second embodiment of a component 18A according to the present invention for use in an actuator is illustrated in FIG 4. Like elements between the first illustrated embodiment of the component 18 and the second illustrated embodiment of the component 18A are designated with the same numeral (the first embodiment having no suffix and the second embodiment having an “A” suffix). The second illustrated embodiment of the component 18A has the same basic elements as the first illustratedSEA04401P00271PC (CRY-033)-14-embodiment of the component 18, and also includes a unitary thermoplastic body 40A that has a screen 42A that defines an inlet side 44A for facing an interior of an actuator and an outlet side 46A for facing an exterior of the actuator. The screen 42A defines (i.e., includes) a plurality of apertures 48A that are substantially and predominantly square in shape. The screen 42A includes a substantially flat, somewhat recessed outlet surface 52A and a tapering inlet surface (not visible in FIG. 4, but identical to that of the first illustrated embodiment). An annular wall 54A extends axially inwardly for engaging a portion of an actuator (e.g., such as the actuator 20 discussed above or any other actuator) to retain the component 18A at a dispensing flow path of the actuator. It will be understood that while the component 18A defines the apertures 48A as squares of generally equal sizes for producing a desirable foam from a liquid fluent substance, the shape, number, size, and arrangement of the apertures 48A could be modified for other applications. For example, the number, size, shape, and arrangement of the apertures 48A could be modified to control the foam characteristics such as foam density, projection, spray rate, bubble size, etc.). The apertures 48A might be circular, oval, polygonal, or irregularly shaped.

[0060] Still referring to FIG.4, the second illustrated embodiment of the component 18A differs from the first illustrated embodiment in that the body 40A does not include any nozzle or flange structures, which minimizes plastic part weight and which may be desirable for some installations within an actuator and some dispensing applications.

[0061] A third embodiment of a component 18B according to the present invention for use in an actuator is illustrated in FIGS. 5 and 6. Like elements between the second illustrated embodiment of the component 18A and the third illustrated embodiment of the component 18B are designated with the same numeral (the second embodiment having an “A” suffix and the third embodiment having a “B" suffix). The third illustrated embodiment of the component 18B has the same basic elements as the second illustrated embodiment of the component 18A, and also includes a unitary thermoplastic body 40B that has a screen 42B that defines an inlet side 44B for facing an interior of an actuatorSEA04401P00271PC (CRY-033)-15-and an outlet side 46B for facing an exterior of the actuator 20. The screen 42B defines a plurality of apertures 48B that are substantially and predominantly square in shape. The screen 42A includes a substantially flat, non-recessed outlet surface 52B and a tapering inlet surface 50B. An annular wall 54B extends axially inwardly for engaging a portion of an actuator (e.g., such as the actuator 20 discussed above or any other actuator) to retain the component 18B at a dispensing flow path 22 of the actuator 20. It will be understood that while the component 18B defines the apertures 48B as squares of generally equal sizes for producing a desirable foam from a liquid fluent substance, the shape, number, size, and arrangement of the apertures 48B could be modified for other applications. For example, the number, size, shape, and arrangement of the apertures 48B could be modified to control the foam characteristics such as foam density, projection, spray rate, bubble size, etc. The apertures 48B might be circular, oval, polygonal, or irregularly shaped.

[0062] Still referring to FIGS. 5 and 6, the third illustrated embodiment of the component 18B differs from the second illustrated embodiment in that the outlet surface 50B of the screen 42B is flush or flat with the axially-outermost end of the wall 54B, which may be desirable for some installations within an actuator and some dispensing applications.

[0063] A fourth embodiment of a component 18C according to the present invention for use in a spray manifold type actuator 120 is illustrated in FIGS. 7-12. Like elements between the third illustrated embodiment of the component 18B and the fourth illustrated embodiment of the component 18C are designated with the same numeral (the third embodiment having a “B” suffix and the fourth embodiment having a “C” suffix). The fourth illustrated embodiment of the component 18C has the same basic elements as the third illustrated embodiment of the component 18B described above, and also includes a unitary thermoplastic body 40C that has a screen 42C that defines an inlet side 44C for facing an interior of an actuator and an outlet side 46C for facing an exterior of the spray manifold 120. The screen 42C defines includes a plurality of apertures 48C that areSEA04401P00271PC (CRY-033)-16-substantially and predominantly square in shape. The screen 42A includes a substantially flat, non-recessed outlet surface 52B and a tapering inlet surface 50B. It can be seen that the body 40C is relatively planar or disc-shaped and lacks any type of annular wall for engaging a portion of an actuator (e.g., such as the actuator 20 discussed above or manifold 120) to retain the component 18C at a dispensing flow path 22 of the actuator 20 or dispensing flow path 122 of the manifold 120. It will be understood that while the component 18C defines the apertures 48C as squares of generally equal sizes for producing a desirable foam from a liquid fluent substance, the shape, number, size, and arrangement of the apertures 48C could be modified for other applications. For example, the number, size, shape, and arrangement of the apertures 48C could be modified to control the foam characteristics such as foam density, projection, spray rate, bubble size, etc. The apertures 48C might be circular, oval, polygonal, or irregularly shaped. It will be understood that the disc-like body 40C, which does not include any nozzle, flange, or annular wall features, minimizes plastic part weight and which may be desirable for some installations within an actuator and some dispensing applications.

[0064] Various modifications and alterations to this invention will become apparent to those skilled in the art without departing from the scope and spirit of this invention. Illustrative embodiments and examples are provided as examples only and are not intended to limit the scope of the present invention.

Claims

SEA04401P00271PC (CRY-033)-17-WHAT IS CLAIMED IS:

1. An assembly ( 0) for use in dispensing a fluent substance from a container (24), said assembly (10) comprising:an actuator (20, 120) for being located at an opening of a container (24) of a fluent substance, said actuator (20, 120) having a dispensing flow path (22, 122) to direct a fluent substance from an interior of the container (24) to an exterior of said actuator (20, 120);a component (18, 18A, 18B, 18C) located in said dispensing flow path (22, 122) of said actuator (20, 120), said component having a unitary thermoplastic body (40, 40A, 40B, 40C) having a screen (42, 42A, 42B, 42C) defining an inlet side (44, 44A, 44B, 44C) facing an interior of said actuator (20, 120) and an outlet side (46, 46A, 46B, 46C) facing an exterior of the actuator (20, 120), said screen (42, 42A, 42B, 42C) defining a plurality of apertures (48, 48A), said screen (42, 42A) configured to receive a fluent substance from said dispensing flow path (22, 122) of said actuator (20, 120) and configured to form a foam from the fluent substance on said outlet side (46, 46A, 46B, 46C); anda mechanical breakup unit insert (60) retained in said actuator (20) at a location on said inlet side (44, 44A, 44B, 44C) of said component (18, 18A, 18B, 18C).

2. The assembly (10) according to claim 1 wherein said body (40, 40A, 40B, 40C) of said component (18, 18A, 18B, 18C) is unitarily molded from a single polymer.

3. The assembly (10) according to any of preceding claims 1-2 wherein said screen (42, 42A, 42B, 42C) further comprises an inlet surface (50, 50A, 50B, 50C) located on said inlet side (44, 44A, 44B, 44C) that is arcuate.SEA04401P00271PC (CRY-033)-18-4. The assembly (10) according to any of preceding claims 1-3 wherein said screen (42, 42A, 42B, 42C) further comprises an outlet surface (52, 52A, 52B, 52C) located on said outlet side (46, 46A) that is substantially flat.

5. The assembly (10) according to any of preceding claims 1-4 wherein said plurality of apertures (48, 48A, 48B, 48C) are square.

6. The assembly (10) according to any of preceding claims 1-5 wherein said body (40, 40A, 40B) of said component (18, 18A, 18B) further comprises an annular wall (54, 54A, 54B) extending inwardly from said inlet side (44, 44A, 44B) for engaging a portion of said actuator (20, 120) to retain said component (18, 18A, 18B) at said dispensing flow path (22, 122) of said actuator (20, 120).

7. The assembly (10) according to any of preceding claims 1-6 wherein said body (40) of said component (18) further comprises a nozzle (56) extending outwardly from said outlet side (46).

8. The assembly (10) according to any of preceding claims 1-7 wherein said body (40) of said component (18) further comprises a flange (58) extending laterally outwardly of, and surrounding, said screen (42).

9. The assembly (10) according to any of preceding claims 1-8 wherein said body (40C) of said component (18C) is planar.

10. The assembly (10) according to any of preceding claims 1-9 wherein said component (18, 18A, 18B, 18C) is unitarily formed with said actuator (20, 120).SEA04401P00271PC (CRY-033)-19-11. The assembly (10) according to any of preceding claims 1-10 in combination with a container (24) of a fluent substance in the form of a package.

12. A method of manufacturing an assembly (10) for use with a container (24) of a fluent substance, the method comprising the steps of:obtaining an actuator (20, 120) for use with a container (24) of a fluent substance, said actuator (20, 120) having a dispensing flow path (22, 122) to direct a fluent substance from an interior of the container (24) to an exterior of said actuator (20, 120);obtaining a component (18, 18A, 18B, 18C) having a unitary thermoplastic body (40, 40A, 40B, 40C) having a screen (42, 42A, 42B, 42C) defining an inlet side (44, 44A, 44B, 44C) for facing an interior of said actuator (20, 120) and an outlet side (46, 46A, 46B, 46C) for facing an exterior of said actuator (20, 120), said screen (42, 42A, 42B, 42C) defining a plurality of apertures (48, 48A, 48B, 48C), said screen (42, 42A, 42B, 42C) configured to receive a fluent substance from said dispensing flow path (22, 122) of said actuator (20, 120) and configured to form a foam from the fluent substance on said outlet side (46, 46A, 46B, 46C);obtaining a mechanical breakup unit insert (60):retaining said mechanical breakup unit insert (60) with said actuator (20, 120) at said dispensing flow path (22, 122);andretaining said component (18, 18A, 18B, 18C) with said actuator (20, 120) at said dispensing flow path (22, 122) to locate said inlet side (44, 44A, 44B, 44C) of said component (18, 18A, 18B, 18C) to face said mechanical breakup unit insert (60).

13. A component (18, 18A, 18B, 18C) for an actuator (20, 120) for use with a container (24) of a fluent substance, the actuator (20, 120) having a dispensing flow pathSEA04401P00271PC (CRY-033)-20-(22, 122) to direct a fluent substance from an interior of the container (24) to an exterior of said actuator (20, 120), said component (18, 18A, 18B, 18C) comprising:a unitary thermoplastic body (40, 40A, 40B, 40C) having a screen (42, 42A, 42B, 42C) defining an inlet side (44, 44A, 44B, 44C) for facing an interior of an actuator (20, 120) and an outlet side (46, 46A, 46B, 46C) for facing an exterior of the actuator (20, 120), said screen (42, 42A, 42B, 42C) defining a plurality of apertures (48, 48A), said screen (42, 42A) configured to receive a fluent substance from a dispensing flow path (22, 122) of the actuator (20, 120) and configured to form a foam from the fluent substance on said outlet side (46, 46A, 46B, 46C), and wherein said body (40) further comprises a nozzle (56) extending outwardly from said outlet side (46).

14. A component (18, 18A, 18B, 18C) for an actuator (20, 120) for use with a container (24) of a fluent substance, the actuator (20, 120) having a dispensing flow path (22, 122) to direct a fluent substance from an interior of the container (24) to an exterior of said actuator (20, 120), said component (18, 18A, 18B, 18C) comprising:a unitary thermoplastic body (40, 40A, 40B, 40C) having a screen (42, 42A, 42B, 42C) defining an inlet side (44, 44A, 44B, 44C) for facing an interior of an actuator (20, 120) and an outlet side (46, 46A, 46B, 46C) for facing an exterior of the actuator (20, 120), said screen (42, 42A, 42B, 42C) defining a plurality of apertures (48, 48A), said screen (42, 42A) configured to receive a fluent substance from a dispensing flow path (22, 122) of the actuator (20, 120) and configured to form a foam from the fluent substance on said outlet side (46, 46A, 46B, 46C), and wherein said body (40) further comprises a flange (58) extending laterally outwardly of, and surrounding, said screen (42).

15. A component (18, 18A, 18B, 18C) for an actuator (20, 120) for use with a container (24) of a fluent substance, the actuator (20, 120) having a dispensing flow path (22, 122) to direct a fluent substance from an interior of the container (24) to an exterior of said actuator (20, 120), said component (18, 18A, 18B, 18C) comprising:SEA04401P00271PC (CRY-033)-21-a unitary thermoplastic body (40, 40A, 40B, 40C) having a screen (42, 42A, 42B, 42C) defining an inlet side (44, 44A, 44B, 44C) for facing an interior of an actuator (20, 120) and an outlet side (46, 46A, 46B, 46C) for facing an exterior of the actuator (20, 120), said screen (42, 42A, 42B, 42C) defining a plurality of apertures (48, 48A), said screen (42, 42A) configured to receive a fluent substance from a dispensing flow path (22, 122) of the actuator (20, 120) and configured to form a foam from the fluent substance on said outlet side (46, 46A, 46B, 46C), and wherein said body (40C) of said component (18C) is planar.

16. The component (18, 18A, 18B, 18C) according to any of preceding claims 13-15 in combination with an actuator (20, 120) having a dispensing flow path (22, 122) configured to direct a fluent substance from an interior of a container (24) to an exterior of said actuator (20, 20).

17. The component (18, 18A, 18B, 18C) and actuator (20, 120) combination according to claim 16 further in combination with a container (24) of a fluent substance in the form of a package.

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