Spray actuator and insert with eductor

Abstract

A spray actuator (20) for use with a container of a fluent product includes a body (56) having a dispensing flow path (76) and an eductor (40) located in the dispensing flow path (76). The eductor (40) may be a unitary insert or a pair of inserts connected with the body (56) in the dispensing flow path (76) or may be a unitary part of body (56). The eductor (40) has a venturi throat (112), at least one air inlet (116), and a diffuser (120).

Description

SEA04401 P00291 PC (CRY-035)-1-SPRAY ACTUATOR AND INSERT WITH EDUCTORTECHNICAL FIELD

[0001] This application claims priority of U. S. Provisional Patent Application No.63 / 760,187, filed February 19, 2025, the entire contents of which is incorporated herein by reference.

[0002] The present invention relates generally to hand-held dispensing packages for dispensing a fluent product, 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 product from the interior of the container. The invention more particularly relates to dispensing packages including an actuator with an eductor.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 other 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 orSEA04401 P00291 PC (CRY-035)-2-thermoplastic 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. Alternatively, the actuator may contact a hand-operated pump for pressurizing the fluent substance within the container.

[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 or mechanical breakup unit (“MBU”) 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 and inserts may not be suitable for non-conventional propellants, such as inert gases and water-based formulas, which may be more environmentally sustainable compared to traditional propellants utilizing solvent-based formulas.

[0007] The inventors have found that creating fine particle sprays can be very challenging with inert gas water-based spray formulas. There exists a need for a feasible, cost-effective, solution for improved dispensing, particularly with respect to the sustainable dispensing systems utilizing inert gas water-based formulas.

[0008] The inventors of the present invention have discovered that it would be desirable to provide a component for use in an actuator which can better accommodateSEA04401 P00291 PC (CRY-035)-3-inert gas water-based formulas for improved sustainability and / or improved spray properties.

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

[0010] The inventors of the present invention have 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 inventors of the present invention have discovered how to provide such a component for an actuator, and assemblies and combinations thereof with an actuator, valve or pump, and / or container, 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 spray actuator is provided for use in dispensing a fluent product from a container. The spray actuator includes a body having a dispensing flow path to direct a fluent product from the container through the actuator. The spray actuator further includes an eductor located in the dispensing flow path and defining a spray axis. The eductor has an inlet end and an outlet end, and further includes a venturi throat located between the inlet end and the outlet end. The eductor includes at least one air inlet extending transversely to theSEA04401 P00291 PC (CRY-035)-4-spray axis. The eductor has a diffuser located between the outlet end and the venturi throat.

[0013] In one form of the present invention, the eductor is a unitary insert retained within the body. Preferably, the eductor is molded from a single polymer.

[0014] In another form of the present invention, the body of the actuator includes a press portion for being engaged by a user of the spray actuator, and the eductor is an elongate cylinder that is received within the dispensing flow path at a location beneath the press portion.

[0015] According to one aspect of the present invention, the at least one air inlet tapers in a direction from the inlet end toward the outlet end from an exterior channel to a location proximate to the venturi throat. In another form, the at least one air inlet can extend from the exterior channel to a location adjacent to the venturi throat.

[0016] In yet another form of the present invention, the eductor has the form of a pair of inserts retained with the body. A first one of the pair of inserts includes the venturi throat and a second one of the pair of inserts includes the diffuser. Preferably, the pair of inserts are spaced apart along the spray axis in a non-contacting relationship when retained in the body of the actuator.

[0017] According to one form of the present invention, the at least one air inlet extends between the pair of inserts and connects to an exterior channel in the body.

[0018] In another form of the present invention, the first one of the pair of inserts including the venturi throat is a mechanical breakup unit with a plate having an aperture and an annular wall surrounding the plate with means for engaging the body. The second one of the pair of inserts including the diffuser is conical with means for engaging the body.

[0019] In still another form of the present invention, the eductor is a unitary construction with the body. Preferably, the body includes a post having an aperture toSEA04401 P00291 PC (CRY-035)-5-define the venturi throat and the body includes at least one support connecting the post to the diffuser. Preferably, the eductor is a 3-D printed, unitary portion of the body.

[0020] According to another aspect of the present invention, the spray actuator is provided in combination with an aerosol valve installed on a container of a pressurized fluent product in the form of a package.

[0021] According to another aspect of the present invention, the spray actuator is provided in combination with a pump installed on a container of a fluent product in the form of a package.

[0022] According to another aspect of the present invention, the eductor is fully retained within the dispensing flow path of the body.

[0023] According to still another form of the present invention, the eductor is an elongate, unitary construction that is retained with the body so as to locate the outlet end of the eductor substantially flush with an orifice in the body.

[0024] According to another aspect of the present invention, the eductor defines a length in a direction of the spray axis and a width in a direction perpendicular to the spray axis, such that the length is shorter than the width.

[0025] In accordance with another broad form of the present invention, an eductor is provided for use with a spray actuator wherein the eductor has a unitary construction for being retained with the spray actuator. The eductor defines a spray axis, an inlet end, and an outlet end. The eductor includes a venturi throat located between the inlet end and the outlet end, and includes one or more air inlets extending transversely to the spray axis. The eductor has a diffuser that is located between the outlet end and the venturi throat.

[0026] In accordance with yet another broad form of the present invention, an eductor is provided for use with a spray actuator wherein the eductor includes a pair of inserts for being retained with the spray actuator. The eductor defines a spray axis, anSEA04401 P00291 PC (CRY-035)-6-inlet end, and an outlet end. A first one of the pair of inserts includes a venturi throat and a second one of the pair of inserts includes a diffuser for being located between the outlet end and the venturi throat.

[0027] In accordance with another broad form of the present invention, a package for dispensing a fluent product is provided. The package includes a container of a pressurized fluent product and an inert gas water-based propellant. The package includes an aerosol valve installed on the container. The package further includes a spray actuator installed on the aerosol valve and the container. The spray actuator includes a body having a dispensing flow path to direct a fluent product from the container through the actuator. The spray actuator further includes an eductor located in the dispensing flow path and defining a spray axis. The eductor has an inlet end and an outlet end, and further includes a venturi throat located between the inlet end and the outlet end. The eductor includes at least one air inlet extending transversely to the spray axis. The eductor has a diffuser located between the outlet end and the venturi throat.

[0028] In accordance with yet another broad form of the present invention, a method of manufacturing a spray actuator for use in dispensing a fluent substance from a container includes the step of molding a thermoplastic body having a dispensing flow path to direct a fluent product from a container through the spray actuator. The method includes the further step of molding a thermoplastic eductor defining a spray axis, an inlet end, and an outlet end. The eductor defines a venturi throat located between the inlet end and the outlet end, with at least one air inlet extending transversely to the spray axis. The eductor further defines a diffuser located between the outlet end and the venturi throat. The method includes the further step of retaining the thermoplastic eductor in the dispensing flow path of the body. Preferably, the step of retaining the thermoplastic eductor in the dispensing flow path of the body includes inserting the eductor as either: a unitary construction within the dispensing flow path; or inserting the eductor as a pair of spaced-apart inserts within the dispensing flow path.SEA04401 P00291 PC (CRY-035)-7-

[0029] In accordance with still another broad form of the present invention, a method of manufacturing a spray actuator for use in dispensing a fluent substance from a container includes the step of unitarily forming: a thermoplastic body having a dispensing flow path to direct a fluent product from a container through the spray actuator; and a thermoplastic eductor defining a spray axis. The eductor defines an inlet end, an outlet end, and a venturi throat located between the inlet end and the outlet end. The eductor includes at least one air inlet extending transversely to the spray axis. The eductor further defines a diffuser located between the outlet end and the venturi throat.

[0030] 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

[0031] FIG. 1 is an isometric view taken from above and the front, right side of a first embodiment of an actuator according to the present invention for being installed on a valve or pump and a container of a fluent product (not illustrated in FIG. 1 );

[0032] FIG. 2 is a front elevation view of the actuator of FIG. 1;

[0033] FIG. 3 is a right-side elevation view of the actuator of FIG. 1;

[0034] FIG. 4 is a top plan view of the actuator of FIG. 1;

[0035] FIG. 5 is a cross-sectional view of the actuator of FIG. 1, taken along the view plane 5-5 in FIG. 4;

[0036] FIG. 6 is an isometric, exploded view from the front, top, and right side of the actuator of FIG. 1, and FIG. 6 shows the unitary eductor insert prior to installation in the body of the actuator;

[0037] FIG. 7 is a top plan view of the unitary eductor insert of FIG. 6;SEA04401 P00291 PC (CRY-035)-8-

[0038] FIG. 8 is a rear elevation view of the inlet end of the unitary eductor insert of FIG. 6;

[0039] FIG. 8A is a cross-sectional view of another eductor for use with the actuator of FIG. 1, taken along the view plane 5-5 in FIG. 4;

[0040] FIG. 9 is an isometric view from the front, top, and right side of a second embodiment of an actuator according to the present invention for being installed on a valve or pump and a container of a fluent product (not illustrated in FIG. 9);

[0041] FIG. 10 is a front elevation view of the actuator of FIG. 9;

[0042] FIG. 11 is a right-side elevation view of the actuator of FIG. 9;

[0043] FIG. 12 is a top plan view of the actuator of FIG. 9;

[0044] FIG. 13 is a cross-sectional view of the actuator of FIG. 9, taken along the view plane 13-13 in FIG. 12;

[0045] FIG. 14 is an isometric, exploded view from the front, top, and right side of the actuator of FIG. 9, and FIG. 14 shows the pair of eductor inserts prior to installation in the body of the actuator;

[0046] FIG. 15 is a top plan view of the mechanical breakup unit eductor insert of FIG. 14;

[0047] FIG. 16 is a rear elevation view of the inlet end of the mechanical breakup unit eductor insert of FIG. 14;

[0048] FIG. 17 is a rear elevation view of the inlet end of the diffuser eductor insert of FIG. 14;

[0049] FIG. 18 is a cross-sectional view of the diffuser eductor insert of FIG. 14, taken along the view plane 18-18 in FIG. 17;

[0050] FIG. 19 is an isometric view from the front, top, and right side of a third embodiment of an actuator according to the present invention for being installed on a valve or pump and a container of a fluent product (not illustrated in FIG. 19);

[0051] FIG. 20 is a front elevation view of the actuator of FIG. 19;

[0052] FIG. 21 is a right-side elevation view of the actuator of FIG. 19;SEA04401 P00291 PC (CRY-035)-9-

[0053] FIG. 22 is a top plan view of the actuator of FIG. 19;

[0054] FIG. 23 is a cross-sectional view of the actuator of FIG. 19, taken along the view plane 23-23 in FIG. 22;

[0055] FIG. 24 is an isometric view from above of a fragmentary upper portion of a container and a spray valve for use with the actuators of the present invention;

[0056] FIG. 25 is a greatly enlarged, isometric view from the front, top, and right side of another embodiment of an eductor insert of the present invention for use in an actuator for being installed on a valve or pump and a container of a fluent product (not illustrated in FIG. 25);

[0057] FIG. 26 is a front elevation view of the eductor of FIG. 25;

[0058] FIG. 27 is a right-side elevation view of the eductor of FIG. 25, the left-side elevation view being the mirror image thereof;

[0059] FIG. 28 is a rear elevation view of the eductor of FIG. 25; and

[0060] FIG. 29 is a cross-sectional view of the eductor of FIG. 25, taken along the view plane 29-29 in FIG. 26.DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0061] While this invention is susceptible of embodiment in many different forms, this specification and the accompanying drawings disclose only some specific forms as 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.

[0062] For ease of description, the components and actuators 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 and actuators would have when installed upon an upright container of a fluent substance or product (the upper portion of a container being only partially illustrated inSEA04401 P00291 PC (CRY-035)-10-FIG. 24). It will be understood, however, that the components and actuators embodying this invention may be manufactured, stored, transported, used, and sold in an orientation other than the position described.

[0063] Figures illustrating the components and actuators of this invention may omit the valve or pump and the container (with the exception of FIG. 24), 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.

[0064] As will be further described in detail, the present invention is directed to an eductor component or insert for an actuator, and an assembly of the component or insert and the actuator, that is used for dispensing a fluent material or product (and is especially suitable for dispensing a pressurized fluent product from a container utilizing inert gas water-based formulas.

[0065] FIGS. 1-8 illustrate a preferred, first embodiment of a spray actuator, or simply referred to herein as an actuator 20, according to the present invention for use in a hand-held dispensing package including a container (e.g., 24 in FIG. 24) of a fluent product that has either a pump or aerosol dispensing valve (e.g., 28 in FIG. 24) installed in the opening of the container 24.

[0066] It should be understood that the actuator 20, the container 24, the pump, 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 or other thermoplastic) bottle. The container 24 is adapted to hold the fluent product (e.g., a liquid) and pressurized gas below the valveSEA04401 P00291 PC (CRY-035)-11-

[0067] With reference to FIG. 24, the valve 28 may be of any suitable conventional or special type. The 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 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.

[0068] The 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 a secure and sealed attachment of the valve body to the mounting cup. U. S. Patent Numbers 8,100,298; 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.

[0069] 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 orSEA04401 P00291 PC (CRY-035)-12-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.

[0070] As best seen in FIG. 6, the first embodiment of the actuator 20 of the present invention includes an eductor insert or module, or simply referred to herein as an eductor 40, that is a unitary thermoplastic construction such as a polypropylene or a polyethylene. The eductor 40 is configured to be received and retained within the body 56 of the actuator 20 as will be discussed in greater detail hereinafter. The eductor 40 and the body 56 are preferably molded or formed from a single polymer categorized in a single recycling identification number (“RIN”) for single stream recycling capability. While the eductor 40 is especially suitable for being mechanically retained within the body 56 by means of friction fit, it will be understood that other means may be employed, such as press fit, welding, heating, gluing, or bi-injection molding, etc., to effectuate the retention of the eductor 40 with the body 56 of the actuator 20. In such cases, it will be understood that the form of the eductor 40 may be re-configured to accommodate different mating surfaces and / or structures of the body 56 of the actuator 20.

[0071] With reference now to FIG. 5, the base or body 56 of the actuator 20 may be installed atop a portion of a pump (not illustrated) or, alternatively, a portion of a valve 28 (shown in FIG. 24 only), and / or a portion of the container 24 (illustrated in FIG.24 only). The body 56 has a skirt portion 60 with retention means 62 in the form of a retention bead or beads for engaging a portion of the container 24 or valve 28 to retain the actuator 20 therewith. The body 56 has a press portion 64 at the top end thereof for being engaged by a user of the actuator 20 to initiate dispensing through the actuatorSEA04401 P00291 PC (CRY-035)-13-body 56. It should be appreciated that there are many possible forms for the body 56 and the press portion 64 depending on the intended application of the actuator 20. For example, the press portion 64 may be forwardly or rearwardly cantilevered relative to the skirt portion 60 to allow for relative motion therebetween. Alternatively, the entire body 56 may be pressed to actuate the valve 28 or pump upon which the actuator 20 is installed. The body 56 includes a downwardly extending, internal stem pocket 72 to securely receive the valve stem 29 (illustrated in FIG. 24 only), or upper portion of the pump (not illustrated) at the opening of the container 24 (illustrated in FIG. 24 only). A dispensing flow passage or path 76 extends through the body 56 to direct fluent product from the valve stem 29 or pump toward the exterior of the actuator 20.

[0072] With reference now to FIGS. 5 and 6, the eductor 40 is mated with the body 56 of the actuator 20 along a spray axis 102 through the center of the eductor 40. The eductor 40 is elongate with an inlet end 104 and an outlet end 108, with a generally cylindrical form for being received within the dispensing flow path 76. Preferably, the outlet end 108 of the eductor 40 is flush with the orifice 109 (FIG. 6 only) in the body 56 communicating with the flow path 76.

[0073] With reference now only to FIG. 5, the eductor 40 includes a venturi throat 112 that is located between the inlet end 104 and the outlet end 108 for restricting flow through the eductor 40. The eductor 40 includes a pair of opposing air inlets 116 extending transversely therein relative to the spray axis 102. The air inlets 116 taper inwardly toward the spray axis 102 and connect to a pair of opposing exterior channels 118 that extend from the outlet end 108 parallel to the spray axis 102. The eductor 40 further includes a diffuser 120 extending between the venturi throat 112 and the outlet end 108.

[0074] With reference to FIG. 8A, another variation of an eductor 40’ for use with the actuator 20 is illustrated. The eductor 40’ includes a venturi throat 112’ and one or more air inlets 116’ extending from an exterior or exterior channel 118’ to a location adjacent (i.e., spaced axially from) the venturi throat 112’ toward the diffuser 120’.SEA04401 P00291 PC (CRY-035)-14-

[0075] The inventors have discovered that the eductor 40 can provide an improvement of particle breakup, as compared to prior art actuators, by introducing ambient air into the fluent product by utilizing a venturi which causes swirling or changing the foam quality by providing improved aeration. The use of ambient air has the advantage that there is no depletion or consumption, or at least reduced depletion or consumption, of the gas inside the aerosol container. Depletion of the gas within the aerosol container lowers the pressure within the container and decreases spray quality over the lifetime of the container.

[0076] The inventors have determined that the venturi choke diameter and the amount of air supplied may be adjusted to account for different fluid viscosities and can be used for specific pressure ranges. For example, the number of exterior channels 118 may be decreased or increased depending on the application of the actuator 20.

[0077] It will be understood that while the preferred application of the present actuator 20 is for use with an aerosol container 24 with a pressurized fluent substance or product, the actuator may be installed on a non-aerosol spray pump or dispenser. The eductor 40 can advantageously be used to spread out the spray pattern, decrease the flow rate, reduce the exit pressure of a dispensed product, and / or create an aerated spray.

[0078] The inventors have further discovered that the unitary eductor 40 may be readily manufactured by conventional means, such as injection molding, and may also be relatively easy to install in conventional and nonconventional types of actuators to function as a substitute for the existing flow path within such actuators.

[0079] A second embodiment of an actuator 20A according to the present invention for use in a dispensing package is illustrated in FIGS. 9-18. Like elements between the first illustrated embodiment of the actuator 20 and the second illustrated embodiment of the actuator 20A are designated with the same numeral (the first embodiment having no suffix and the second embodiment having an “A” suffix).SEA04401 P00291 PC (CRY-035)-15-

[0080] With reference to FIG. 13, the second illustrated embodiment of the actuator 20A has the same basic components as the first embodiment of the actuator 20 of an eductor 40A installed within a body 56A. The body 56A includes a skirt portion 60A with attachment or retention means 62A in the form of a retention bead or beads for engaging a portion of the container 24 or valve 28 or pump to retain the actuator 20A therewith. The body 56A has a press portion 64A at the top end thereof for being engaged by a user of the actuator 20A to initiate dispensing through the actuator body 56A. The body 56A includes a downwardly extending, internal stem pocket 72A to securely receive the valve stem 29 (illustrated in FIG. 24 only) at the opening of the container 24 (illustrated in FIG. 24 only). A dispensing flow passage or path 76A extends through the body 56A to direct fluent product from the valve stem 29 toward the exterior of the actuator 20A.

[0081] With reference to FIGS. 13 and 14, the second illustrated embodiment of the actuator 20A differs from the first illustrated embodiment of the actuator 20 in that the eductor 40A is comprised of a pair of spaced apart inserts mated with the body 56A of the actuator 20A along a spray axis 102A extending through the center of the eductor 40A. The first one of the inserts has the form of an MBU with a venturi throat 112A. One or more air inlets 116A are positioned between the venturi throat 112A and the second one of the inserts which has the form of a diffuser 120A.

[0082] Still referring to FIGS. 13 and 14, the first or MBU insert with the venturi throat 112A includes a plate 200A with an aperture 210A and an annular wall 220A extending inwardly along the spray axis 102A. The annular wall 220A includes means 230A for engaging the interior of the dispensing flow path 76A to retain the MBU insert with the body 56A of the actuator 20. The second insert of the eductor 40A with the diffuser 120A is generally conical with means 240A on the radially outward surface for engaging the interior of the dispensing flow path 76A to retain the diffuser insert with the body 56A of the actuator 20A.SEA04401 P00291 PC (CRY-035)-16-

[0083] The second illustrated embodiment of the actuator 20A may be advantageous in that it may modify existing, conventional actuators to achieve an eductor functionality for some dispensing applications. While the pair of inserts constituting the eductor 40A is especially suitable for being mechanically retained within the body 56A by means of friction fit, it will be understood that other means may be employed, such as press fit, welding, heating, gluing, or bi-injection molding, etc., to effectuate the retention of the eductor 40A with the body 56A. In such cases, the form of the eductor 40A may be re-configured to accommodate different mating surfaces of the dispensing flow path 76A and / or structures of the actuator body 56A.

[0084] A third embodiment of an actuator 20B according to the present invention for use in a dispensing package is illustrated in FIGS. 19-23. Like elements between the first illustrated embodiment of the actuator 20 and the third illustrated embodiment of the actuator 20B are designated with the same numeral (the first embodiment having no suffix and the third embodiment having a “B” suffix).

[0085] With reference to FIG. 23, the third illustrated embodiment of the actuator 20B has the same basic components as the first illustrated embodiment of the actuator 20 of an eductor 40B and a body 56B. The body 56B includes a skirt portion 60B for engaging a portion of the container 24, and / or valve 28 or pump, to retain the actuator 20B therewith. The body 56B has a press portion 64B at the top end thereof for being engaged by a user of the actuator 20B to initiate dispensing through the actuator body 56B. The body 56B includes a downwardly extending, internal stem pocket 72B to securely receive the valve stem 29 (illustrated in FIG. 24 only) at the opening of the container 24 (illustrated in FIG. 24 only). A dispensing flow passage or path 76B extends through the body 56B to direct fluent product from the valve stem 29 toward the exterior of the actuator 20B. A spray axis 102B is defined extending through the geometric center of the eductor 40B flow path.

[0086] Still referring to FIG. 23, the third illustrated embodiment of the actuator 20B differs from the first illustrated embodiment of the actuator 20 in that the eductorSEA04401 P00291 PC (CRY-035)-17-40B is formed as a unitary construction with the body 56B of the actuator 20B. The eductor 40B and body 56B may be formed by way of three-dimensional printing, additive manufacturing, molding in halves or with slides, or other conventional or non-conventional manufacturing means. Preferably, the actuator 20B is formed from a plastic material selected from a single resin identification number for improved recyclability.

[0087] The body 56B includes a post 200B surrounding and partly defining the dispensing flow path 76B. The post 200B includes an aperture 210B to define a venturi throat 112B. The body 56B further includes a diffuser 120B connected to the post 200B by one or more supports 220B. Air inlets 116B extend between the supports 220B to supply air to the flow stream. The diffuser 120B is generally conical and is spaced from the post 200B along the spray axis 102B.

[0088] The third illustrated embodiment of the actuator 20B may be advantageous in that it may be more easily manufactured and recycled, and does not require additional manufacturing steps of assembling parts.

[0089] A fourth embodiment of an eductor 40C according to the present invention is illustrated in FIGS. 25-29, for use in an actuator (such as the actuator 20, 20A, or other conventional actuator). Like elements between the first illustrated embodiment of the eductor 40 and the fourth illustrated embodiment of the eductor 40C are designated with the same numeral (the first embodiment having no suffix and the fourth illustrated embodiment having a “C” suffix).

[0090] With reference now to FIG. 29, the fourth illustrated eductor 40C functions in a similar manner as the eductor 40, wherein the eductor 40C is to be mated with the body of an actuator along a spray axis 102C extending generally through the center of the eductor 40C. The eductor 40C differs from the first-discussed embodiment in that the eductor 40C is advantageously compact in form for being received within a wide variety of actuators, and defines an inlet end 104C and an outlet end 108C that areSEA04401 P00291 PC (CRY-035)-18-minimally spaced along the axis 102C. Preferably, the outlet end 108C of the eductor 40C is flush with the orifice of the actuator body communicating with the flow path.

[0091] Still referring to FIG. 29, the eductor 40C includes a venturi throat 112C that is located between the inlet end 104C and the outlet end 108C for restricting flow through the eductor 40C. The eductor 40C includes two pairs of opposing air inlets 116C extending transversely therein relative to the spray axis 102C. The air inlets 116C extend generally perpendicularly to the spray axis 102C and taper inwardly in the radially inward direction toward the spray axis 102C. Each air inlet 116C connects to a corresponding exterior channel 118C that extend from the outlet end 108 parallel to the spray axis 102C. The eductor 40C further includes a diffuser 120C extending between the venturi throat 112C and the outlet end 108C.

[0092] With reference to FIGS. 28 and 29, the outer portion of the eductor 40C includes mechanical engagement or retention means in the form of a flange 230C for frictionally engaging the interior of the dispensing flow path of an actuator to retain the eductor 40C with the body of the actuator. The eductor 40C further includes four mixing channels 250C for receiving a fluent substance prior to entering the venturi throat 112C.

[0093] The eductor 40C is advantageously formed as a unitary construction for being inserted into any specialized or conventional actuator. The eductor 40C may be formed by way of three-dimensional printing, additive manufacturing, molding in halves or with slides, or other conventional or non-conventional manufacturing means. Preferably, the eductor 40C and its associated actuator are formed from a plastic material selected from a single resin identification number for improved recyclability.

[0094] The inventors have discovered that the eductor 40C can provide an improvement of particle breakup, as compared to prior art actuators, by introducing ambient air into the fluent product by utilizing a venturi which causes swirling or changing the foam quality by providing improved aeration. The use of ambient air has the advantage that there is no depletion or consumption, or at least reduced depletion or consumption, of the gas inside the aerosol container. Depletion of the gas within theSEA04401 P00291 PC (CRY-035)-19-aerosol container lowers the pressure within the container and decreases spray quality over the lifetime of the container. The eductor 40C may advantageously be formed as a compact insert, having a greatly decreased length “L” along the spray axis 102C as compared to the first illustrated embodiment of the eductor 40. The eductor 40C has a length “L” along the spray axis 102C about equal to its width “W” or diameter (in the radial direction relative to the axis 102C), and more preferably, eductor 40C has a length “L” along the spray axis 102C that is less than its width “W” (as shown in FIGS.27 and 28).

[0095] 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 actuators, eductors, valves, pumps, and the containers, and assemblies thereof, that are within the scope of the invention. For example, the size, shape, eductor length, air inlet number and arrangement, and venturi diameter size can be modified from those illustrated to achieve different spray characteristics and / or to accommodate different fluent products and / or different dispensing pressures.

[0096] 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

SEA04401 P00291 PC (CRY-035)-20-WHAT IS CLAIMED IS:

1. A spray actuator (20, 20A, 20B) for use in dispensing a fluent product from a container (24), said spray actuator (20, 20A, 20B) comprising:a body (56, 56A, 56B) having a dispensing flow path (76, 76A, 76B) to direct a fluent product from the container (24) through said actuator (20, 20A, 20B); andan eductor (40, 40A, 40B, 40C) located in said dispensing flow path (76, 76A, 76B) and defining a spray axis (102, 102A, 102B, 102C), said eductor (40, 40A, 40B, 40C) defining an inlet end (104, 104A, 104B, 104C) and an outlet end (108, 108A, 108B, 108C), said eductor (40, 40A, 40B, 40C) defining a venturi throat (112, 112A, 112B, 112C) located between said inlet end (104, 104A, 104B, 104C) and said outlet end (108, 108A, 108B, 108C) and having at least one air inlet (116, 116A, 116B, 116C) extending transversely to said spray axis (102, 102A, 102B, 102C), and said eductor (40, 40A, 40B, 40C) defining a diffuser (120, 120A, 120B, 120C) located between said outlet end (108, 108A, 108B, 108C) and said venturi throat (112, 112A, 112B, 112C).

2. The spray actuator (20) according to claim 1 wherein said eductor (40, 40C) is a unitary insert retained with said body (56).

3. The spray actuator (20) according to any of preceding claims 1-2 wherein said eductor (40, 40C) is unitarily molded from a single polymer.

4. The spray actuator (20) according to any of preceding claims 1-3 wherein said body (56) includes a press portion (64) for being engaged by a user of said spray actuator (20), and said eductor (40) is an elongate cylinder that is received within said dispensing flow path (76) beneath said press portion (64).SEA04401 P00291 PC (CRY-035)-21-5. The spray actuator (20) according to any of preceding claims 1-4 wherein said at least one air inlet (116) tapers in a direction from said inlet end (104) toward said outlet end (108) from an exterior channel (118) to a location proximate to said venturi throat (112).

6. The spray actuator (20A) according to claim 1 wherein said eductor (40A) has the form of a pair of inserts retained with said body (56A), wherein a first one of said pair of inserts comprises said venturi throat (112A) and a second one of said pair of inserts comprises said diffuser (120A).

7. The spray actuator (20A) according to claim 6 wherein said pair of inserts are spaced apart along said spray axis (102A) in a non-contacting relationship.

8. The spray actuator (20A) according to any of preceding claims 6-7 wherein said at least one air inlet (116A) extends between said pair of inserts and connects to an exterior channel (118A) in said body (56A).

9. The spray actuator (20A) according to any of preceding claims 6-8 wherein said first one of said pair of inserts comprising said venturi throat (112A) is a mechanical breakup unit with a plate (200A) having an aperture (210A) and an annular wall (220A) surrounding said plate (200A) with means (230A) for engaging said body (56A) and said second one of said pair of inserts comprising said diffuser (120A) is conical with means (240A) for engaging said body (56A).

10. The spray actuator (20B) according to claim 1 wherein said eductor (40B) is unitarily formed with said body (56B).SEA04401 P00291 PC (CRY-035)-22-11. The spray actuator (20B) according to claim 10 wherein said body (56B) includes a post (200B) having an aperture (210B) to define said venturi throat (112B), said body (56B) includes at least one support (220B) connecting said post (200B) to said diffuser (120B).

12. The spray actuator (20) according to any of preceding claims 1-3 wherein said eductor (40C) defines a length (L) in a direction of said spray axis (102C) and a width (W) in a direction perpendicular to said spray axis (102C), wherein said length (L) is shorter than said width (W).

13. The spray actuator (20, 20A, 20B) according to any of preceding claims 1-12 in combination with an aerosol valve (28) and a container (24) of a pressurized fluent product in the form of a package.

14. The spray actuator (20, 20A, 20B) according to any of preceding claims 1-12 in combination with a pump and a container (24) of a fluent product in the form of a package.

15. An eductor (40, 40C) for use with a spray actuator (20) to dispense a fluent product, said eductor (40, 40C) comprising:a unitary construction for being retained with the spray actuator (20) and defining a spray axis (102, 102C), said eductor (40, 40C) defining an inlet end (104, 104C) and an outlet end (108, 108C), said eductor (40, 40C) defining a venturi throat (112, 112C) located between said inlet end (104, 104C) and said outlet end (108, 108C) and having at least one air inlet (116, 116C) extending transversely to said spray axis (102, 102C), said eductor (40, 40C) defining a diffuser (120, 120C) located between said outlet end (108, 108C) and said venturi throat (112, 112C).SEA04401 P00291 PC (CRY-035)-23-16. An eductor (40A) for use with a spray actuator (20A) to dispense a fluent product, said eductor (40A) comprising:a pair of inserts for being retained with the spray actuator (20A), defining a spray axis (102A) and having at least one air inlet (116A) extending transversely to said spray axis (102A) at a location between said pair of inserts, said pair of inserts defining an inlet end (104A) and an outlet end (108A), a first one of said pair of inserts including a venturi throat (112A) and a second one of said pair of inserts including a diffuser (120A) for being located between said outlet end (108A) and said venturi throat (112A).

17. A method of manufacturing a spray actuator (20, 20A) for use in dispensing a fluent product from a container (24), the method comprising the steps of:molding a thermoplastic body (56, 56A) having a dispensing flow path (76, 76A) to direct a fluent product from the container (24) through said actuator (20, 20A);molding a thermoplastic eductor (40, 40A, 40C) defining a spray axis (102, 102A, 102C), said eductor (40, 40A, 40C) defining an inlet end (104, 104A, 104C) and an outlet end (108, 108A, 108C), said eductor (40, 40A, 40C) defining a venturi throat (112, 112A, 112C) located between said inlet end (104, 104A, 104C) and said outlet end (108, 108A, 108C) and having at least one air inlet (116, 116A, 116C) extending transversely to said spray axis (102, 102A, 102C), and said eductor (40, 40A, 40C) defining a diffuser (120, 120A, 120C) located between said outlet end (108, 108A, 108C) and said venturi throat (112, 112A, 112C); andretaining said thermoplastic eductor (40, 40A, 40C) in said dispensing flow path (76, 76A) of said body (56, 56A).

18. The method of manufacturing a spray actuator (20, 20A) according to claim 17 wherein said step of retaining said thermoplastic eductor (40, 40A, 40C) in said dispensing flow path (76, 76A) of said body (56, 56A) comprises inserting said eductorSEA04401 P00291 PC (CRY-035)-24-(40, 40C) as a unitary construction within said dispensing flow path (76) or inserting said eductor (40A) as a pair of spaced-apart inserts within said dispensing flow path (76A).

19. A method of manufacturing a spray actuator (20B) for use in dispensing a fluent product from a container (24), the method comprising the steps of:unitarily forming a thermoplastic body (56B) having a dispensing flow path (76B) to direct a fluent product from the container (24) through said actuator (20B) and a thermoplastic eductor (40B) defining spray axis (102B), said eductor (40B) defining an inlet end (104B) and an outlet end (108B), said eductor (40B) defining a venturi throat (112B) located between said inlet end (104B) and said outlet end (108B) and having at least one air inlet (116B) extending transversely to said spray axis (102B), and said eductor (40B) defining a diffuser (120B) located between said outlet end (108B) and said venturi throat (112B).

20. A package for dispensing a fluent product, said package comprising: a container (24) of a pressurized fluent product and an inert gas water-based propellant;an aerosol valve (28) installed on said container (24); anda spray actuator (20, 20A, 20B) installed on said aerosol valve (28) and said container (24), said spray actuator (20, 20A, 20B) includinga body (56, 56A, 56B) with a dispensing flow path (76, 76A, 76B) to direct a fluent product from the container (24) through said spray actuator (20, 20A, 20B), andan eductor (40, 40A, 40B, 40C) located in said dispensing flow path (76, 76A, 76B) and defining a spray axis (102, 102A, 102B, 102C), said eductor (40, 40A, 40B, 40C) defining an inlet end (104, 104A, 104B, 104C) and an outlet end (108, 108A, 108B, 108C), said eductor (40, 40A, 40B, 40C) defining a venturi throat (112, 112A, 112B, 112C) located between said inlet end (104, 104A, 104B,SEA04401 P00291 PC (CRY-035)-25-104C) and said outlet end (108, 108A, 108B, 108C) and having at least one air inlet (116, 116A, 116B, 116C) extending transversely to said spray axis (102, 102A, 102B, 102C), and said eductor (40, 40A, 40B, 40C) defining a diffuser (120, 120A, 120B, 120C) located between said outlet end (108, 108A, 108B, 108C) and said venturi throat (112, 112A, 112B, 112C).

21. The spray actuator (20, 20A, 20B) according to any preceding claim wherein said eductor (40, 40A, 40B, 40C) is fully retained within said dispensing flow path (76, 76A, 76B) of said body (56, 56A, 56B).

22. The spray actuator (20) according to any preceding claim wherein said eductor (40, 40C) is an elongate, unitary construction retained with said body (56) so as to locate said outlet end (108, 108C) of said eductor (40, 40C) substantially flush with an orifice (109) in said body (56).

23. The spray actuator (20B) according to any preceding claim wherein said eductor (40B) is a 3-D printed unitary portion of said body (56B).

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