AN AEROSOL DISPENSER

Field of the Invention The present invention relates to a cap for an aerosol dispenser, and in particular to a cap that is engageable with both a primary and a secondary aerosol dispenser. The invention also relates to methods of using an aerosol dispenser incorporating the inventive cap, allowing for refilling of the secondary aerosol dispenser as well as dispersal of an aerosol from the primary aerosol dispenser.

Background to the Invention

Aerosol dispensers are popular consumer items that are designed to convert a pressurised fluid into a fine mist or spray by, through the use of a propellant, ejecting the fluid through an aperture or nozzle. Aerosol dispensers come in a variety of shapes and sizes to suit various different needs. One example is the small, hand-held dispenser as illustrated in Figure 1 . Dispenser 10 is suitable for containing a perfume in fluid form, and is capable of being conveniently and discretely stored in a handbag, for example. The fluid is mixed with a propellant having a relatively high vapour pressure, and is contained in a canister 12. When a nozzle 14 is activated, a valve in dispenser 10 is opened, creating a pressure differential between the interior of canister 12 and the outside environment. The pressure differential causes the propellant to vaporise and drive the fluid out through a dip tube, and the fluid is atomised into fine droplets or a mist as it passes through nozzle 14, allowing for an even distribution of the perfume.

Once depleted, the dispenser must typically be disposed of, and it is therefore desirable to provide a device that may be used to refill an aerosol dispenser. Furthermore, typical aerosol dispensers provide no further usefulness or functionality beyond their simple dispensing capability. The present invention seeks to provide an improved cap for an aerosol dispenser, that addresses these and other disadvantages encountered in the prior art. The present invention also seeks to provide improved methods of using such a cap, that may be used in the fields of liquid dispersal and transferable aerosol products. Summary of the Invention

In a first aspect of the present invention, there is provided a cap for an aerosol dispenser. The cap comprises first and second valves, each valve being actuatable to move from a closed position to an open position. The cap also comprises a fluid inlet, and first and second fluid outlets. The cap is configured such that actuating the first valve causes the fluid inlet to enter into fluid communication with the first fluid outlet, and such that actuating the second valve causes the fluid inlet to enter into fluid communication with the second fluid outlet.

The cap effectively provides two fluid exit points that may alternately be brought into fluid communication with a common fluid entry point. Thus, the cap provides greater functionality than in the prior art, wherein an aerosol cap typically only provides a single spray hole. The cap of the present invention furthermore provides for a dual dispensing functionality using only a single fluid entry point, by allowing a user to alternately open first one valve, and then the other, as needed. The valves of the present invention are typically one-way valves, and may take the form of any valve that is suitable for use with the present invention, for example a spring valve.

The cap may be further configured to engage with a secondary aerosol dispenser such that engagement of the cap with the secondary aerosol dispenser actuates the second valve so as to allow a pressurised fluid to flow from the cap into the secondary aerosol dispenser, via the second fluid outlet. Thus, any pressurised fluid that is present at the fluid entry point of the cap may be brought into fluid communication with the interior of the secondary aerosol dispenser, and may travel from the cap (e.g. starting from the fluid entry) into the secondary aerosol dispenser via the second valve and via the second fluid outlet. The secondary aerosol dispenser is typically a small, highly portable dispenser such as a perfume dispenser that may be easily stored in a clutch bag, for example, or even one's pocket. Such dispensers, through regular use, are rapidly depleted of their contents and the present invention allows one to refill them with ease. The secondary aerosol dispenser typically comprises an inlet that, when the secondary dispenser is engaged with the cap, may mate with or otherwise engage with the second fluid outlet of the cap.

The secondary aerosol dispenser may comprise a third valve actuatable to move from a closed position to an open position. The cap may be further configured such that the engagement of the cap with the secondary aerosol dispenser actuates the third valve so as to allow the pressurised fluid to flow from the cap into the secondary aerosol dispenser, via the second fluid outlet and the third valve. The third valve may be positioned at the base of the secondary dispenser and, when not engaged with the cap, may ensure that the contents of the secondary aerosol dispenser does not escape therefrom. The secondary aerosol dispenser may be injection-moulded from a type of plastic, such as flame-retardant plastic. This may allow the third valve to be incorporated more easily with the secondary aerosol dispenser.

The cap may be further configured such that the engagement of the cap with the secondary aerosol dispenser actuates the third valve before actuating the second valve. This may be achieved by modifying the spring constant of either valve. This may provide the benefit that mixture flowing into the secondary aerosol dispenser does not leak out of the second fluid outlet before being allowed into the secondary aerosol dispenser via the third valve. In some embodiments, it may be advantageous to have the second valve open before the third valve is opened. Again, this can be achieved by modifying the spring constant of the second valve and/or the third valve, as necessary.

The cap may further comprise a recessed portion for receiving the secondary aerosol dispenser. Any overspill from the refilling process may gather in the recess and evaporate. The recess may also guide and help stabilise the secondary dispenser during the refill process.

The cap may be further configured to engage with a primary aerosol dispenser such that a pressurised fluid may flow from the primary aerosol dispenser into the cap, via the fluid inlet. By engaging the cap of the present invention with a suitably sized primary aerosol dispenser, an aerosol dispenser of typical size and shape to those widely available may be obtained. Pressurised fluid from the primary aerosol dispenser may flow into the cap by engagement of the primary dispenser therewith. Until they are opened, the first and second valves disposed within the cap may prevent the mixture from travelling out of the cap. For example, the mixture may be allowed to flow into only a portion of the cap (e.g. the Y-section of the conduit arrangement described below) before being prevented from flowing further by closed first and second valves.

The pressurised fluid may take many different forms, and may include, for example, a perfume, a lens cleaner solution, a body spray, a hairspray, an insect repellent, an air freshener, a household cleaning product, a polisher, a sanitising product, an antiperspirant, a deodorant, or any other fluid mixture which may be suitable as an aerosol product.

The primary aerosol dispenser may comprise a fourth valve actuatable to move from a closed position to an open position. The cap may be further configured such that, when the cap is engaged with the primary aerosol dispenser, actuating the first or second valve causes the fourth valve to actuate such that the pressurised fluid may flow from the primary aerosol dispenser into the cap, via the fourth valve and the fluid inlet. Thus, actuating the first or second valves correspondingly causes the fourth valve to actuate and open.

The cap may further comprise a fluid conduit system or arrangement having first and second fluid conduits, each fluid conduit having at least a portion being movable relative to the cap. The fluid conduits are typically flexible to a degree, and may be formed of thin, flexible plastic pipe. In one embodiment, the movable portion of a fluid conduit refers to the conduit portion of greater flexibility (e.g. one portion of the conduit may be relatively fixed with respect to the cap, whilst another portion may be flexible such that it may move in relation to the cap). In one embodiment, the entire second fluid conduit is movable relative to the cap.

Each movable portion of the fluid conduits may be movable from a respective first position to a respective second position. When moved to their second position, they may contact and cause corresponding actuation of a respective valve. Each movable portion of the fluid conduits may therefore move into contact with a respective first and second valve, in order to actuate them. Sufficient contact pressure will cause the corresponding valve to actuate and thereby open.

The cap may further comprise a pusher member for moving the movable portion of the first fluid conduit and thereby actuating the first valve. The pusher member may take many varied forms, and in one embodiment may be physically linked to the movable portion of the first fluid conduit. Alternatively, the pusher member may be a distinct component of the first fluid conduit, and may be movable between a non-contact position and a position in contact with the first fluid conduit.

The first fluid conduit may fluidly connect the first valve with the first fluid outlet. Thus, when the first valve is open, the fluid inlet is brought into fluid communication with the first fluid outlet via the first valve. Likewise, the second fluid conduit may fluidly connect the second valve with the second fluid outlet. Thus, similarly, when the second valve is open, the fluid inlet is brought into fluid communication with the second fluid outlet via the second valve.

The fluid conduit arrangement may further comprise a third fluid conduit movable relative to the cap. The third fluid conduit may be coupled to a flexible support, membrane, holding lug or other fixing means, and may be retained in position by means of the flexible support. The flexible support may be arranged to flex in response to movement of the third fluid conduit. The third fluid conduit may fluidly connect the fluid inlet with the first and second valves. For example, the third fluid conduit may take the form of a Y-section or Y-junction, linking all three of the fluid inlet, the first valve and the second valve.

The third fluid conduit may be rigidly connected to the first and second valves, and the flexibility of the support may be configured such that, when the third fluid conduit moves between its first position and its second position, the flexible support may flex or deform to allow for the movement of the third fluid conduit. In some embodiments, the third fluid conduit may possess a degree of flexibility, but is generally more rigid than the flexible support, so as to allow for deformation of the support in response to increased pressure being applied to the third fluid conduit so as to move the third fluid conduit.

The cap may be further configured such that the engagement of the cap with the secondary aerosol dispenser causes the movable portion of the second fluid conduit to move and thereby actuate the second valve. During the engagement, the movable portion of the second fluid conduit may meet with and engage with an inlet of the secondary dispenser. As the secondary dispenser is engaged with cap, pressure may be applied to the movable portion of the second fluid conduit and thereby cause the movable portion to be displaced from its first position to its second position. In its second position, the movable portion may make contact with the second valve and actuate the valve, thereby opening it.

The second fluid conduit may extend at least partly into the recessed portion such that the engagement of the cap with the secondary aerosol dispenser causes the movable portion of the second fluid conduit to move and thereby actuate the second valve. Thus, the movable portion of the second fluid conduit may contact the secondary dispenser before the secondary dispenser is fully engaged with the cap. The recessed portion may be configured such that, when full engagement of the secondary dispenser with the cap has taken place, the second fluid conduit has moved to the extent whereby the second valve has been actuated.

The cap may be further configured such that the engagement of the cap with the secondary aerosol dispenser causes the second valve to actuate, thereby actuating the fourth valve so as to allow a pressurised fluid to flow from the primary aerosol dispenser into the secondary aerosol dispenser, via the fluid inlet and the second fluid outlet. Actuation of the fourth valve may be caused through the application of continued pressure to the second valve (e.g. via pressure applied to the second fluid conduit from the secondary aerosol dispenser). This may cause the movable third fluid conduit to be displaced and move into contact with, and actuate, the fourth valve. Again, the recessed portion may be configured such that, when full engagement of the secondary dispenser with the cap has taken place, the second fluid conduit has moved to the extent whereby both the second valve and the fourth valve have been actuated. Thus, when pressure is applied to the movable portion of either the first or second fluid conduits (e.g. via a pusher member or via engagement of a secondary aerosol dispenser), the respective first or second fluid conduit (or a portion thereof) may move into contact with and actuate a respective valve. Continued pressure may cause the third fluid conduit to also move as a result (and thereby actuate the fourth valve). Again, the spring constants of the valves may be modified to allow for a specific valve to open before/after another specific valve. For example, as the secondary aerosol dispenser is engaged with the cap, the cap being engaged with a primary aerosol dispenser, then the valves may be configured to open in the following order: first the third valve (of the secondary dispenser), then the second valve (of the cap), and finally the fourth valve (of the primary dispenser). Thus, a fluidic mixture in the primary dispenser will be allowed to flow into the secondary dispenser only once the third and second valves are open.

In a second aspect of the present invention, there is provided a primary aerosol dispenser suitable for refilling a secondary aerosol dispenser. The primary aerosol dispenser comprises a cap according to the present invention. Thus, known aerosol dispensers may be retrofitted to include the cap of the present invention.

The present invention furthermore seeks to provide new and improved methods of using the inventive cap described herein.

In a third aspect of the present invention, there is provided a method of refilling an aerosol dispenser. The method comprises providing a primary aerosol dispenser containing a pressurised fluid. The primary aerosol dispenser comprises a cap having an actuator, a fluid inlet and at least one fluid outlet. The actuator is for opening a valve between the fluid inlet and one of the at least one fluid outlet. The method further comprises engaging a secondary aerosol dispenser with the actuator so as to open the valve, thereby bringing the pressurised fluid into fluid communication with the secondary aerosol dispenser and allowing the pressurised fluid to flow from the primary aerosol dispenser into the secondary aerosol dispenser, via the fluid inlet and the at least one fluid outlet. Thus, the present invention provides for the possibility of refilling a secondary aerosol dispenser from a primary aerosol dispenser. Multiple, smaller dispensers may be rapidly replenished from a single, larger dispenser. This allows for a more efficient and economic use of smaller dispensers that in the past have typically been disposed of once their contents are depleted.

In a fourth aspect of the present invention, there is provided a method of using an aerosol dispenser. The method comprises providing a primary aerosol dispenser comprising a cap according to the present invention. The primary aerosol dispenser contains a pressurised fluid. The method further comprises either dispensing the pressurised fluid by actuating the first valve so as to allow the pressurised fluid to be dispensed out of the primary aerosol dispenser via the first fluid outlet, or engaging a secondary aerosol dispenser with the cap so as to actuate the second valve, thereby allowing the pressurised fluid to flow from the primary aerosol dispenser into the secondary aerosol dispenser, via the fluid inlet and the second fluid outlet.

This allows for the filling/refilling of a compact pocket or clutch bag -sized aerosol dispenser from a larger aerosol container, for example. The compact aerosol container thus may be used more than once. The invention provides for aerosol dispensers of greater flexibility and versatility than in the prior art. Not only may an aerosol be dispensed from a primary canister, but, by engaging a secondary aerosol dispenser with the inventive cap and thereby actuating the second valve, the secondary aerosol dispenser may be refilled from the very same primary canister. This 'mother can' and cap combination thus provides for the dual functionality of aerosol dispensing and canister refilling. This functionality is conveniently and efficiently provided for with a single apparatus.

Brief Description of the Drawings

Several embodiments of the present invention will now be described by way of example and with reference to the following drawings, in which:

Figure 1 illustrates a typical aerosol dispenser as commonly used in the prior art; Figure 2 is a cut-away schematic representation of a cap in accordance with a first embodiment of the present invention;

Figure 3 is a cut-away schematic representation of a primary aerosol dispenser that may be engaged with the cap of Figure 2;

Figure 4 is a cut-away schematic representation of a secondary aerosol dispenser that may be engaged with the cap of Figure 2;

Figure 5 is an illustration of an exemplary primary aerosol dispenser engaged with a cap according to the present invention; and

Figure 6 is an illustration of an exemplary secondary aerosol dispenser engaged with the cap and primary aerosol dispenser of Figure 5. Note that the secondary aerosol dispenser seen in Figure 6 is different from the secondary aerosol dispenser seen in Figure 1 in that it is engageable, and has been engaged with, the cap seen in Figure 2. Detailed Description of a Preferred Embodiment

Whilst various embodiments of the present invention are described below, the invention is not limited to these embodiments and variations of these embodiments may well fall within the scope of the invention which is to be limited only by the appended claims.

As seen in Figure 2, according to a first embodiment of the present invention, there is provided a cap 20 for use with an aerosol dispenser. Cap 20 comprises a housing 21 and is substantially cylindrical so as to fit over a similarly cylindrical aerosol dispenser. In other embodiments, cap 20 may have other shapes, such as a rectangular shape, for example. Housing 21 may be constructed of any suitable material, such as plastic. Cap 20 is largely hollow and comprises a recess 22, an activator button 23, a holding lug 24 and a spray hole 25. Within cap 20 is a conduit arrangement or system which comprises a plurality of fluid conduits, pipes, tubes or channels.

The conduit arrangement comprises a fixed, rigid tube portion or Y-section 26 coupled to holding lug 24. Y-section 26 comprises a pair of fixed tube sections, referred to respectively as spray tube section 26a and refill tube section 26b, each forming a branch of Y-section 26. Refill tube section 26b is disposed centrally along the cylindrical axis of cap 20. The conduit arrangement further includes a movable tube portion or spray tube 27. Spray tube 27 is also Y- shaped and comprises a pair of spray tube sections, 27a and 27b, each forming a branch of the Y-shape. Spray tube section 27a is resiliently deformable and movable relative to cap 20. A first one-way valve, spray valve 29a, is disposed between spray tube section 26a and spray tube section 27a. Spray tube section 27a is movable into contact with spray valve 29a, and in doing so may actuate spray valve 29a. Spray tube section 27b extends from the Y-juncture in spray tube 27 to a side of cap 20, and terminates in a fluid outlet or spray hole 25.

The conduit arrangement further comprises another movable tube portion or refill tube 28. Refill tube 28 is movable relative to cap 20 and is positioned in a substantially parallel manner to the cylindrical axis of cap 20. Another one-way valve, refill valve 29b, is disposed between refill tube section 26b and refill tube 28. Refill tube 28 is movable into contact with refill valve 29b so as to actuate refill valve 29b. Spray valve 29a and refill valve 29b are typical one-way vales movable between respective closed and open positions.

Recess 22 is formed in an upper portion of cap 20, and refill tube 28 extends partway into recess 22 such that a stem 28a of refill tube 28 protrudes into a gap formed by recess 22. Cap 20 further comprises a slanted portion with a pusher member or activator button 23 disposed therein. Activator button 23 is movable relative to cap 20 so as to cause spray tube section 27a to move, thereby actuating spray valve 29a. In the present embodiment, activator button 23 is a separate component to spray tube section 27a, and is moved into contact with spray tube section 27a when pressure is applied to activator button 23. In other embodiments, activator button 23 may be integrally connected to spray tube section 27a, and moving activator button 23 inwards towards the centre of cap 20 may cause spray valve 29a to actuate and thereby open.

Holding lug 24 is disposed near the bottom of cap 20 so as to lend support to Y-section 26. Holding lug 24 is relatively flexible compared to Y-section 26, and may flex in response to movement from Y-section 26. An inlet 26c is formed in Y-section 26 and protrudes beneath holding lug 24. Figure 3 illustrates a primary aerosol dispenser, herein referred to as mother can 30, that may be used with cap 20 of the present embodiment. Mother can 30 comprises a solid outer wall 31 to retain a pressurised fluidic mixture, such as a mixture of a perfume in fluid form, and a propellant, as known in the art. A dip tube 32 extends from an opening in the topmost portion of mother can 30 into the interior of mother can 30. A one-way valve, referred to as mother can valve 33, is positioned in communication with, and at the topmost end of, dip tube 32. Dip tube 32 may therefore fluidly communicate with one end of mother can valve 33. An activator stem 34 is positioned on the other end of mother can valve 33. Activator stem 34 is movable to engage with and actuate mother can valve 33 and thereby open mother can valve 33. Alternatively, dip tube 32 may simply terminate in mother can valve 33. Cap 20 of the present embodiment is configured to fit over mother can 30 such that the bottom portion of Y-section 26 may be positioned in contact with activator stem 34, and such that inlet 26c may fluidly communicate with activator stem 34.

Figure 4 illustrates a relatively small, compact secondary aerosol dispenser (referred to as portable spray canister 40). Portable spray canister 40 is typically constructed differently from mother can 30, and in the present embodiment is injection-moulded from flame-resistant plastic. A dip tube 41 extends from the top of portable spray canister 40 into the interior of the canister. The bottom of portable spray canister 40 comprises a niche 42 that is configured to receive stem 28a of refill tube 28. A one-way valve, referred to as portable canister valve 43, is positioned on the bottom surface of portable spray canister 40. Portable canister valve 43 is actuatable to move from a closed position to an open position.

Cap 20 of the present embodiment may be used to alternately refill portable spray canister 40 as well as allow for the dispersal of the mixture contained in mother can 30. In use, cap 20 may be positioned over mother can 30 such that cap 20 engages with mother can 30. Cap 20 may also be disengaged from mother can 30, and thus cap 20 is effectively designed to fit over a variety of different shapes and sizes of mother cans, and may be removed from one mother can and placed on another, different mother can.

Positioning cap 20 over mother can 30 causes inlet 26c at the bottom of Y- section 26 to move into proximity of activator stem 34. In one embodiment, when cap 20 is engaged with mother can 30, inlet 26c may be in contact with activator stem 34. Figure 5 is an exemplary illustration of a cap that has been positioned on and engaged with a mother can, in accordance with the present invention.

In order to dispense the fluid mixture contained in mother can 30, having engaged cap 20 with mother can 30, a user presses down on activator button 23. This causes spray tube section 27a to move into contact with and actuate spray valve 29a, thereby opening spray valve 29a. Because of the relative flexibility of holding lug 24, as further pressure is applied to activator button 23, Y-section 26 is also moved fractionally downwards, causing inlet 26c to press down on activator stem 34, in turn actuating mother can valve 33 and causing mother can valve 33 to open. Thus, spray hole 25 is brought into fluid communication with the interior of mother can 30, via mother can valve 33, inlet 26c, spray tube section 26a, spray valve 29a, spray tube section 27a, and spray tube section 27b. A pressure differential then exists between the interior and the exterior of cap 20, and the aerosol mixture may be dispensed from mother 30 via spray hole 25. The mixture in mother can 30 will not flow out through refill tube section 26b and refill tube 28, as refill valve 29b will be shut, allowing the user to spray directly from mother can 30 without any danger of the mixture being sprayed into their face.

In order to refill a portable aerosol dispenser such as portable spray canister 40, portable spray dispenser 40 is brought into engagement with cap 20, by inserting portable spray dispenser 40 into recess 22. By pushing portable spray dispenser into recess 22, portable canister valve 43 is first actuated and opened. By pressing further down on portable spray canister 40, refill tube 28 is moved to actuate refill valve 29b. Again, because of the relative flexibility of holding lug 24, Y-section 26 may move fractionally down with continued pressure applied to portable spray canister 40. This in turn causes inlet 26c to engage activator stem 34 and thereby cause mother can valve 33 to open. Thus, the contents of mother can 30 is brought into fluid communication with the interior of portable spray dispenser 40, via mother can valve 33, inlet 26c, refill tube section 26b, refill valve 29b, refill tube 28, the outlet of stem 28a, and portable canister valve 43. Mixture in mother can 30 may therefore travel into portable spray canister 40, via cap 20. Portable spray canister 40 will therefore be refilled from the mixture contained in mother can 30. The mixture will not be able to escape through spray hole 25 on the side of cap 20 as spray valve 29a will be closed. Any overspill from this process will gather in recess 22 and evaporate, thus keeping the user's hands clean and free from the mixture.

Figure 6 illustrates an exemplary portable spray dispenser engaged with a cap according to the present invention.

The invention has been described with regard to a preferred embodiment only, and many variations may be made thereto without departing from the scope of the invention. For example, in one alternative embodiment, the cap and the mother may form a single unit, and the cap may be integrally fixed to the mother can. Another alternative is for the cap to comprise a T-valve which would serve the dual purpose of allowing aerosol to be dispensed out of one outlet whilst allowing for an aerosol to be ejected out of the second outlet and into a portable canister. The T-valve version would work by twisting the cap in one direction to release the product into the portable canister, with a nipple on the inside of the cap to prevent the mixture escaping directly from the mother can. The cap may then be twisted back to allow the mixture to spray from the mother can, through the spray hole in the side of the cap.