Cross-reference to related application

[0001] This application claims benefit of and priority to Australian provisional patent application no 2017 902932 entitled 'Actuator for aerosol assemblies' filed on 26 July 2017, which is hereby incorporated by reference in its entirety.

Field of the Invention

[0002] The present invention relates to actuators for aerosol containers that may be used for spraying paint and other materials.

Background

[0003] Conventional aerosol spray paint cans use finger-operated actuators to dispense the paint from the containers in a single spray pattern. However, the actuators can be difficult or uncomfortable to use over extended periods of time, and only a single spray pattern is produced by conventional actuator designs.

Summary of the Invention

[0004] The present invention provides actuators for aerosol containers that are easy and comfortable to use, and can generate multiple spray patterns.

[0005] One aspect of the invention provides a spray actuator for an aerosol container comprising: a base structured and arranged for attachment to the aerosol container; and a housing mounted on the base comprising: a nozzle stem structured and arranged to contact a delivery stem of the aerosol container; a spray nozzle in flow communication with the nozzle stem; a front trigger surface; and a top trigger surface, wherein pressure applied against the front trigger surface and/or the top trigger surface opens flow communication between the delivery stem of the aerosol container and the spray nozzle. The spray nozzle may be removably mounted in the housing. [0006] Another aspect of the invention provides a spray nozzle for an aerosol spray actuator comprising: a central contoured opening in a front portion of the spray nozzle configured to produce a spray pattern; opposing tabs extending from the spray nozzle on opposite sides of the central contoured opening; and a threaded rear portion structured and arranged for releasable engagement with the aerosol spray actuator.

Brief Description of the Drawings

[0007] Various non-limiting embodiments/aspects of the invention will now be described with reference to the following drawings in which:

[0008] Fig. 1 is an isometric view of an aerosol container including a spray actuator in accordance with an embodiment of the present invention.

[0009] Fig. 2 is an isometric view of the spray actuator of Fig. 1.

[0010] Figs. 3-5 are additional isometric views of the spray actuator of Fig. 1.

[0011] Fig. 6 is an isometric view of a spray actuator similar to that shown in Figs. 1-5, but with an alternative spray nozzle in accordance with an embodiment of the present invention.

[0012] Fig. 7 is an isometric view of a spray actuator similar to that shown in Figs. 1-5, but with an alternative spray nozzle in accordance with a further embodiment of the present invention.

[0013] Fig. 8 is a front view of an aerosol container including a spray actuator in accordance with an embodiment of the present invention.

[0014] Fig. 9 is a side view of the aerosol container and spray actuator of Fig. 8.

[0015] Fig. 10 is a back view of the aerosol container and spray actuator of Fig. 8.

[0016] Fig. 11 is a side view of a spray actuator showing a spray discharge angle when the spray actuator is in an open or actuated position in accordance with an embodiment of the present invention.

[0017] Fig. 12 is a side view of a spray actuator showing a spray discharge angle when the spray actuator is in a closed or neutral position in accordance with an embodiment of the present invention. [0018] Fig. 13 is a front view of a spray actuator in accordance with an embodiment of the present invention with its spray nozzle removed.

[0019] Fig. 14 is a top view of the spray actuator of Fig. 13.

[0020] Fig. 15 is a bottom view of the spray actuator of Fig. 13.

[0021] Fig. 16 is a top view of a spray actuator in accordance with an embodiment of the present invention.

[0022] Fig. 17 is a sectional view taken through line A-A of Fig. 16.

[0023] Fig. 18 is a side sectional view of an aerosol container including a fluid delivery stem mechanism in accordance with an embodiment of the present invention.

[0024] Figs. 19-22 are front, side, top and rear views, respectively, of a spray nozzle in accordance with an embodiment of the present invention.

[0025] Figs. 23-26 are front, side, top and rear views, respectively, of a spray nozzle in accordance with another embodiment of the present invention.

[0026] Figs. 27-30 are front, side, top and rear views, respectively, of a spray nozzle in accordance with a further embodiment of the present invention.

[0027] Fig. 31 is an exploded view of an aerosol spray actuator in accordance with an embodiment of the present invention.

[0028] Fig. 32 is another exploded view of an aerosol spray actuator in accordance with an embodiment of the present invention.

[0029] Fig. 33 illustrates the interchangeability of different spray nozzles that may be installed in an aerosol spray actuator and different paint spray patterns achieved with the different nozzles in accordance with an embodiment of the present invention.

[0030] Fig. 34 illustrates the orientation of a hand-held aerosol container and paint spray actuator during a spraying operation in accordance with an embodiment of the present invention.

[0031] Figs. 35 and 36 illustrate orientations of conventional aerosol paint spray actuators during operation. Detailed Description

[0032] Figs. 1-34 illustrate features of spray actuators 10 for aerosol containers 5 in accordance with embodiments of the present invention. In Figs. 1, 8-10 and 17, the spray actuator is shown in an installed position on the aerosol container 5. The aerosol containers 5 and spray actuators 10 may be used for spraying paint. However, other types of materials may be contained and sprayed using the present spray actuators, including textured coatings, lubricants, sprays, degreasers, adhesives, sealants, powders, cure-on-demand materials, and the like.

[0033] As shown in Figs. 1-5, the spray actuator 10 includes a base 20, a housing 30 and an interchangeable spray nozzle 40. The housing 30 pivots in relation to the base 20 during spraying operations, as more fully described below. The housing 30 includes a threaded front opening 31 for receiving the interchangeable spray nozzle 40, as well as a front trigger surface 32 and a top trigger surface 33. The housing 30 functions as the trigger for the spray actuator 10, and also serves as the support structure for the spray nozzle 40.

[0034] A slidable locking mechanism 50, 51 is provided through the base 20 for selectively locking the housing 30 against rotation on the base 20. In the position shown in Figs. 2-5, the locking button 51 of the locking mechanism is depressed and the unlocking button 50 is extended, thereby holding the housing 30 in a locked position in relation to the base 20. As further shown in Figs. 2-5, the base 20 includes a contoured hand-engaging portion 22 which provides an ergonomic design, as more fully described below.

[0035] Interchangeable spray nozzles 40, 140 and 240 may be removably installed in the front opening 31 of the housing 30 in order to provide varying spray patterns. For example, for aerosol paint spray actuators, paint spray patterns may be varied depending upon the particular spray nozzle chosen. As described in more detail below and illustrated in the figures, different spray nozzles 40, 140 and 240 may be used to form spray patterns that are generally square, flat, round and the like. For example, the spray nozzle 40 shown in Figs. 1-5 may produce a generally square spray pattern; the spray nozzle 140 shown in Fig. 6 may produce a generally flat spray pattern; and the spray nozzle 240 shown in Fig. 7 may produce a generally round spray pattern.

[0036] In accordance with embodiments of the present invention, the nozzle housing 30 may be provided as an integral component that includes a front trigger surface 32 below the spray nozzle 40 at the front of the housing 30, and a top trigger surface 33 at the top of the housing 30 above the spray nozzle 40. When operating the spray actuator 10, the user may elect to use either or both of the front trigger surface 32 and/or the top trigger surface 33 during spraying operations. For example, a user may choose to depress the front trigger surface 32 with a finger, or to depress the top trigger surface 33 with a finger or thumb. Alternatively, the top upper trigger surface 33 may be depressed by the user's other hand.

[0037] In accordance with embodiments of the present invention, the spray nozzles 40, 140 and 240 are mounted in the housing 30 of the actuator 10 at a spray discharge angle A that is not perpendicular to the longitudinal axis of the aerosol container 5, and is not parallel with a plane defined by the bottom rim of the actuator base 20. As shown in Fig. 9, the spray discharge angle A may be measured from a line L that is perpendicular to the longitudinal axis base 20 of the aerosol container 5 when the actuator 10 is in its closed or neutral position. The spray discharge angle A may also be measured in relation to a plane P defined by the lower rim of the actuator base 20. The spray discharge angle A may typically range from 5-50°, for example, from 10-45°, or from 12-40°, or from 15-30°, or from 18-25°. In a particular non-limiting example, the discharge spray angle may be about 20 or 21°.

[0038] Spray discharge angles are also illustrated in Figs. 11 and 12. In Fig. 1 1, the actuator is in a closed or neutral position, and the spray discharge angle A corresponds to that shown in Fig. 9.

[0039] Fig. 12 illustrates that the spray discharge angle A' may be decreased from the spray discharge angle A shown in Figs. 9 and 11 when the actuator 10 is in its fully open or actuated position. The decreased spray discharge angle A' may result from rotational movement of the housing 30 during spraying operations. For example, the actuated spray discharge angle A' may be from 0-12° less than the neutral spray discharge angle, or from 1 -10° less, or from 3-8° less.

[0040] Figs. 14 and 15 illustrate a spray actuator 10 with the spray nozzle removed. As shown most clearly in Fig. 11, the circular front opening 31 is provided in the housing 30 with internal threads extending inward from the front surface of the housing 30. A paint delivery port 37 is located at the center of the threaded housing opening 34. [0041] As shown most clearly in the sectional view of Fig. 17, the housing includes a nozzle stem 34 including a tubular section 35 with a central fluid delivery line 36 and a lower inlet opening 37 that contacts the stem 8 of the container 5. An upper outlet opening 38 is provided at the outlet end of the fluid delivery line 36. A selected spray nozzle 140 may be installed in the opening 31 of the housing 30 by threading the spray nozzle 140 into the threaded housing opening 31. A delivery line 45 for paint or other material extends centrally through the spray nozzle 140, and is in flow communication with the delivery port 37 and delivery line 36 of the nozzle stem 34.

[0042] As further shown in Fig. 17, the housing 30 may rotate in a direction R around a pivot pin 24 from the closed position shown in Fig. 17 to an open position in which the nozzle stem 34 presses against and depresses the stem 8 of the aerosol container 5. Such rotational movement R allows paint or other material contained within the spray container 5 to exit through the delivery line 36 and port 37 of the nozzle stem 34 into the delivery line 45 of the spray nozzle 140 for discharge from the nozzle. The rotation R may be caused by pressing the housing 30 at locations such as the front trigger surface 32 and/or top trigger surface 33. In the embodiment shown, the trigger housing 30 may be biased against rotation by the valve stem 8 of the aerosol container, as more fully described below and shown in Fig. 18. Alternatively, the trigger housing 30 may be biased against rotation by any other suitable means known to those skilled in the art, such as a spring, resilient compressible material, living hinge, or the like. The locking mechanism 50, 51 is used to allow or prevent the rotation R.

[0043] Fig. 18 illustrates a conventional aerosol container stem 8 and stem biasing mechanism 9, which may be used to bias the trigger housing 30 toward its closed or neutral position. The spring-loaded biasing mechanism 9 resists the rotation R such that a desired amount of pressure must be applied by the user to the front and/or top trigger surfaces 32 and 33 during spraying operations. The spring-loaded stem biasing mechanism 9 also exerts sufficient force to the aerosol container stem 8 and the delivery port 37 of the nozzle stem 34 in order to return the housing 30 to its closed neutral position after spraying operations.

[0044] Details of the different spray nozzles 40, 140 and 240 are shown in Figs. 19-30. In Figs. 19-22, the spray nozzle 40 includes a central spray discharge opening 41 and a generally cross-shaped depression that creates a generally square spray pattern. Opposing finger tabs 43 extend from the front of the spray nozzle 40 to allow the user to twist the threads 46 of the nozzle 40 into and out of the front opening 31 of the housing 30.

[0045] The spray nozzle 140 shown in Figs. 27-30 has many of the same features as the spray nozzle 40 shown in Figs. 19-22, except a generally linear depression 142 is provided that creates a flat spray pattern.

[0046] The spray nozzle 240 shown in Figs. 24-27 also has many of the same features as the spray nozzle 40 shown in Figs. 19-22, except a generally circular conical depression 242 is provided that creates a round spray pattern.

[0047] Figs. 31 and 32 are exploded views of the container 5 and spray actuator 10, illustrating the various component parts thereof.

[0048] Fig. 33 illustrates different types of spray patterns achievable with different types of spray nozzles 40, 140 and 240 in accordance with embodiments of the present invention. The spray nozzle 40 produces a generally square spray pattern 48; the spray nozzle 140 produces a generally flat spray pattern 148; and the spray nozzle 240 produces a generally circular pattern 248.

[0049] As shown in Fig. 34, during spray operations, the aerosol container 5 may be held in a non-vertical orientation that results in a generally horizontal discharge direction, which may be desired for many types of spraying operations including spray painting. The spray discharge angle A of the nozzles 40, 140 and 240 thus provides an ergonomically favorable angled orientation for the aerosol container in which the operator's hand is in an extended position, as shown in Fig. 34, rather than bent back at a significant angle, e.g., as shown for conventional aerosol paint spray actuators in Figs. 35 and 36.

[0050] In accordance with embodiments of the present invention, ergonomic advantages are provided through the use of the contoured hand-engaging portion 22 that extends around the sides and back of the spray actuator base 20 to provide a cradle surface that generally conforms with the shape of the thumb and index finger region of a typical user's hand. In addition, the front trigger 32 under the spray nozzle 40 has a relatively large surface area for comfortable engagement with at least one finger of the operator, and the top trigger surface 33 has a relatively large surface area for comfortable engagement with the operator's finger(s), thumb and/or other hand.

[0051] In accordance with embodiments of the present invention, the spray discharge angle A, contoured hand cradle 22, and enlarged front and top trigger surfaces 32 and 33 all contribute to an improved ergonomic design that is comfortable to use.

[0052] For purposes of the description above, it is to be understood that the invention may assume various alternative variations and step sequences except where expressly specified to the contrary. Moreover, other than in any operating examples, or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specification and claims, are to be understood as being modified in all instances by the term "about". Accordingly, unless indicated to the contrary, the numerical parameters set forth are approximations that may vary depending upon the desired properties to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0053] It should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of "1 to 10" is intended to include all sub-ranges between (and including) the recited minimum value of 1 and the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.

[0054] In this application, the use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, in this application, the use of "or" means "and/or" unless specifically stated otherwise, even though "and/or" may be explicitly used in certain instances. In this application, the articles "a," "an," and "the" include plural referents unless expressly and unequivocally limited to one referent.

[0055] Whereas particular embodiments of this invention have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present invention may be made without departing from the invention. [0056] In this specification where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date publicly available, known to the public, part of the common general knowledge or known to be relevant to an attempt to solve any problem with which this specification is concerned.

[0057] The word 'comprising' and forms of the word 'comprising' as used in this description and in the claims does not limit the invention claimed to exclude any variants or additions.