Description

Continuous Spray Overcap

^• Technical Field

This invention relates to an overcap assembly of the type primarily used in conjunction with an aerosol dispenser and more particularly to an overcap for continuously dis¬ pensing the product of the aerosol dispenser.

Background Art

Presently there exists many different types of aerosol dispensers with various types of valve assemblies. Some assemblies are of the continuous type which are primarily designed to remain in an "open" or "On" position once actuated by an operator. Typically, room deodorants and bug sprays and the like use continuous valve assemblies. One prior art continuous spray assembly has an extra- long, closed end valve stem having scored or crimped in¬ dentations therein. To actuate the valve, the stem is bent back and forth at the scored indentation until the stem severs to allow the product and propellant to escape. The major disadvantage of this type of continuous spray assembly is the inability to terminate or turn "Off" the spray once the stem has been severed. This valve can be particularly hazardous if the stem is accidentally severed during ship¬ ment or storage. Another disadvantage is the inability of the severed stem to create a desired spray pattern. The product and propellant just haphazardly spews out of the stem.

Another type of continuous spray button assembly consists of a clip which holds the stem of a tilt valve in a tilted position. The clip is placed over the button and engages a rim of the aerosol dispenser. A hole within the clip allows the product and propellant to be dispensed from the terminal orifice of the button. Unfortunately the clip

cannot be easily dislodged from the rim after actuation of the continuous spray assembly. A further disadvantage of this structure is the use of two separate pieces of the structure. The clip is usually just loosely contained within an overcap of the aerosol dispenser raising the possibility that the clip will be lost, especially when displayed and subjected to customer handling.

Another type of continuous spray assembly consists of a button mounted upon a tilt valve type assembly. The stem of the assembly has an integral protruding arm with a hooked portion at an outer end. As the button is tilted to an "On" position, the hook portion engages a rim of the aerosol dis¬ penser. An upstanding tab which is integrally molded onto the protruding arm may be pressed to disengage the hook portion of the protruding arm, thereby releasing the button. The buirton then returns to the original vertical "Off" position. Unfortunately, this structure is complicated and expensive and has many of the same problems as the previousl described continuous spray button assemblies. Another type of continuous spray assembly is an actua¬ tion cap shown in U. S. Patent 3,765,573. The actuation cap comprises a cylindrical sidewall with a transverse wall extending therebetween. The transverse wall includes a conical protuberance having a vertical axis offset from the vertical axis of the valve stem. The actuation cap is inverted and reseated on the rim of the mounting cup causing the protruberance to actuate the valve stem by tilting the valve into an "On" position. The product and propellant are then dispensed through an opening in the apex of the pro- tuberance. The major disadvantage of this type of con¬ tinuous spray assembly is the configuration of the pro¬ tuberance. The valve stem does not fit into the protuber¬ ance, but is only tilted by the protuberance. This arrange¬ ment occasionally causes the product and propellant to impinge onto the interior of the protuberance causing leakage around the rim. Furthermore, the product accumulates in the opening which interferes with proper issuance

product. In extreme cases, clogging may occur which renders the aerosol dispenser inoperable. Another major disad¬ vantage of this structure is the inability to easily incorporate various swirl chambers, expansion chambers and terminal orifices within the structure.

Therefore, in order to overcome the inherent and particular inadequacies of -the prior art, it is an object of this invention to produce a continuous spray overcap assembly which may be easily turned "On" and "Off". Another object of this invention is to provide a means to prevent leakage of the product before the product issues from the terminal orifice.

Still another object of this invention is to provide a structure which may utilize various swirl chambers, ex- pansion chambers, inserts and terminal orifices to achieve a desired spray pattern.

A ^" further object of this invention is to provide a structure which may be used with a large variety of existing aerosol dispensers. A still further object of this invention is to provide a structure which is easy and economical to manufacture.

Other objects and a fuller understanding of the inven¬ tion may be had by referring to the summary of the invention, the description and the claims, taken in conjunction with the accompanying drawings.

Disclosure of Invention

The invention relates to a con ^* tinuous spray overcap assembly of the type primarily used with aerosol dispensers or cans. The invention functions as a standard protective overcap for the aerosol can during shipment and shelf storage. A valve assembly in the aerosol container includes a projecting valve stem. The overcap assembly may be removed and remounted in an inverted position onto a rim on the top of the aerosol can. In the inverted position, the overcap moves the valve stem into an "On" position, thereby

dispensing the product and propellant. Removal of the overcap assembly causes the stem to return to the original "Off" position. The overcap assembly can then be reinverted and fitted onto the rim of the can of the aerosol dispenser for further shelf storage. It should be evident that all or only a portion of the product and propellant may be dispense from this continuous spray overcap.

In the preferred embodiment of this invention, the overcap assembly has a cup-shape. A valve actuation means is disposed in the base of the cup-shaped cavity. The rim of the cavity is configured to be resiliently mounted onto a rim of the aerosol dispenser, such as the mounting cup rim, a rim on the chime or the outer rim of the aerosol can. An inside rim of the mounting cup or an undercut on the chime as well as an inside rim of the can may also be used for mounting. In any case, a plurality of lugs or a mere annular ^" lip may be utilized to hold the overcap assembly in an inverted valve actuating mounted position.

In the first embodiment, the valve actuation means comprises a nipple for receiving the stem of the aerosol valve. As the inverted overcap assembly is mounted, the valve stem is simultaneously depressed to actuate the valve to spray product and propellant through a hole in the nipple. In the second embodiment, the valve actuation means has the nipple structure of the first embodiment with a terminal orifice insert fitted into a recess of the nipple. Any type of insert may be utilized depending on the desired spray pattern. In the third embodiment, the valve actuation means comprises an aperture which encircles the valve button of the aerosol valve. The button may be ridigly press-fitted onto the valve stem or may be an integral valve button with depending stem. The lower portion of the button has an outer annular step. When the overcap assembly is inverted and remounted on the aerosol can, the button extends through

the aperture with the edge of the aperture seated on the annular step to depress the button.

In some circumstances, it is not desirable to manu¬ facture a valve button with an annular step. In the fourth embodiment, the valve actuation means has a hollow cage with a top whereby a standard valve button may be received within the cage. The top of the cage depresses the button, thereby actuating the valve.

Alternatively, the cage may be simply one or more up- standing arms. The hand of the arm depresses the button as the overcap is mounted in the inverted position. A desir¬ able feature of this embodiment is that the arm may be made to flex outwardly to accommodate various diameters of buttons. Ajnajor feature of this invention is the ability to turn the spray "On" and "Off" at leisure. In many appli¬ cations, this feature is most desirable. For example, when a large portion of product must be dispensed, it may be desirable to spray for a rather lengthy period. Ordinarily, the user would be fatigued by the continued depression of the button. For example, bug defoggers, household deodorants, paint sprayers or rug cleaners frequently require such lengthy spray application. Bug fumigators generally require a totally continuous spray until complete exhaustion of the product and the propellant.

Another feature of this invention is the elimination of buildup of product as it issues from the terminal orifice. Specifically, in the first and second embodiments of the actuation means, the cavity of the nipple is specially con- figured to graspingly receive the valve stem. This pre¬ cludes leakage of product before the product issues from the nipple. The continued use of a valve button in the third and fourth embodiments inherently precludes leakage.

Another feature of this invention is the ability to achieve almost any type of spray pattern. Specifically, the valve actuation means may include various swirl chambers or

expansion chambers prior to the terminal orifice. Hence, various type spray patterns may be achived. Additionally, inserts such as mechanical breakup (MBU) inserts may be used to mechanically atomize the product before dispensing. The invention accordingly comprises the features of construction, combination of elements and arrangement of parts which will be exemplified in the construction here¬ inafter set forth and the scope of the invention will be indicated in the claims.

Brief Description of the Drawings

For a fuller understanding of the nature and objects of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which: Fig. 1 is a cross-sectional view of the continuous spray overcap assembly in the valve protecting position; Fig. 2 is a cross-sectional view of the continuous spray overcap assembly in the inverted spray actuating position; Fig. 3 is a detailed cross-sectional view of a first embodiment of the valve actuating means;

Fig. 4 is a detailed cross-sectional view of a second embodiment of the valve actuating means;

Fig. 5 is a detailed cross-sectional view of a third embodiment of the valve actuating means;

Fig. 6 is a detailed cross-sectional view of a fourth embodiment of the valve actuating means;

Fig. 7 is a detailed cross-sectional view of a fifth embodiment of the valve actuating means; Fig. 8 is an enlarged cross-sectonal view of the second embodiment of valve actuation means and including an insert shown therein;

Fig. 9 is an enlarged cross-sectional view of the third embodiment of valve actuation means and including a button and insert shown therein;

Fig. 10 is a top view of the fourth embodiment shown in Fig. 6 illustrating a cage disposed about a standard valve stem;

Fig. 11 is a cross-sectional view taken along lines 11-11 of Fig. 10 showing .the cylindrical wall of the cage; Fig. 12 is a top view of another embodiment of the cage structure showing upstanding arms; and

Fig. 13 is a cross-sectional view taken along lines 13-13 of Fig. 12 showing a hand of each arm depressing the top of the valve button.

Similar reference characters refer to similar parts throughout the several views of the drawings. Best Mode for Carrying Out the Invention

As generally shown in Figs. 1 and 2, this invention comprises a continuous spray assembly including an overcap

1 having a cup-shaped body. A cavity 3 is located in the base of the cup with a valve actuation means 7 being disposed in the center of the cavity 3.

The overcap 1 functions as a standard protective overcap during shipment and shelf storage. However the overcap 1 may be inverted and mounted onto the aerosol can 9 as shown in Fig. 2. In the inverted position, the actuation means 7 depresses a valve stem 11 of a container within the aerosol can 9 to dispense the product and propellant as shown by arrows 15. Subsequent removal- of the overcap 1 causes the valve assembly to return to an "Off" position.

As shown in Fig. 1, the overcap 1 in the valve protec¬ tion position is attached to the outer rim 17 of the aerosol can 9. In this position, the overcap 1 protects the valve stem 11 from accidental actuation. Inwardly extending lugs 19 spaced around the rim 20 of the overcap may be used as the attachment means. Alternatively an inwardly directed continuous lip may be used in addition to equivalent struc¬ tures.

It should be noted that the overcap 1 may attach to other parts of the aerosol dispenser. For example the overcap 1 may attach onto an undercut in the rim 21 of the valve turret or the chime or onto the inside of the rim 17 of. the aerosol can. The overcap 1 may also be mounted onto the outside of the rim 21 of the mounting cup, or onto an inside crimp on the mounting cup.

In the first embodiment shown in Fig. 3, the cavity 3 of the overcap 1 has an annular sidewall 25 and a shallow conical top 27 with lugs 29 disposed at the bottom edge of the wall 25. When the overcap 1 is inverted and remounted on the rim 21 of the mounting cup, wall 25 flexes outwardly to enable lugs 29 to snap over the rim 21. In this inverted position, the overcap 1 depresses the valve stem to open the valve and dispense the product and propellant.

In"the second embodiment shown in Fig. 4, the cavity 3 of the overcap is configured to secure to an inside crimp 31 on the mounting cup 23. In this embodiment, a depending annular skirt 37 extends downwardly from a dome 35. Lugs 41 are disposed on the outside of the skirt 37. When this embodiment is positioned in the inverted position, the skirt 37 resiliently flexes inwardly as overcap 1 is pressed downwardly. The lugs 41 engage crimp 31 to hold overcap 1 in the "Valve On" position. In the third embodiment shown in Fig. 5, the cavity 3 of the overcap fits onto the crimp 43 of the valve turret 45. A depending annular skirt 49 extends from the bottom edge 51 of the dome 47 with lugs 53 being disposed on the inside of the skirt 49. The skirt 49 resiliently flexes outwardly as the overcap 1 is pressed into the inverted remounted position. The lugs 53 engage the crimp 43 to hold the overcap 1 in the "Valve On" position.

In the fourth embodiment shown in Fig. 6, the cavity 3 fits onto an undercut rim 55 of chime 57 of the can 9. The base of cavity 3 has a partially spherically shaped dome 59

with the lower edge 63 having inwardly directed lugs 65 to grasp the rim 55. Dome 59 resiliently flexes outwardly as the overcap 1 is remounted on the can 9 enabling lugs 65 to engage rim 55 to hold overcap 1 in the "Valve On" position. In the fifth embodiment shown in Fig. 7, the cavity 3 fits onto the rim 69 of the aerosol can 71. The cavity 3 has an angular-shaped dome 73 with a rim 75 grasping onto the aerosol can rim 69 through lugs 79. Rim 75 resiliently flexes outwardly as the overcap 1 is removed in the inverted position as lugs 79 snap over the rim to hold the overcap 1 in the "Valve On" position.

It should be understood that the lugs utilized in all of the embodiments of the cavity may comprise a plurality of lugs or an annular protuberance. Furthermore, it should also be understood that a plurality of legs may be used instead-of the skirt shown in the various embodiments.

The first embodiment of the actuation means is best seen in Fig. 3 and comprises a hollow shaped nipple 83 disposed in the base of the cup-shaped cavity 3. The cavity 87 in the nipple 83 tightly receives the valve stem 89. The outer edge 91 of the nipple cavity 87 may be chamfered as shown to help locate the valve stem 89. When the overcap 1 is inverted and mounted on rim 21, the valve stem 89 locates in cavity 87 and depresses the valve stem 89 to open and valve and dispense product through an overcap nipple orifice 99.

The second embodiment of the actuator means is best shown in Fig. 8 and comprises a nipple 101 having a cavity 104 dimensioned to receive an insert 105 and a valve stem 107. Edges 109 of the nipple 101 may be chamfered to help locate the valve stem 107.

The third embodiment of the actuator means is best shown in Fig. 9 and comprises an aperture 111 disposed in the base of the cup-shaped cavity 3. An enlarged valve

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button 113 having an annular step 115 is mounted on the valve stem 117. When the overcap 1 is inverted and re¬ mounted the button 113 extends through the aperture 111 with the edge 118 of the aperture 111 seated on top of the step 115 to depress the stem 117 thereby dispensing product and propellant.

The fourth embodiment of the actuator means is best shown in Figs. 10, 11, 12 and 13 and comprises a cage 119 disposed over an aperture 120. In Fig. 11, the cage includes a substantially cylindrical wall 121 with a top 123 having an axial orifice 125 therein. When the overcap 1 is inverted and remounted, the valve button with or without insert 127 is enclosed in the cage 119 and depressed by top 123 thereby actuating the valve assembly (not shown) . Product and pro- pellant are dispensed through a terminal orifice 129 of the button -with or without insert 127 and through the axial orifice 125.

Figs. 12 and 13 illustrate a cage 119 comprising at ' least one upstanding arm 131 with hand 133 disposed at the end of each arm 131. As the button with or without insert 135 enters cage 119, the hand 133 grasps the button edge 137 and depresses the button 135 to dispense the product. It should be noted that this particular embodiment may be used with various size valve buttons. Thus, regardless of the diameter of the button, arms 131 may flex outwardly as shown by arrow 139 and grasp edge 137 of the button 135 to activate the valve.

The cage configuration also enables use of a side orifice button whereby the spray is emitted horizontally such as a right angle spray passage 141.

From the foregoing it should be evident that a superior continuous spray overcap has been designed. The cooperative fit between the valve stem and the overcap, or between the valve button and the overcap prevents leakage therebetween.

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The invention also enables use of a side spray pattern as well as the use of terminal orifice inserts or buttons with such inserts. Mechanical breakup buttons or other special spray or breakup or even aspirator feed flow patterns can be incorporated into the overcap or button structure if desired. It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes _. may be made in the above construction without departing from the scope of the invention, it is intended that all matter con¬ tained in the above description or shown in the accompanying drawing shall be interpreted as illustrative and not in a limiting sense.