U.S. patent application number 15/186973 was filed with the patent office on 2016-10-20 for insert for dispensing a compressed gas product, system with such an insert, and method of dispensing a compressed gas product.
This patent application is currently assigned to S.C. Johnson & Son, Inc.. The applicant listed for this patent is S.C. Johnson & Son, Inc.. Invention is credited to Bhaveshkumar Shah, Nitin Sharma.
Application Number | 20160303270 15/186973 |
Document ID | / |
Family ID | 48017168 |
Filed Date | 2016-10-20 |
United States Patent
Application |
20160303270 |
Kind Code |
A1 |
Shah; Bhaveshkumar ; et
al. |
October 20, 2016 |
INSERT FOR DISPENSING A COMPRESSED GAS PRODUCT, SYSTEM WITH SUCH AN
INSERT, AND METHOD OF DISPENSING A COMPRESSED GAS PRODUCT
Abstract
An insert, a system, and a method for dispensing a compressed
gas product. The insert includes a swirl chamber, inlet ports to
the swirl chamber, and an outlet orifice. The insert has
specifically configured parameters relating to the diameter of the
swirl chamber, the diameter of the outlet orifice, the length of
the outlet orifice, and the depth of the swirl chamber. The insert,
system, and method can provide a dispensed compressed gas product
with a remarkably constant flow rate and with a remarkably constant
particle size.
Inventors: |
Shah; Bhaveshkumar;
(Kenosha, WI) ; Sharma; Nitin; (Kenosha,
WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
S.C. Johnson & Son, Inc. |
Racine |
WI |
US |
|
|
Assignee: |
S.C. Johnson & Son,
Inc.
Racine
WI
|
Family ID: |
48017168 |
Appl. No.: |
15/186973 |
Filed: |
June 20, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
13428945 |
Mar 23, 2012 |
9393336 |
|
|
15186973 |
|
|
|
|
61457925 |
Jul 8, 2011 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 83/206 20130101;
A61L 9/14 20130101; A61L 2209/134 20130101; B05B 1/3426 20130101;
B05B 1/3421 20130101; Y10T 137/0318 20150401; B05B 7/10 20130101;
B05B 1/3436 20130101; Y10T 137/2087 20150401; B05B 1/3478 20130101;
A01M 1/2038 20130101; B65D 83/48 20130101 |
International
Class: |
A61L 9/14 20060101
A61L009/14; B65D 83/20 20060101 B65D083/20; B65D 83/48 20060101
B65D083/48; B05B 1/34 20060101 B05B001/34 |
Claims
1. A method of dispensing a compressed gas product from a container
and dispensing assembly that includes an insert with a swirl
chamber, the method comprising: providing a product in the
container such that the pressure inside the container is less than
about 157 psi at 70.degree. F.; dispensing the product from the
container through the insert such that the flow rate of product out
of the insert when the container is about 13% full of product is at
least about 65% that of the initial flow rate of product out of the
insert when the container is 100% full of product.
2. A method according to claim 1, wherein a flow rate of product
during an initial sixty second dispensing from the container is at
least about 1.7 g/sec.
3. A method according to claim 2, wherein an average particle size
during the sixty second dispensing is about 65 .mu.m.
4. A method according to claim 1, wherein a flow rate of product
when the container is about 13% full of product is about 1.3
g/s.
5. A method according to claim 4, wherein an average particle size
when the container is about 13% full of product is about 85
.mu.m.
6. A method according to claim 1, wherein the pressure inside the
container prior to any dispensing of the product is about 135
psig.
7. A method according to claim 6, wherein the compressed gas
product includes an air freshening compound.
8-14. (canceled)
15. A system for dispensing a compressed gas product, the system
comprising: a container for containing a volume of compressed gas
product; and a compressed gas product inside the container, the
compressed gas product including a gas component and a liquid
component, wherein the compressed gas product dispensed from the
container has a flow rate of (i) at least about 2.0 g/s during an
initial ten second dispensing period from the container, and (ii)
at least about 1.3 g/s during a ten second dispensing period when
the container has about 13% of the initial amount of compressed gas
product remaining in the container.
16. A system according to claim 15, wherein about 230 grams of the
compressed gas product are initially provided in the container.
17. A system according to claim 15, wherein an initial pressure of
the container is about 135 psig.
18. A system according to claim 15, wherein the liquid component of
the compressed gas product includes an air freshener.
19. A system for dispensing a compressed gas product, the system
comprising: a container for containing a volume of compressed gas
product; and a compressed gas product inside the container, the
compressed gas product including a gas component and a liquid
component, wherein the compressed gas product dispensed from the
container has a flow rate of (i) at least about 2.0 g/s during an
initial ten second dispensing period from the container, (ii) at
least about 1.7 g/s during a ten second dispensing period when the
container has about 66% of the initial amount of compressed product
remaining, (iii) at least about 1.4 g/s during a ten second
dispensing period when the container has about 33% of the initial
amount of compressed product remaining, and (iv) at least about 1.3
g/s during a ten second dispensing period when the container has
about 13% of the initial amount of the compressed gas product
remaining.
20. A system according to claim 19, wherein about 230 grams of
compressed gas product are initially provided in the container.
21. A system according to claim 19, wherein an initial pressure of
the container is about 135 psig.
22. A system according to claim 19, wherein the liquid component of
the compressed gas product includes an air freshener.
23. A system for dispensing a compressed gas product, the system
comprising: a container; and a compressed gas product provided
inside the container, the compressed gas product including a gas
component and a liquid component, wherein the system is configured
to dispense the compressed gas product such that a flow rate of
compressed gas product when the system is about 13% full of product
is at least about 65% that of an initial flow rate of product when
the system is 100% full of product, and wherein the system is
configured to dispense the compressed gas product such that the
particle size increases by less than about 40% as the amount of
product in the container drops to 13% of the initial amount of
product in the container.
24. A system according to claim 23, wherein the compressed gas
product dispensed from the container has a flow rate of about 1.85
g/s during an initial sixty second dispensing from the container,
and wherein an average particle size dispensed from the container
during the sixty seconds of dispensing is about 65 .mu.m.
25. A method of maintaining a spray rate of compressed gas product,
the method comprising: providing the compressed gas product inside
a container such that the pressure inside the container is less
than about 157 psi; and dispensing the compressed gas product from
the container, wherein the compressed gas product has a flow rate
of at least about 1.7 g/s during an initial sixty second dispensing
from the container, and wherein the spray rate decreases by less
than about 0.7 g/s as the compressed gas product is discharged from
a full container to a point when the container has about 13% of the
compressed gas product remaining.
Description
[0001] The application is a divisional application of copending
U.S. patent application Ser. No. 13/428,945, filed Mar. 23, 2012,
which is a non-provisional application based on U.S. Provisional
Patent Application No. 61/457,925, filed Jul. 8, 2011.
BACKGROUND
[0002] 1. Field of the Invention
[0003] Our invention relates to an insert for dispensing a
compressed gas product, a system that includes such an insert, and
a method of dispensing a compressed gas product. More generally,
our invention relates to apparatuses, systems, and methods for
dispensing compressed gas products with a relatively constant flow
rate and with a relatively constant particle size.
[0004] 2. Related Art
[0005] In general, aerosol dispensers provide low cost, easy to use
methods of dispensing products, typically, as an airborne mist.
Thus, aerosol dispensers have been commonly used to dispense
personal, household, industrial, and medical products. The airborne
mist provided by an aerosol dispenser itself may provide a desired
effect, as is the case with air freshening fragrances.
Alternatively, the mist may be used to form a thin coating on
surfaces, such as with furniture polishes.
[0006] Typically, aerosol dispensing systems include a container
that holds a product with liquid and gas parts. Examples of liquid
compositions included in aerosol systems are air and fabric
fresheners, soaps, insecticides, paints, deodorants, disinfectants,
and the like. The gas included with the liquid product acts as a
propellant to discharge the liquid product from the container. The
propellant pressurizes the container holding the liquid
composition, and provides a force to expel the liquid composition
from the container when a user actuates the aerosol dispenser by
pressing an actuator button or trigger.
[0007] There are two main types of propellants used in aerosol
systems: (1) liquefied gas propellants, such as hydrocarbon and
hydrofluorocarbon (HFC) propellants, and (2) compressed gas
propellants, such as carbon dioxide and nitrogen. In the past,
chlorofluorocarbon propellants (CFCs) were used as propellants in
aerosol systems. The use of CFCs, however, has essentially been
phased out due to the potentially harmful effects of CFCs on the
environment.
[0008] In an aerosol system that uses a liquefied petroleum
gas-type propellant (LPG), the container is loaded with liquid
composition and LPG propellant to a pressure approximately equal to
the vapor pressure of the LPG. After being filled, the container
has a certain amount of space that is not occupied by liquid. This
space is referred to as the headspace. Since the container is
pressurized to approximately the vapor pressure of the LPG
propellant, some of the LPG is dissolved or emulsified in the
liquid product. The remainder of the LPG remains in the vapor phase
and fills the headspace. As the product is dispensed, the pressure
in the container remains approximately constant because liquid LPG
moves from the liquid to the vapor in the headspace, thereby
replenishing discharged LPG propellant vapor.
[0009] In contrast, compressed gas propellants in aerosol systems
largely remain in the vapor phase. That is, only a relatively small
portion of a compressed gas propellant is contained in the liquid
composition. Hence, a "compressed gas product" includes a liquid
composition and a compressed gas propellant. As a result, the
pressure within a compressed gas aerosol dispenser assembly
decreases as the product is dispensed. While this aspect of using
compressed gas propellants is, in some ways, disadvantageous, the
use of compressed gas propellants has gained favor as compressed
gas propellants do not usually contain volatile organic compounds
(VOCs). On the other hand, LPGs are considered to be VOCs, thereby
making their use subject to various regulations.
[0010] From a consumer satisfaction standpoint, an important aspect
of an aerosol system is that the system provides a consistent
fragrance experience provided by a consistent flow rate and a
consistent particle size. A consistent flow rate and a consistent
particle size ensures that a relatively consistent effect is
achieved as the product is dispensed from the container. For
example, in the case of air freshening products, the fragrance
experience is a function of the amount of fragrance in the air,
which in turn is related to both the flow rate and particle size of
product dispensed by the related system. Thus, it is important that
the flow rate and particle size of product that is dispensed when
the container is relatively full be as close as possible to the
flow rate and particle size of product that is dispensed when the
container is relatively empty so that the user can achieve the same
levels of air freshening with equal lengths of application,
regardless of the amount of product remaining in the container.
[0011] Ideally, in an aerosol system configured to dispense an air
freshener, the system dispenses a product with a flow rate and a
particle size such that a sufficient amount of fragrance experience
is achieved soon after the dispensing, but also such that there is
longevity in the fragrance experience. The higher the flow rate of
product from the system, the more fragrance that will be available
with a given length of application. Too high of flow rate, however,
may lead to an overwhelming fragrance experience. With respect to
particle size, larger particles provide a smaller total surface
area for evaporation of the fragrance as compared to an equivalent
volume of smaller particles. The smaller surface area for
evaporation of fragrance in larger particles provides for less of
an initial fragrance experience compared to an equivalent volume of
smaller particles. However, the smaller surface area for
evaporation of fragrance in larger particles provides for a longer
fragrance experience compared to an equivalent volume of smaller
particles, i.e., the fragrance evaporates more slowly from the
larger particles. Still other factors are taken into account when
considering the particle size for an air freshener. Smaller
particles may be more easily carried away with air flow, which also
reduces the longevity of the fragrance experience. On the other
hand, there is a greater tendency for larger particles to fall out
of the air and onto surfaces. Such fall out behavior of larger
particles is often undesirable because of the resulting
accumulation on a surface.
[0012] Ideally, an aerosol system is configured to provide a flow
rate and particle size that balances these considerations. That is,
the aerosol system provides a flow rate and particle size such that
a sufficient amount of fragrance is available quickly after
dispensing the product, with the product particle sizes providing
longevity to the fragrance experience, but not so large to present
substantial fall out. With compressed gas propellants, however,
there is a tendency for the spray rate to decrease as the product
is dispensed from a container. Further, there is a tendency for the
particle size to increase as the product is dispensed from the
container. In prior art dispensing systems, the flow rate may
decrease by more than 40% as the product in the container is used
up. In the same prior art systems, the particle size may increase
by more than 50% as the product in the container is used up.
Accordingly, the desired effects of the dispensed product achieved
by having a consistent flow rate and a consistent particle size are
not found in prior art compressed gas aerosol systems. Further,
even if the initial flow rate and initial particle size can provide
an air freshener with a good fragrance experience, the changes in
the flow rate and particle size may degrade the fragrance
experience.
SUMMARY OF THE INVENTION
[0013] According to one aspect of the invention, an insert is
provided for use with an assembly to dispense a compressed gas
product from a container. The insert comprises a swirl chamber
having a diameter Ds and a depth Ls, at least one inlet port
opening to the swirl chamber, and an outlet orifice having a
diameter do and a length lo. The insert is configured such that
Ds/do is about 3.0 to about 3.5, lo/do is about 0.4 to about 0.6,
and Ls/Ds is about 0.3 to about 1.0.
[0014] Another aspect of the invention is a method of dispensing a
compressed gas product from a container and a dispenser assembly
that includes an insert with a swirl chamber. The method comprises
providing a product in the container such that the pressure inside
the container is less than about 157 psi. The product is dispensed
from the container through the insert such that the flow rate of
product out of the insert when the container is about 13% full of
product is at least about 65% that of the initial flow rate of
product when the container is 100% full of product.
[0015] Yet another aspect of the invention is a method of
dispensing a compressed gas product from a container that includes
an insert with a swirl chamber. The method comprises providing a
product in the container such that the pressure inside the
container is less than about 157 psi, and dispensing the product
from the container through the insert such that the particle size
increases by less than about 40% as the amount of product in the
container drops to 13% of the initial amount of product in the
container.
[0016] Another aspect of the invention is related to a method of
minimizing a change in flow rate of a compressed gas product and
minimizing an increase in particle size of the compressed gas
product dispensed from a container through a dispenser assembly
that includes an insert. The insert has (i) a swirl chamber with a
diameter Ds and a length Ls, (ii) at least one inlet port opening
to the swirl chamber, the at least one inlet port having a
cross-sectional area Ap, and (iii) an outlet orifice having a
diameter do and a length lo. The method comprises adjusting the
ratio Ds/do to be in the range of about 3.0 to about 3.5, adjusting
the ratio lo/do to be in the range of about 0.4 to about 0.6,
adjusting the ratio Ls/Ds to be in the range of about 0.3 to about
1.0, and adjusting the ratio Ap/(Dsdo) to in the range of about 0.3
to about 0.9.
[0017] According to a further aspect of the invention, a system is
provided for dispensing a compressed gas product. The system
comprises a container for containing a volume of compressed gas
product, and a compressed gas product inside the container, with
the compressed gas product including a compressed gas component and
a liquid component. The compressed gas product dispensed from the
container has a flow rate of (i) at least about 2.0 g/s during an
initial ten second dispensing period from the container, and (ii)
at least about 1.3 g/s during a ten second dispensing period when
the container has about 13% of the initial amount of compressed gas
product remaining in the container.
[0018] According to another aspect of the invention, a system is
provided for dispensing a compressed gas product. The system
comprises a container for containing a volume of compressed gas
product, with the compressed gas product including a compressed gas
component and a liquid component. The compressed gas product
dispensed from the container has a flow rate of (i) at least about
2.0 g/s during an initial ten second dispensing period from the
container, (ii) at least about 1.7 g/s during a ten second
dispensing period when the container has about 66% of the initial
amount of compressed product remaining, (iii) at least about 1.4
g/s during a ten second dispensing period when the container has
about 33% of the initial amount of compressed product remaining,
and (iv) at least about 1.3 g/s during a ten second dispensing
period when the container has about 13% of the initial amount of
the compressed gas product remaining.
[0019] A different aspect of the invention is directed to a system
for dispensing a compressed gas product. The system comprises a
container, and a compressed gas product provided inside the
container, with the compressed gas product including a compressed
gas component and a liquid component. The system is configured to
dispense the compressed gas product with a flow rate of such that a
flow rate of compressed gas product when the system is about 13%
full of product is at least about 65% that of an initial flow rate
of product when the system is 100% full of product. The system is
also configured to dispense the compressed gas product such that
the particle size increases by less than about 40% as the amount of
product in the container drops to 13% of the initial amount of
product in the container.
[0020] In other aspects of the invention, a method is provided for
minimizing a change in flow rate of a compressed gas product and
minimizing an increase in particle size of the compressed gas
product dispensed from a container through an insert provided to a
dispenser assembly associated with the container. The insert has
(i) a swirl chamber with a diameter Ds and a length Ls, (ii) at
least one inlet port opening to the swirl chamber, the at least one
inlet port having a cross-sectional area Ap, and (iii) an outlet
orifice having a diameter do and a length lo. The method comprises
adjusting the ratio Ds/do, adjusting the ratio lo/do, adjusting the
ratio Ls/Ds, and adjusting the ratio Ap/(Dsdo). A spray rate during
an initial sixty second dispensing of the compressed gas product
through the insert is at least about 1.7 g/s.
[0021] Another aspect of the invention is directed to a method of
maintaining a spray rate of compressed gas product. The method
comprises providing the compressed gas product inside a container
such that the pressure inside the container is less than about 157
psi, and dispensing the compressed gas product from the container.
The compressed gas product has a flow rate of at least about 1.7
g/s during an initial sixty second dispensing from the container,
and the spray rate decreases by less than about 0.7 g/s as the
compressed gas product is discharged from a full container to a
point when the container has about 13% of the compressed gas
product remaining.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a cross-sectional view of an aerosol dispenser
having an insert according to the invention.
[0023] FIG. 2 is a cross-sectional view of an insert according to
the invention.
[0024] FIG. 3 is a cross-sectional view of the swirl chamber of the
insert shown in FIG. 2.
[0025] FIG. 4 is a rear elevation view of the insert shown in FIG.
2.
[0026] FIG. 5 is a front elevation view of the insert shown in FIG.
2.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Our invention is related to an insert for dispensing a
compressed gas product, a system that includes such an insert, and
a method of dispensing a compressed gas product. As will be
described below, the insert can be used with an aerosol dispenser
assembly to dispense a compressed gas product from a container in a
manner that maintains a relatively constant flow rate and a
relatively constant particle size. Similarly, a method according to
the invention provides steps for dispensing a compressed gas
product with a relatively constant flow rate and a relatively
constant particle size.
[0028] FIG. 1 depicts an aerosol dispenser assembly 10 that
includes an insert 21 according to the invention. The aerosol
dispenser assembly 10 includes a container 11 covered by a mounting
cup 12. A mounting gasket (not shown) may be disposed between an
upper rim of the container 11 and the underside of the mounting cup
12. A valve assembly 13 is used to selectively release the contents
from the container 11 to the atmosphere. The valve assembly 13
comprises a valve body 14 and a valve stem 15. The valve stem 15
includes a lower end 16 that extends through a return spring 17. An
actuator body 18 is mounted on top of the valve stem 15 and defines
a primary passageway 19. The actuator body 18 is also connected to
the nozzle insert 21 that defines an exit orifice shown generally
at 22. The insert 21 will be discussed in greater detail below.
[0029] An upper rim 23 of the valve body 14 is affixed to the
underside of the mounting cup 12 by a friction fit and the valve
stem 15 extends through the mounting cup 12. The actuator body 18
is frictionally fitted onto the upwardly extending portion 24 of
the valve stem 15. The lower end 25 of the valve body 14 is
connected to a dip tube 26. Gaskets may or may not be provided
between the valve body 14 and the mounting cup 12, and between the
valve stem 15 and the mounting cup 12, depending upon the materials
used for each component. Suitable materials that will permit a
gasket-less construction will be apparent to those skilled in the
art. Similarly, gaskets or seals are typically not required between
the actuator body 18 and the upper portion 24 of the valve stem 15.
While the dispenser assembly 10 of FIG. 1 employs a vertical
action-type actuator body or cap 18, other actuator cap designs may
be used, such as an actuator button with an integral over cap, a
trigger actuated assembly, a tilt action-type actuator cap, or
other designs.
[0030] In operation, when the actuator body 18 is depressed, the
valve stem 15 moves downward, thereby allowing pressurized liquid
product to be propelled upward through the dip tube 26 and the
lower portion 25 of the valve body 14 by the propellant. From the
valve body 14, the product is propelled past the lower end 16 of
the valve stem 14 through the channel 26 and through the stem
orifice(s) 27, out the passageway 28 of the valve stem and into the
primary passageway 19 of the actuator body 18. In some embodiments,
two valve stem orifices 27 are employed, as is shown in FIG. 1,
although a single valve stem orifice 27 or more than two valve stem
orifices 27 may be used. Multiple valve stem orifices 27 may
provide greater flow and superior mixing of the compressed gas
product.
[0031] It should be noted that while specific features and a
configuration for a system for providing a compressed gas product
are exemplified in the dispenser assembly 10, our invention is not
limited to such features and configuration. Indeed, as will be
appreciated by those skilled in the art, a wide variety of
dispenser assemblies could be used with the inventive insert,
systems, and methods described herein.
[0032] FIGS. 2-5 show an example embodiment of an insert 21
according to the invention. The insert 21 includes a sidewall 32
that defines a substantially circular shape, and an endwall 29 that
includes an outlet orifice 22. It should be noted, however, the
shape of the sidewall could be varied such that the insert 21
includes, for example, a plurality of sidewalls defining a
rectangular shape or any other polygonal shape. Of course, the
corresponding slot in the actuator body of the dispenser assembly
that receives the insert 21 will be shaped to correspond to the
shape of the sidewall 29.
[0033] The insert 21 includes a plurality of inlet ports 30 that
lead to a swirl chamber 31. The swirl chamber 31 is in fluid
communication with the outlet orifice 22. Thus, the insert 21
provides a fluid pathway from the inlet ports 30 to the swirl
chamber 31, and then out of the insert 21 through the outlet
orifice 22. Thus, a compressed gas product contained in a system
including a container and dispenser assembly, such as those
described above, can be dispensed through the fluid pathway in the
insert 21.
[0034] The configuration of the swirl chamber 31 and the
tangentially positioned inlet ports 30 creates a swirling motion to
the liquid in the chamber 31. As a result, a core of air extends
from the rear of the swirl chamber 31 to the outlet orifice 22.
Thus, the product dispensed from the outlet orifice 22 is released
as an annular sheet, which spreads radially outward to form a
hollow conical spray. It should be noted that although four inlet
ports 30 are shown in the depicted embodiment, the number of inlet
ports 30 can be any number, including only a single inlet port. The
number of inlet ports 30 will depend on factors such as, for
example, the size of the corresponding system, the desired shape of
the system, etc.
[0035] Certain parameters of the insert 21 are shown in FIGS. 2 and
3. One such parameter is the "diameter" Ds of the swirl chamber 31.
As is apparent from FIGS. 3-4, the swirl chamber 31 has a
substantially square shape. In view of the substantially square
shape, the diameter Ds represents the maximum diameter of a circle
that can be contained in the swirl chamber 31. In alterative
embodiments, however, the swirl chamber 31 can have a circular
shape, wherein the diameter Ds is the actual diameter of the
chamber.
[0036] Other parameters of the swirl chamber 31 and outlet orifice
22 are shown in FIG. 2. One such parameter is the depth of the
swirl chamber Ls. In this case, the depth Ls is the same size as
the depth of the inlet ports 30 provided to the swirl chamber 31.
In other embodiments, however, the depth of the swirl chamber 31
may be different from the depths of the inlet ports 30. Parameters
of the outlet orifice 22 include a diameter do, and a length lo
that the outlet orifice extends from the swirl chamber 31 to the
final outlet of insert 21.
[0037] The inlet ports 30 leading to the swirl chamber 31 are
substantially rectangular in shape, and therefore have a length and
depth (or width). As such, the inlet ports 30 provide a total
cross-sectional area Ap opening to the swirl chamber 31. As noted
above, that the number of inlet ports 25 provided to the swirl
chamber 31 can be varied. Along these lines, the shape and angle of
the ports 30 with respect to the swirl chamber 31 can also be
varied. It should be noted, however, that regardless of aspects
such as the number, shape, and positioning of the inlet ports 30,
differently configured inlet ports still can provide the equivalent
cross-sectional areas Ap.
[0038] Prior art nozzle inserts have included swirl chambers, inlet
ports, and exit orifices. And attempts have been made in the prior
art to adjust some of the parameters of these structures in order
to achieve various effects in dispensing compressed gas products.
For example, U.S. Patent Application Pub. No. 2009/0020621, the
disclosure of which is incorporated by reference in its entirety,
discloses a design methodology for an actuator body and a swirl
nozzle (insert) so as to maintain a small particle size using a
compressed gas VOC-free propellant for an air freshener product.
What we have surprisingly found is that certain ratios of
parameters, including the diameter of the swirl chamber Ds, the
diameter of the outlet orifice do, the length of the outlet orifice
lo, the depth of the swirl chamber Ls, and the total
cross-sectional areas of the inlet ports Ap, can lead to remarkably
consistent flow rates and remarkably consistent particle sizes when
dispensing compressed gas products using the insert. In particular,
when the insert is configured such that Ds/do is 3.0 to 3.5, lo/do
is 0.4 to 0.6, Ls/Ds is 0.3 to 1.0, and Ap/(Dsdo) is 0.3 to 0.9,
surprisingly low amount of decrease in the flow rate occurs as a
compressed gas product is dispensed from a compressed gas system
that uses the insert. These same ratios also provide surprisingly
low rates of increase in particle size as a compressed gas product
is dispensed from the container. The effect of these ratios will be
demonstrated in the tests set forth below.
[0039] Without being limited by any theory, it is believed that if
the ratios of Ds/do, lo/do, Ls/Ds, and Ap/(Dsdo) are outside the
ranges described above, the swirling and particle breakup of the
product that occurs in the swirl chamber changes more significantly
as the product is dispensed from the container. As discussed above,
unlike LPG in LPG systems, the amount of compressed gas propellant
in a system is reduced as the product is dispensed. This aspect of
a compressed gas system may contribute to the decrease in flow rate
and the increase in particle size as the compressed gas product is
dispensed. On the other hand, having the above-described ratios of
parameters in the identified ranges may act to negate some of the
effects of the reduced amount of compressed gas on the flow rate
and particle size.
[0040] As will be appreciated by those skilled in the art, a wide
variety of compressed gas products can be used in systems according
to the invention. As non-limiting examples, such compressed gas
products can include air fresheners, combination air and fabric
fresheners, refreshers, deodorizers, sanitizers, disinfectants,
soaps, insecticides, insect repellants, fertilizers, herbicides,
fungicides, algaecides, pesticides, rodenticides, paints,
deodorants, deodorants, body sprays, hair sprays, topical sprays,
cleaners, polishes, and shoe or footwear spray products. Examples
of specific compressed gas product formulations that can be used
with apparatuses, systems, and methods according to the invention
are set forth in U.S. patent application Ser. No. 13/422,096, the
disclosure of which is incorporated by reference in its entirety.
Along these lines, one of ordinary skill in the art will appreciate
that properties of such compressed gas products, including
viscosity, density, and surface tension, can easily be adjusted to
achieve desired effects. In example embodiments, the density of the
compressed gas product is about 1.00 g/cm.sup.3, the surface
tension is about 30 mN/m, and the viscosity is about 1.0-1.6
cP.
[0041] The particular type of compressed gas that is used as the
propellant in systems according to the invention can be selected
based on convenience, cost, properties of the corresponding
container, properties of the liquid product formulation, etc.
Examples of known compressed gases that can be used in systems
according to the invention include air, argon, nitrogen, nitrous
oxide, inert gases, and carbon dioxide. Along with the particular
type of compressed gas, the amount of headspace provided by the
compressed gas can be adjusted or tailored as desired. As
compressed gases do not significantly dissolve in the liquid
portion of a compressed gas product, the amount of headspace is
primarily a function of the amount of compressed gas used in the
container. In example embodiments of systems according to the
invention, a headspace of 30 to 40% is used. However, in
alternative embodiments the headspace could be lower than 30% or
higher than 40%.
[0042] The container for use in systems of the invention may be a
metallic container, such as a steel or aluminum canister, or
combinations thereof. Alternatively, the container could be
manufactured using any plastic or resin. Example of such plastics
or resins include polyethylene terepthalate (PET), preferably clear
PET, polycarbonate, polyacrylate, polyethylene naphthalate (PEN), a
sandwhich layer plastic such as ethylene vinyl alcohol copolymer
(EVOH) and PET, a copolyester such as is sold under the trademark
TRITON.TM. by Eastman Chemical Company of Kingsport, Tenn., or
impact-modified acrylonitrile-methyl acrylate copolymers such as
are sold under the trademark BAREX.RTM. by Ineos Olefins &
Polymers of League City, Tex. Of course, one of ordinary skill in
the art will recognize that there are other materials that could
also be used to manufacture the canister.
[0043] The container can also be adopted for the particular
compressed gas formulation, as is described in the aforementioned
U.S. patent application Ser. No. 13/422,096, or other alternative
compressed gas formulations. As will be appreciated by those
skilled in the art, containers used to provide compressed gas
products are required by law to be made in accordance with
Department of Transportation (DOT) and Interstate Commerce
Commission (ICC) regulations. These regulations mandate certain
dimensional, material, manufacture, wall thickness, and testing
requirements for a container to be charged to a given pressure. For
example, a 2P rated container can be used if the internal pressure
is from 140 to 160 psig at 130.degree. F., and a 2Q rated container
can be used if the internal pressure is from 161 to 180 psig at
130.degree. F. In general, the containers used in conjunction with
the present invention can be adjusted to meet these regulations,
and as such, be used to provide a compressed gas product at any
given pressure in the container. In particular embodiments,
however, systems of the invention are specifically designed as 2Q
and 2P rated containers. Example embodiments of the invention
include containers initially charged with up to 157 psig at
70.degree. F. of compressed gas product.
Insert Parameter and Container Pressure Testing
[0044] In order to determine the effect of the above-described
parameters of an insert on the flow rate and particle size of a
dispensed compressed gas product, a series of tests was conducted
with different inserts. The parameters of the inserts varied, and
the parameters are listed in Table 1 below. In Table 1, the same
abbreviations for the insert parameters are used as are described
above. Specifically, the diameter of the outlet orifice is labeled
do, the diameter of the swirl chamber is labeled Ds, the length of
the outlet orifice is labeled lo, the depth of the swirl chamber is
labeled Ls, and the total cross-sectional area of the inlet ports
to the swirl chamber is labeled Ap. The values of all of these
parameters are given in inches, except for the cross-sectional area
Ap, which is given in square inches. Table 1 further indicates the
number of inlet ports "n" leading to the swirl chamber of each
insert.
[0045] The flow rates indicated in Table 1 were determined by
discharging systems including the inserts for sixty seconds. The
flow rate was measured using a stopwatch and a scale made by
Mettler-Toledo of Columbus, Ohio. All of the other parameters of
the system, such as the configuration of the dispenser assembly and
container, the size of the containers, the initial pressure in the
containers, etc., were the same for all of the inserts.
Additionally, all of the tests were conducted at ambient
temperature (about 70.degree. F.).
TABLE-US-00001 TABLE 1 Flow Ap Rate Insert do Ds Ds/do lo lo/do n
Ls Ls/Ds Ap (Ds do) (g/s) 1 0.014 0.046 3.30 0.007 0.50 4 0.010
0.22 0.0004 0.6184 1.40 2 0.014 0.046 3.30 0.011 0.79 4 0.008 0.17
0.0003 0.3958 1.15 3 0.013 0.046 3.54 0.011 0.85 4 0.010 0.22
0.0004 0.6689 1.11 4 0.015 0.046 3.07 0.007 0.47 4 0.011 0.24
0.0005 0.7014 1.50 5 0.015 0.046 3.07 0.007 0.47 4 0.015 0.33
0.0006 0.8696 1.72 6 0.013 0.041 3.15 0.013 1.00 5 0.008 0.20
0.0007 1.2758 1.56 7 0.015 0.031 2.07 0.011 0.73 5 0.015 0.48
0.0009 1.9355 1.79
[0046] As demonstrated by the data in Table 1, the parameters do,
Ds, lo, Ls, and Ap function together synergistically to affect the
flow rate dispensed through an insert. That is, while one of the
parameters, such as the diameter of the outlet orifice, might be
directly related to the flow rate, the actual flow rate is a result
of the combination of all the parameters.
[0047] More importantly, we found from tests such as those shown in
Table 1 that the above-described specific ratios of Ds/do, lo/do,
Ls/Ds, and Ap/(Dsdo) lead to surprisingly consistent flow rates and
particle sizes. Further tests demonstrating our findings with
respect to the ratio of parameters are described below.
[0048] Tests were also conducted to correlate the pressure of the
container having an insert according to the invention with the
amount of product remaining in the container. The results of these
tests are shown in Table 2.
TABLE-US-00002 TABLE 2 % of Full Target Fill Pressure Measurements
(psig) Container Weight (g) Sample 1 Sample 2 Sample 3 Average 100
227 135 136 136 135.6 .+-. 0.5 90 204 116 116 117 116.3 .+-. 0.5 80
182 100 101 100 100.3 .+-. 0.5 66 150 86 87 87 86.6 .+-. 0.5 50 113
72 72 72 72.0 .+-. 0.0 33 75 61 62 61 61.3 .+-. 0.5 13 30 51 52 51
51.3 .+-. 0.53 0 0 42 36 40 39.3 .+-. 3.0
[0049] As can be seen from the data in Table 2, the pressure in the
container of the system ranged from about 135 psig when the
container was initially filled with the compressed gas product, to
about 40 psig when all of the compressed gas product had been
dispensed from the container. These pressures can be directly
correlated to the amount of product remaining in the container in
the tests involving Insert A described below.
Insert Parameter Comparison Testing
[0050] An insert A according to the invention was compared in the
tests discussed below to the inserts B and C, which were provided
on compressed gas product dispensing systems that are sold in
retail stores.
[0051] The insert A according to the invention was provided on a
system that included a dispenser assembly and associated container,
as generally described above. The container initially included 227
grams (about 8 ounces) of an air freshening product, and nitrogen
was used as the gas propellant. The container was initially
pressurized to about 135-138 psi with the compressed gas product,
and had 36% headspace. The parameters of insert A are shown in
Table 3 below.
[0052] The insert B was part of a product available in retail
stores. The system with insert B included a container having 226
grams of an air freshening product. Insert C was also part of a
product available in retail stores. The system with insert C
included a container having 275 grounds of an air freshening
product. The specific parameters for inserts B and C are shown in
Table 3 below.
[0053] The same abbreviations and units of measure for the insert
parameters are used in Table 3 as are used in Table 1 above.
TABLE-US-00003 TABLE 3 Ap Insert do Ds Ds/do lo lo/do n Ls Ls/Ds Ap
(Ds do) A 0.015 0.046 3.07 0.007 0.47 4 0.015 0.32 0.00060 0.8696 B
0.013 0.053 4.07 0.010 0.77 4 0.010 0.19 0.00060 0.8708 C 0.014
0.038 2.71 0.015 1.07 3 0.010 0.26 0.00042 0.7894
[0054] It should be noted that some of the individual parameters of
Insert A shown in Table 3 are not significantly different from the
parameters for Inserts B and C. For example, the diameter do of the
outlet orifice for Insert A is very close to the diameters do for
Inserts B and C, and the diameter of the swirl chamber Ds of Insert
A falls between the diameters Ds for Inserts B and C. Some of the
ratios of parameters for Insert A, however, such as Ds/do, lo/do,
and Ls/Ds are significantly different than the ratios for Inserts B
and C. As discussed above, it is believed that configuring an
insert with these ratios leads to a surprisingly consistent flow
rate and surprisingly consistent particle size as the compressed
gas product is dispensed, and tests demonstrated such consistency
in the dispensed product are discussed below.
Sixty Second Spray Comparisons
[0055] The flow rates dispensed from compressed gas systems using
inserts A, B, and C were compared. In each case, three fully
charged systems having the inserts were provided, and each of the
systems was discharged for sixty seconds. The flow rate was
determined using a stopwatch and a scale made by Mettler-Toledo of
Columbus, Ohio. All of the tests were conducted at ambient
temperature (about 70.degree. F.). The results of the flow rate
tests are shown in Table 4.
TABLE-US-00004 TABLE 4 Sample Flow Rate (g/sec.) Number Insert A
Insert B Insert C 1 1.85 1.48 1.18 2 1.85 1.45 1.35 3 1.84 1.43
1.39 Average 1.85 .+-. 0.005 1.45 .+-. 0.02 1.30 .+-. 0.011
[0056] The results shown in Table 4 indicate that Insert A had a
higher flow rate than did Inserts B and C.
[0057] The average particle size dispensed from Inserts A, B, and C
was determined in a sixty second dispensing test. In this test, the
samples from three fully charged systems with Insert A were
dispensed and the particle size was determined using a particle
analyzer made by Malvern Instruments of Malvern, Worcestershire,
UK. A mass median diameter (MMD) of particles in the samples was
thereby obtained, with the MMD representing a particle diameter
that is larger than 50% of the sampled volume. All of the tests
were conducted at ambient temperature (about 70.degree. F.). The
result of the test is shown in Table 5.
TABLE-US-00005 TABLE 5 Sample Particle Size (.mu.m) Number Insert A
Insert B Insert C 1 63.01 74.18 66.01 2 67.08 75.52 68.95 3 65.59
76.01 68.82 Average 65.23 .+-. 2.05 75.23 .+-. 0.9 67.86 .+-.
1.6
[0058] As can be seen from the results shown in Table 5, Insert A
provided during the sixty second dispensing test an average
particle size of about 65 .mu.m, while Inserts B and C provided
average particle sizes of about 75 .mu.m and 68 .mu.m,
respectively.
[0059] As discussed above, in the case of air fresheners a goal is
to dispense a product with a flow rate and a particle size such
that a sufficient amount of fragrance experience is achieved soon
after the dispensing, while at the same time dispensing the product
in a manner that provides for longevity of the fragrance
experience. In embodiments of the present invention, the
combination of flow rate and particle size that were found in the
sixty second dispensing tests using Insert A are conducive to both
a favorable initial fragrance experience and a sustained fragrance
experience.
Ten Second Spray Comparisons
[0060] The flow rates and particle sizes in ten second sprays from
systems that included the Inserts A, B, and C were compared. In
each case, three systems having the inserts were provided, and the
systems were discharged for ten seconds. The flow rates and average
particle sizes (MMD) were determined according to the methods
described above. The tests were then repeated when the containers
had 66%, 33%, and 13% of the initial amount of product (by mass)
remaining in the containers. All of the tests were conducted at
ambient temperature (about 70.degree. F.).
[0061] The results of the tests are shown in Tables 6-9 below.
Table 6 show the results of the 10 second spray from 100% full
containers. Tables 7, 8, and 9 show the results from 66%, 33%, and
13% full (by mass) containers, respectively.
TABLE-US-00006 TABLE 6 100% Full Containers Insert A Insert B
Insert C Spray Particle Spray Particle Spray Particle Sample Rate
Size Rate Size Rate Size Number (g/s) (.mu.m) (g/s) (.mu.m) (g/s)
(.mu.m) 1 2.03 67.32 1.73 70.14 1.58 61.69 2 2.04 65.69 1.68 70.22
1.65 60.43 3 2.04 61.61 1.74 70.61 1.51 59.36 Average 2.036 .+-.
0.01 64.96 .+-. 3.0 1.72 .+-. 0.03 70.32 .+-. 0.25 1.58 .+-. 0.07
60.49 .+-. 1.16
TABLE-US-00007 TABLE 7 66% Full Containers Insert A Insert B Insert
C Spray Particle Spray Particle Spray Particle Sample Rate Size
Rate Size Rate Size Number (g/s) (.mu.m) (g/s) (.mu.m) (g/s)
(.mu.m) 1 1.69 70.68 1.37 77.84 1.22 70.64 2 1.68 69.25 1.34 79.04
1.32 67.11 3 1.66 75.85 1.35 82.18 1.16 73.56 Average 1.67 .+-.
0.01 71.93 .+-. 3.47 1.35 .+-. 0.01 79.68 .+-. 2.24 1.23 .+-. 0.08
70.44 .+-. 3.23
TABLE-US-00008 TABLE 8 33% Full Containers Insert A Insert B Insert
C Spray Particle Spray Particle Spray Particle Sample Rate Size
Rate Size Rate Size Number (g/s) (.mu.m) (g/s) (.mu.m) (g/s)
(.mu.m) 1 1.42 75.23 1.17 93.31 1.00 81.89 2 1.44 78.38 1.13 95.57
1.11 79.71 3 1.42 75.67 1.15 98.91 0.94 82.45 Average 1.43 .+-.
0.01 76.43 .+-. 1.70 1.15 .+-. 0.02 95.93 .+-. 2.82 1.02 .+-. 0.08
81.35 .+-. 1.45
TABLE-US-00009 TABLE 9 13% Full Containers Insert A Insert B Insert
C Spray Particle Spray Particle Spray Particle Sample Rate Size
Rate Size Rate Size Number (g/s) (.mu.m) (g/s) (.mu.m) (g/s)
(.mu.m) 1 1.33 87.47 1.05 109.4 0.89 91.12 2 1.35 80.13 1.06 117.5
0.96 89.46 3 1.31 87.47 1.01 107.2 0.82 90.42 Average 1.33 .+-.
0.02 85.02 .+-. 4.24 1.04 .+-. 0.03 111.3 .+-. 5.25 0.89 .+-. 0.07
90.33 .+-. 0.83
[0062] As is evident from Tables 6-9, the flow rate of product
dispensed using Insert A remained much more constant than the flow
rates of the products dispensed using Inserts B and C. The flow
rate of Insert A, which was about 2.0 g/s for the initial 10 second
dispensing, dropped by 18% to about 1.7 g/s when the amount of
product remaining was 66% the original amount of product. When 33%
of the original amount of product remained, the flow rate had
dropped 30% to about 1.4 g/s, and decreased by about 35% to about
1.3 g/s when 13% of the original amount of product remained in the
container. In other words, the flow rate when the container was 13%
full of product was still about 65% that of the flow rate when the
container was full. On the other hand, the flow rates using Inserts
B and C had decreased by about 40% and about 44%, respectively,
when 13% of the initial amount of product remained in the
containers of the systems. Moreover, at every measured step, i.e.,
66%, 33%, and 13% product remaining, the flow rate using Insert A
decreased by a lower percentage than the flow rates decreased using
Inserts B and C. Thus, Insert A provided a significantly more
consistent flow rate as the product was discharged from the
system.
[0063] As is also evident from Tables 6-9, the particle size
dispensed with Insert A remained much more constant than the
particle size dispensed with Inserts B and C. The particle size
using Insert A, which was about 65 .mu.m for the initial 10 second
dispensing, increased by 11% to about 72 .mu.m when the amount of
product remaining was 66% the original amount. When 33% of the
original amount of product remained, the particle size had
increased by about 18% to about 76 .mu.m, and increased by about
31% to about 85 .mu.m when 13% of the original amount of product
remained in the container. On the other hand, the particle size
using Inserts B and C had increased by about 58% and about 49%,
respectively, when 13% of the initial amount of product remained in
the containers of the systems. Moreover, at every measured step,
i.e., 66%, 33%, and 13% product remaining, the particle size using
Insert A increased by a lower percentage than the particle sizes
increased using Inserts B and C. Thus, Insert A provided a
significantly more consistent particle size as the product was
discharged from the system.
[0064] As discussed above, important aspects of a system of
providing an aerosol product are consistent flow rate of product
and consistent particle size. While the flow rate dispensed using
Insert A decreased and the particle size increased, the relative
amount of change in these aspects of product performance was
significantly less than what occurred in the commercially-available
systems that included Inserts B and C. Based on a comparison of the
parameters of the Inserts A, B, and C shown in Table 3, it is
apparent that the above-identified ratios involving the diameter of
the swirl chamber Ds, the diameter of the outlet orifice do, the
length of the outlet orifice lo, and the depth of the swirl chamber
Ls, are responsible for the surprisingly stable flow rates and
stable particle sizes found when using Insert A. Indeed, these
results are all the more surprising when considering that, as noted
above, some of these parameters for Insert A were, in and of
themselves, nearly the same as the parameters found in Inserts B
and C.
[0065] As discussed above, factors such as temperature, pressure in
the container, and properties of the product formulation, such as
density and surface tension, might influence the performance of a
compressed gas product, including the flow rate and particle size
of the dispensed product. The above results clearly demonstrate,
however, that at ambient temperature and over the pressure ranges
tested, i.e., from about 150 psig to about 45 psig, a relatively
consistent flow rate and relatively consistent average particle
size can be obtained by configuring the dispensing insert with the
combination of parameters described above. Moreover, as one of
ordinary skill in the art will readily appreciate, while the
actually measured flow rate and particle size that are dispensed
with a given insert might be changed by a change in the
temperature, pressure, product formulation, etc., the
above-described combinations of parameters of the insert that are
used to achieve the relatively constant flow rate and relatively
constant particle size will remain the same.
[0066] Although this invention has been described in certain
specific exemplary embodiments, many additional modifications and
variations would be apparent to those skilled in the art in light
of this disclosure. It is, therefore, to be understood that this
invention may be practiced otherwise than as specifically
described. Thus, the exemplary embodiments of the invention should
be considered in all respects to be illustrative and not
restrictive, and the scope of the invention to be determined by any
claims supportable by this application and the equivalents thereof,
rather than by the foregoing description.
INDUSTRIAL APPLICABILITY
[0067] The inventive apparatuses, systems, and methods described
herein can be used to dispense a wide variety of commercial
products, such as air fresheners, soaps, insecticides, paints,
deodorants, disinfectants. As such, inventive apparatuses, systems,
and methods described herein are applicable in a wide variety of
industries.
* * * * *