Spray Head For An Aerosol Dispenser

Abstract

This invention relates to a spray head for an aerosol container and is characterized by an expansion chamber, an exit orifice in fluid flow communication with the expansion chamber, and a breakup bar mounted in the expansion chamber, combined in such a manner as to produce a desirable spray effect.

Description

This invention relates to aerosol dispensers and more particularly to a new spray head for such dispensers. Spray heads or tips constructed in accordance with the concept of this invention are particularly adapted, among other possible uses, for use with those products which have a relatively high propellant discharge rate and wherein the propellant is discharged with a product in significant quantities.

While many different types of spray heads have been used with reasonable success heretofore, our contribution to the art is a new spray head which is an improvement over such prior art devices, as will become apparent as the description proceeds. Related patents in this art include U.S. Pat No. 3,008,654 issued Nov. 14, 1961; U.S. Pat. No. 3,083,917 issued Apr. 2, 1963; and U.S. Pat. No. 3,083,918 issued Apr. 2, 1963, which show mechanical breakup spray tips or heads. U.S. Pat. No. 3,112,074 issued Nov. 26, 1963 and U.S. Pat. No. 3,129,893 issued Apr. 21, 1964 show swirl chambers by the use of an insert.

In the dispensing of certain products under pressure it is desirable to employ a spray head which produces a finely dispersed spray pattern throughout which the particles of viscous materials are uniformly distributed in discrete and separated form; and which avoids dispensing such material in large droplets with excessive drip from the spray head or squirting the material in the form of a stream. It is also desirable to provide a spray head that does not readily become clogged by the material being dispensed. Thus, the purpose of this invention is the provision of a device affording the above desired structural and operative features while eliminating the aforementioned difficulties and disadvantages.

In order to accomplish the desired results we provide a new and improved spray head for an aerosol dispenser characterized by means for receiving one end of a discharge conduit, an expansion chamber in fluid flow communication with the discharge conduit, and an exit orifice in fluid flow communication with the expansion chamber. A breakup bar is mounted in the expansion chamber by means of radially extending ribs.

In one form of our invention we provide a one-piece tubular spray head for dispensing material, which includes product and propellant, from an aerosol container having a recess for receiving the end of a discharge conduit. An expansion chamber is provided having fluid flow communication with the recess and a cylindrically shaped exit orifice is disposed in fluid flow communication with the expansion chamber. According to one aspect of our invention, an outer portion of the exit orifice has a greater passage area than an inner portion thereof and the outside diameter of the expansion chamber is substantially greater than the diameter of the exit orifice. According to another aspect, the expansion chamber has a tapered or sloping front face.

A breakup bar is mounted in the expansion chamber by means of two oppositely disposed radially extending ribs which are positioned between the front face of the expansion chamber and the bar. Preferably, the ribs are slightly offset and parallel one with respect to the other. Additionally, a longitudinally extending post may be mounted on the outside end of the breakup bar adjacent the exit orifice and the post may be provided with a conically shaped front face with an outwardly disposed apex. In one form, the post extends partially into the exit orifice; and we may provide a pair of radially extending fins mounted on the outside of the breakup bar.

It will be appreciated that by changing the shape of the exit orifice, variations in spray patterns may be obtained.

In another form of the invention, the spray head is integrally formed with a container overcap.

As we have mentioned, the spray head is of one-piece construction. This is important because it simplifies the fabrication problems, improves the precision of the valve and substantially reduces the cost thereof.

There has thus been outlined rather broadly the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional features of the invention that will be described hereinafter which will form the subject of the claims appended hereto. Those skilled in the art will appreciate that the conception on which this disclosure is based may readily be utilized as the basis for the design of other structures for carrying out the several purposes of the invention. It is important, therefore, that this disclosure be regarded as including such equivalent constructions as do not depart from the spirit and scope of the invention.

Several embodiments of the invention have been chosen for purposes of illustration and description, and are shown in the accompanying drawings, forming a part of the specification, wherein:

FIG. 1 is a perspective view of an aerosol container having mounted thereon a spray head constructed in accordance with the concept of this invention;

FIG. 2 is an enlarged, medial, vertical, sectional view of the spray head of FIG. 1;

FIG. 3 is an enlarged, medial, vertical, sectional view, similar to FIG. 2, but taken at an angle of 90.degree. with respect to the view of FIG. 2;

FIG. 4 is an enlarged, perspective view of the spray head of FIGS. 1--3;

FIG. 5 is an enlarged end view showing the inside end of the spray head of FIGS. 1--4;

FIG. 6 is an enlarged end view showing the outside end of the spray head of FIGS. 1--5;

FIG. 7 is an enlarged, medial, vertical, sectional view of another spray head constructed according to the concept of this invention;

FIG. 8 is an enlarged, medial, vertical, sectional view similar to FIG. 7, but taken at an angle of 90.degree. with respect to the view of FIG. 7;

FIG. 9 is an enlarged, fragmentary, perspective view of the spray head of FIGS. 7 and 8;

FIG. 10 is an enlarged, fragmentary, perspective view of still another spray head constructed according to the concept of this invention;

FIG. 11 is an enlarged end view of still another spray head constructed in accordance with this invention;

FIG. 12 is an enlarged, fragmentary, perspective view of the spray head of FIG. 11;

FIG. 13 is a medial, vertical, sectional, perspective view of another spray head constructed according to the concept of this invention;

FIG. 14 is an enlarged, medial, vertical, sectional, perspective view similar to FIG. 13, but taken at an angle of 90.degree. with respect to the view of FIG. 13;

FIG. 15 shows a fluid passage window on one side of the breakup bar superimposed on a window on the other side of the breakup bar in the embodiment of FIGS. 13 and 14;

FIG. 16 is a medial, vertical, sectional, perspective view of still another spray head constructed in accordance with the concept of this invention;

FIG. 17 is an enlarged, medial, vertical, perspective, sectional view similar to FIG. 16, but taken at an angle of 90.degree. with respect to the view of FIG. 16;

FIG. 18 shows a fluid passage window on one side of the breakup bar superimposed on a window on the other side of the breakup bar in the embodiment of FIGS. 16 and 17;

FIG. 19 is a medial, vertical, sectional, perspective view of still another spray head constructed in accordance with the concept of this invention;

FIG. 20 is an enlarged, medial, vertical, perspective, sectional view similar to FIG. 19 but taken at an angle of 90.degree. with respect to the view of FIG. 19;

FIG. 21 shows a fluid passage window on one side of the breakup bar superimposed on a window on the other side of the breakup bar in the embodiment of FIGS. 19 and 20;

FIG. 22 is a medial, vertical, sectional, perspective view of another spray head constructed in accordance with the invention;

FIG. 23 is an enlarged, medial, vertical, perspective, sectional view similar to FIG. 22, but taken at an angle of 90.degree. with respect to the view of FIG. 22;

FIG. 24 shows a fluid passage window on one side of the breakup bar superimposed on a window on the other side of the breakup bar in the embodiment of FIGS. 22 and 23;

FIG. 25 is an enlarged, medial, vertical, sectional view of still another spray head;

FIG. 26 is an enlarged, medial, vertical, sectional view similar to FIG. 25, but taken at an angle of 90.degree. with respect to the view of FIG. 25;

FIG. 27 is an end view of the spray head of FIGS. 25 and 26;

FIG. 28 is an enlarged end view similar to FIG. 27, but of the opposite end of the spray head;

FIG. 29 is an enlarged, fragmentary, perspective view of the spray head of FIGS. 25--28;

FIG. 30 is a medial, vertical, sectional view of an actuator overcap incorporating an integral spray head constructed according to the invention;

FIG. 31 is a top plan view of the overcap of FIG. 30;

FIG. 32 is an enlarged, detailed, vertical, sectional view showing the spray head portion of the overcap of FIGS. 30 and 31;

FIG. 33 is an enlarged, vertical, sectional view similar to FIG. 32, but taken at an angle of 90.degree. with respect to the view of FIG. 32; and

FIG. 34 is an enlarged, detailed, vertical, sectional view showing a conically shaped spray head portion of the overcap of FIGS. 30 and 31;

In the embodiment of the invention illustrated in FIGS. 1--6, and with particular reference to FIG. 1, there is shown an aerosol container 10 having an overcap 12 and a tubular shaped one-piece insert or spray head, indicated generally at 14, mounted thereon. Normally, the container is charged with a product and a pressurized propellant for effecting discharge of the product from the container through a dispensing assembly operated by a manual pushdown button which actuates a manual shutoff valve in the container for venting the container contents for so long as the button is held in its depressed position against a resilient force. Upon release of the button, the resilient force serves to close the shutoff valve and prevent further discharge of the product from the container. The product being dispensed from the container combines in the spray head with the propellant to form a mixture or solution, hereinafter referred to as material, which must be formed into a satisfactory spray pattern by high turbulence and agitation. The spray head may be formed as an integral unit with the container or it may be connected thereto in any suitable manner so that the fluid material, whether it is a mixture or a solution, can readily pass from the container through the spray head during operation. Referring to FIGS. 2--4, the spray head 14 has a recess 16 for receiving the upper end of the container in fluid-receiving attitude. An expansion chamber 18, FIGS. 2 and 3, is in fluid flow communication with the recess 16, and is in longitudinal alignment with respect thereto; and a cylindrically shaped exit orifice 20 is in fluid flow communication with the expansion chamber 18, and is in longitudinal alignment with respect thereto. FIG. 6 is an end view of the exit orifice. As seen in FIG. 3, the diameter of the expansion chamber 18 is substantially greater than the diameter of the exit orifice. THe expansion chamber 18 has a front face 22, and a portion thereof 24 is tapered radially inwardly and backwardly.

For purposes of agitating and mechanically breaking up the fluid, a breakup bar 26 is centrally mounted in the expansion chamber 18 by means of two oppositely disposed radially extending ribs 28. These ribs, as seen in FIG. 2, extend from the front face 22 of the expansion chamber 18 of the inside edge 30 of the recess 16. The outside diameter of the breakup bar 26, FIG. 3, is less than the diameter of the exit orifice. The rear face 31 and the front face 33 of the breakup bar 26 are substantially flat; and a longitudinally extending post 32 is mounted on the front end of the breakup bar 26 adjacent the exit orifice 20. This post is of substantially smaller diameter than the diameter of the exit orifice, and it has a conically shaped front face 34 with an outwardly disposed apex.

A pair of radially extending fins 36, FIG. 5, is mounted on the outside of the breakup bar 26; and they extend around the circumference of the breakup bar between the ribs respectively. As seen in FIGS. 3 and 4, these fins have substantially flat front faces 38, which are located in front of the front face 33 of the breakup bar 26 and in back of the front face of the post 32. The back faces 40 of the fins 36 are backwardly, inwardly tapered.

In operation, the product plus the propellant pass into the spray head 14, where it is mixed, agitated and mechanically dispensed. That is, it is deflected by the back face 31 into the expansion chamber 18 wherein it engages the breakup bar 26, and then it is deflected by the fins 36 and the ribs 28. Thereafter, it is guided between the front face 22 of the expansion chamber 18 and the post 32 to the exit orifice 20, from which it exits as a spray having those desirable characteristics already alluded to.

Referring now to the embodiment of FIGS. 7--9, the spray head 14 serves a function similar to that of the spray head discussed more fully hereinbefore in connection with the embodiment of FIGS. 1--6. This spray head has a recess 42 for receiving the upper end of the container in fluid-receiving attitude. An expansion chamber 44, FIGS. 8 and 9, is in fluid flow communication with the recess 42, and is in longitudinal alignment with respect thereto; and a cylindrically shaped exit orifice 46 is in fluid flow communication with the expansion chamber, and is in longitudinal alignment with respect thereto. As seen in FIGS. 8 and 9, the diameter of the expansion chamber 44 is substantially greater than the diameter of the exit orifice, and the expansion chamber 44 has a front face 48 which is substantially flat.

A breakup bar 50, which serves to agitate and mechanically break up the fluid, is centrally mounted in the expansion chamber 44 by means of two oppositely disposed radially extending ribs 52, FIGS. 7 and 8. These ribs extend from the front face 48 of the expansion chamber 44 to the inside edge 54 of the recess 42. Again, the outside diameter of the breakup bar 50 is less than the diameter of the exit orifice 46. The back face 56 of the breakup bar 50 is substantially flat, and the front face thereof is provided with a conical indentation 58, FIG. 9. The ribs 52 coact with the breakup bar 50 to form a rectangular fluid passage window 59, FIG. 7, on each side of the breakup bar, so that in operation the fluid flows radially inwardly therethrough as it passes towards the discharge orifice.

A pair of radially extending fins 60, FIG. 9, is mounted on the outside of the breakup bar 50, and extends around the circumference of the breakup bar between the ribs, respectively. These fins have substantially flat front faces 62, and they have back faces 64 which are backwardly, inwardly tapered.

In operation, the product plus the propellant pass into the spray head 14, where it is subjected to agitation and mechanical breakup. It is deflected by the back face 56 into the expansion chamber 44, wherein it engages the breakup bar 50, and then it is deflected by the fins 60 and the ribs 52. Thereafter, it is guided between the front face 48 of the expansion chamber 44 and the front face 58 of the breakup bar, as well as the front face 62 of the fins 60, to the exit orifice 46, from which it is discharged in the form of a fine spray or mist.

Referring next to the embodiment of FIG. 10, the spray head 14 is here illustrated as having a recess 66 for receiving the upper end of the container in fluid-receiving attitude. As in the embodiments already described, an expansion chamber 68 is in fluid flow communication with the recess 66, and is in longitudinal alignment with respect thereto; and a cylindrically shaped exit orifice 70 is in fluid flow communication with the expansion chamber 68, and is in longitudinal alignment with respect thereto. The diameter of the expansion chamber 68 is substantially greater than the diameter of the exit orifice, and as in the embodiment of FIGS. 7 to 9, expansion chamber 68 has a front face 72 which is substantially flat.

For purposes of agitating and mechanically breaking up the fluid, a breakup bar 74 is centrally mounted in the expansion chamber 68 by means of two oppositely disposed radially extending ribs 76 (only one being shown). These ribs extend from the front face 72 of the expansion chamber 68 to the inside edge 78 of the recess 66. The diameter of the breakup bar 74 is less than the diameter or the exit orifice, and the back face 80 of the breakup bar 74 substantially flat. A longitudinally extending post 82 is mounted on the outside end of the breakup bar 74 adjacent the exit orifice 70. This post is formed with a conically shaped front face 84 with an outwardly disposed apex, and has a substantially smaller diameter than the diameter of the exit orifice. In this embodiment, it will be noted that the post extends a substantial distance into the orifice.

A pair of radially extending fins 86 is mounted on the outside of the breakup bar 74, and extend around the circumference of the breakup bar between the ribs, respectively. These fins have inwardly, backwardly, tapered front faces 88 which are located in back of the front face of the post 82, and they are formed with backwardly, inwardly, tapered back faces 90.

In operation, the material to be discharged passes into the spray head 14 where it is subjected to agitation and mechanical breakup after which it is deflected by the back face 80 into the expansion chamber 68 wherein it engages the breakup bar 74. The fluid is again deflected by the fins 86 and ribs 76, and then it is guided between the front face 72 of the expansion chamber 68 and the post 82 to the exit orifice 70, from which it exits in 55 form of a fine spray. It will be appreciated that the long post 82 serves to cause a pressure drop accompanied by an increase in velocity of the material at the exit.

Referring next to the embodiment of FIGS. 11 and 12, the spray head 14 is formed with a recess 92 for receiving the upper end of the container in fluid receiving attitude. An expansion chamber 94 is in fluid flow communication with the recess 92 and is in longitudinal alignment with respect thereto. A cylindrically shaped exit orifice 96 is in fluid flow communication with the expansion chamber 94 and is also in longitudinal alignment with respect thereto. The diameter of the expansion chamber 94 is substantially greater than the diameter of the exit orifice, and the expansion chamber 94 is formed with a front face 98 which is substantially flat.

A breakup bar 100, which serves to agitate and mechanically break up the fluid to be discharged, is centrally mounted in the expansion chamber 94 by means of two radially extending ribs 102 which are disposed in offset relationship one with respect to the other, thereby forming channels 103 for the fluid, as best seen in FIG. 11. These ribs extend from the front face 98 of the expansion chamber 94 to the back face 104, FIG. 12, of the breakup bar 100; and the diameter of the breakup bar 100 is the same or less than the diameter of the exit orifice. The back face 104 of the breakup bar 100 is backwardly, inwardly tapered, and the front face thereof has a conical indentation.

In operation, upon opening the valve, the material to be discharged passes into the spray head 14 where it is subjected to agitation and mechanical breakup. It is deflected by the back face 104 into the expansion chamber 94 wherein it engages the breakup bar 100. The fluid is deflected by the offset ribs 102, and then it is guided between the front face 98 of the expansion chamber and the front face of the breakup bar to the exit orifice 96, from which it is discharged as a fine spray. The offset ribs cause the material to form a swirling pattern.

Further embodiments of our inventive concept are illustrated in FIGS. 13--24, wherein the spray head 14 is provided with a lead-in 108, FIGS. 13, 16, 19 and 22, for receiving the upper end of the container in fluid-receiving attitude. There is a recess in the lower portion of the head, and an expansion chamber 213, FIG. 13, is arranged for fluid flow communication with the recess 110, and is in longitudinal alignment with respect thereto, while a cylindrically shaped exit orifice 112 is in fluid flow communication with the expansion chamber 213, and is in longitudinal alignment with respect thereto. The diameter of the expansion chamber 213 is substantially greater than the diameter of the exit orifice.

In the present case, the breakup bar 114 is centrally mounted in the expansion chamber by means of a pair of oppositely disposed radially extending ribs 116, and the bar has two parallel flat sides and a flat back face 118. Both of the ribs 116 extend from the front face of the expansion chamber to the back face of the breakup bar, the sides thereof being parallel to the sides of the breakup bar 114 and the width thereof being equal to the width of the breakup bar. The front face of the expansion chamber is located in front of the front face of the breakup bar. In this case, we have constructed the exit orifice 112 with an inner portion 120 having two flat sides which are parallel to the two flat sides of the breakup bar 114. As illustrated in FIGS. 13--15, the front face of the expansion chamber is flat, as at 122, and the front face of the breakup bar is also flat, as at 124. This provides a rectangular fluid passage window 126 on each side of the breakup bar and ribs, as seen in FIG. 15, both windows being identical. These windows are formed between the front faces of the expansion chamber and the front face of the breakup bar so that in operation the fluid flows radially inwardly therethrough as it passes towards the discharge orifice.

The embodiment of the invention illustrated in FIGS. 16--18 is similar to the embodiment shown in FIGS. 13--15, except that the front faces of the expansion chamber 213 slope in a direction parallel to the radially extending ribs, the face on one side of the ribs being sloped in one direction, as at 128, and the face on the other side of the ribs being sloped in the opposite direction, as at 130. As in the embodiment of FIGS. 13--15, the front face of the breakup bar is flat, as at 124. This provides a fluid passage window 134 on one side of the breakup bar and ribs, and a superimposed fluid passage window 136 on the other side of the breakup bar and ribs, as seen in FIG. 18. These windows are formed between the front faces of the expansion chamber and the front face of the breakup bar so that in operation the fluid flows radially inwardly therethrough as it passes towards the discharge orifice.

FIGS. 19--21 illustrate a construction which is similar to that shown in FIGS. 16--18 except that the front face of the breakup bar has two triangularly shaped projections with sloping front faces, one surface 138 sloping in one direction and the other surface 140 sloping in the opposite direction. As in the embodiment of FIGS. 16--18, the front faces of the expansion chamber slope in a direction parallel to the radially extending ribs, the face on one side of the ribs being sloped in one direction, as at 128, and the face on the other side of the ribs being sloped in the opposite direction, as at 130. As best seen in FIG. 19, the surface 128 is parallel to the surface 138 and the surface 130 is parallel to the surface 140, thus providing an elongated fluid passage window 142 on one side of the breakup bar and ribs, and a superimposed similar but diametrically oppositely extending fluid passage window 144 on the other side of the breakup bar and ribs, as seen in FIG. 21. These windows are formed between the front faces of the expansion chamber and the front face of the breakup bar. In operation the fluid flows radially inwardly from the recess 110, against the rear face 118 of the breakup bar 114, around the latter and through the windows to the discharge orifice.

The embodiment of the invention illustrated in FIGS. 22--24 is similar to the embodiment shown in FIGS. 16--18, except that the front face of the breakup bar has two triangularly shaped projections with sloping front faces, one surface 146 sloping in one direction and the other surface 148 sloping in the opposite direction. As in the embodiment of FIGS. 16--18, the front faces of the expansion chamber slope in a direction parallel to the radially extending ribs, the face on one side of the ribs being sloped in one direction, as at 128, and the face on the other side of the ribs being sloped in the opposite direction as at 130. As distinguished from the embodiment of FIGS. 19--21, the surface 146 slopes in the opposite direction with respect to its adjacent front face 128 of the expansion chamber, and the surface 148 slopes in the opposite direction with respect to its adjacent front face 130 of the expansion chamber. This construction provides a triangularly shaped fluid passage window 150 on one side of the breakup bar and ribs, and a superimposed fluid passage window 152 on the other side of the breakup bar and ribs, the relationship of these windows being shown in FIG. 24. These windows are formed between the front face of the expansion chamber and the front face of the breakup bar so that in operation the fluid flows radially inwardly therethrough as it passes towards the discharge orifice.

In the embodiment of FIGS. 25--29, the spray head 14 serves the same function as the spray head discussed more fully hereinbefore in connection with the embodiment of FIGS. 1--6. This spray head is provided with a recess 154 which receives part of the actuator overcap or the upper end of the container 155 in fluid flow relationship with respect thereto, the product following the product path 157. The recess 154 merges into an expansion chamber 159, FIG. 26. A cylindrically shaped exit orifice 158 is in fluid flow communication with the expansion chamber 159. As best seen in FIGS. 26 and 29, the exit orifice has an outer portion 160 of greater diameter than the inner portion 162. FIG. 27 shows an end view of the exit orifice. As seen in FIGS. 26 and 29, the outside diameter of the expansion chamber 159 is substantially greater than the diameter of the exit orifice 158. The expansion chamber has a front face 164, and a portion 166 thereof is tapered radially outwardly and backwardly.

A breakup bar 168, which serves to agitate and mechanically break up the fluid, is centrally mounted in the expansion chamber 159 by means of two oppositely disposed radially extending ribs 170. These ribs, as seen in FIG. 28, extend from the front face of the expansion chamber 159 a short distance toward the back of the chamber. A longitudinally extending flat-sided window 172, FIG. 25, is formed in front of the breakup bar 168. The recess 154 is provided with four longitudinally extending spaced flattened sides 176, FIGS. 25, 26, 28 and 29, for keeping the central portion of the container 155 centered in the recess 154.

In operation, the material being dispensed passes into the recess 154, and then into the expansion chamber 159 where it is subjected to agitation and mechanical breakup. It is deflected by the faces 166 of the recess 159, and thence it passes through the fluid passage windows 172, FIG. 25. Thereafter, it is guided between the front face 164 of the expansion chamber and the front of the breakup bar 168 to the exit orifice 158, from which it is discharged in the form of a fine spray or mist.

In the embodiment of FIGS. 30--34, an actuator overcap, indicated generally at 182, incorporates a spray head, indicated generally at 14, as a single integral unit. As an example, FIG. 32 shows the spray head portion by broken lines, as at 184. The overcap has upstanding sidewalls 186, FIG. 30, which engage the edge of the container (not shown), as at 188. The spray head portion 14 has a recess 190, and a pushbutton 192 is provided for deflecting the spray head, and thereby causing flow of product and propellant from the container in a conventional manner. An expansion chamber 194 is in fluid flow communication with the recess 190, FIG. 30, and is in longitudinal alignment with respect thereto. The end portion of the expansion chamber towards the discharge outlet thereof is disposed at any desirable angle, such as an angle of about 20.degree., for example, with respect to the center line of the remainder of the expansion chamber and the container, although any suitable angular relationship may be employed. A cylindrically shaped exit orifice 196, FIG. 32, or a conically shaped exit orifice 196', FIG. 34, is in longitudinal alignment with respect to the expansion chamber 194. As best seen in FIG. 33, the exit orifice has an outer portion 198 of greater cross-sectional area than the inner portion 200, and the expansion chamber is formed with a front face 202, and a portion 204 thereof extends conically, radially outwardly and backwardly.

A breakup bar 206, FIG. 32, which serves to agitate and mechanically break up the fluid is centrally mounted in the expansion chamber 194 by means of two oppositely disposed radially extending ribs 208. These ribs extend from front face 202 of the expansion chamber backwardly a short distance in the chamber and the outside diameter of the breakup bar, FIG. 33, is substantially equal to the width of the inner portion 200 of the exit orifice.

As seen in FIG. 34, a fan spray concept is employed. That is, the exit orifice 196' has outwardly tapered walls. This concept can be employed on any of the embodiments described herein. One of the advantages of this construction is in the molding operation. Because of the natural draft, the pull or orifice pin does not have to be removed prior to splitting the mold and removing the head therefrom.

In operation, the product plus the propellant pass from the container into the expansion chamber 194 wherein it engages the breakup bar 206 and is subjected to agitation and mechanical breakup. It is deflected by the ribs 208, and then it is guided between the front face 202 of the expansion chamber and the breakup bar front face to the exit orifice, from which it is discharged in the form of a fine spray or mist.

It has been found that the present invention does indeed contribute an improved spray head which is relatively inexpensive to manufacture and which provides a superior spray pattern and more complete product particle breakup as compared to prior art devices known to us. Those skilled in the art will readily appreciate that each of the embodiments of our invention as herein described lends itself to a molding arrangement wherein the head, though of complex construction to the extent that a number of shapes, surfaces and angulated relationships are comprehended therein, can be completely formed as a one-piece element, thus assuring production uniformity as well as reliable operation and eliminating assembly problems. This is true with spray head inserts as well as when the spray head is constructed as part of the actuator overcap as seen in FIG. 30.

Although several embodiments of the invention as herein disclosed for purposes of explanation, various modifications thereof, after study of this specification, will be apparent to those skilled in the art to which the invention pertains.

Claims

What We claim and desire to secure by letters patent is:

1. A spray head for dispensing material from an aerosol container comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, an exit orifice in fluid flow communication with said expansion chamber, said expansion chamber having a front face and cylindrical sidewalls, a breakup bar having a front face and a back face, a pair of oppositely disposed radially extending ribs for mounting said breakup bar in said expansion chamber, both of said ribs extending from the front face of said expansion chamber back a substantial distance in said expansion chamber, the front face of said expansion chamber being located in front of the front face of said breakup bar, said front face of said expansion chamber and said front face of said breakup bar coacting to form a fluid passage window for agitating and mechanically breaking up said material.

2. A spray head for dispensing material from an aerosol container according to claim 1 wherein said expansion chamber and said breakup bar have flat front faces.

3. A spray head for dispensing material from an aerosol container according to claim 1 wherein said exit orifice has an outwardly diverging configuration.

4. A spray head for dispensing material from an aerosol container according to claim 1, wherein the front face of said expansion chamber slopes in a direction parallel to the radially extending ribs, the face on one side of said ribs being sloped in one direction and the face on the other side of said ribs being sloped in the opposite direction.

5. A spray head dispensing material from an aerosol container according to claim 1, wherein the front face of said breakup bar has two triangularly shaped projections with sloping front surfaces, one surface sloping in one direction and the other surface sloping in the opposite direction.

6. A spray head for dispensing material from an aerosol container comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, an exit orifice in fluid flow communication with said expansion chamber, said expansion chamber having a front face, a breakup bar, rib means for mounting said breakup bar in said expansion chamber, a longitudinally extending post mounted on the outer end of said breakup bar adjacent said exit orifice, a pair of radially extending fins mounted on the outside of said breakup bar.

7. A spray head for dispensing material from an aerosol container according to claim 6 wherein a portion of the front face of said expansion chamber is tapered radially inwardly and backwardly.

8. A spray head for dispensing material from an aerosol container according to claim 6 wherein said rib means comprises two oppositely disposed radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber to the back of said expansion chamber.

9. A spray head for dispensing material from an aerosol container according to claim 6 wherein the outside diameter of said breakup bar is less than the diameter of said exit orifice.

10. A spray head for dispensing material from an aerosol container according to claim 6 wherein the outside diameter of said post is substantially smaller than the diameter of said exit orifice.

11. A spray head for dispensing material from an aerosol container according to claim 6 wherein said fins extend substantially around the circumference of said breakup bar between said ribs respectively, said fins having a front face located in front of the front face of the breakup bar and in back of the front face of said post.

12. A spray head for dispensing material from an aerosol container according to claim 11 wherein the front faces of said fins are flat and the back faces of the fins are backwardly, inwardly tapered, and the outside diameter of the fins are substantially equal to the diameter of the exit orifice.

13. A tubular spray head for dispensing material from an aerosol container comprising means for receiving an end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, a cylindrically shaped exit orifice in fluid flow communication with said expansion chamber and in longitudinal alignment therewith, said expansion chamber having a front face, a breakup bar, two oppositely disposed radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber substantially to the back thereof, a longitudinally extending post mounted on the outside end of said breakup bar adjacent said exit orifice, a pair of radially extending fins mounted on the outside of said breakup bar and extending substantially around the circumference of said breakup bar between said ribs respectively, the front faces of said fins being located in front of the front face of said breakup bar and in back of the front face of said post.

14. A spray head for dispensing material from an aerosol container according to claim 13 wherein a portion of said front face of said expansion chamber is tapered radially inwardly and backwardly, and wherein the front face and back face of said breakup bar are substantially flat, and wherein said post has a conically shaped front face with an outwardly disposed apex, and wherein the front faces of said fins are flat and back faces of said fins are backwardly, inwardly tapered.

15. A spray head for dispensing material from an container according to claim 13 wherein the outside diameter of said expansion chamber is greater than the diameter of said exit orifice, and wherein the outside diameter of said breakup bar is less than the diameter of said exit orifice, and wherein the outside diameter of said post is smaller than the diameter of said exit orifice.

16. A one-piece tubular spray head for dispensing material from an aerosol container comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, a cylindrically shaped exit orifice in fluid flow communication with said expansion chamber and in longitudinal alignment therewith, the outside diameter of said expansion chamber being substantially greater than the diameter of said exit orifice, said expansion chamber having a front face, a portion of said front face being tapered radially inwardly and backwardly, a breakup bar, two oppositely disposed radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber to the back thereof, the front face and the back face of said breakup bar being substantially flat, a longitudinally extending post mounted on the outside end of said breakup bar adjacent said exit orifice, said post having a conically shaped front face with an outwardly disposed apex, a pair of radially extending fins mounted on the outside of said breakup bar and extending around the circumference of said breakup bar between said ribs respectively, said fins having substantially flat front faces, the front faces of said fins being located in front of the front face of said breakup bar and in back of the front face of said post, the back faces of said fins being backwardly, inwardly tapered, the outside diameter of said breakup bar being less than the diameter of said exit orifice, the outside diameter of said post being substantially smaller than the diameter of said orifice, and the outside diameter of said fins being substantially equal to the diameter of said exit orifice.

17. A one-piece tubular spray head for dispensing material from an aerosol container comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, a cylindrically shaped exit orifice in fluid flow communication with said expansion chamber and in longitudinal alignment therewith, the outside diameter of said expansion chamber being substantially greater than the diameter of said exit orifice, said expansion chamber having a substantially flat front face, a breakup bar, two oppositely disposed radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber to the back thereof, the back face of said breakup bar being substantially flat, a pair of radially extending fins mounted on the outside of said breakup bar and extending around the circumference of said breakup bar between said ribs respectively, said fins having substantially flat front faces, the back faces of said fins being backwardly, inwardly tapered.

18. A tubular spray head for dispensing material from an aerosol container, comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, a cylindrically shaped exit orifice in fluid flow communication with said expansion chamber and in longitudinal alignment therewith, said expansion chamber having a front face, a breakup bar, two oppositely disposed radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber to the back thereof, a longitudinally extending post mounted on the outside end of said breakup bar and extending partially into said exit orifice, a pair of radially extending fins mounted on the outside of said breakup bar and extending substantially around the circumference of said breakup bar between said ribs respectively, the front faces of said fins being located in front of the front face of said breakup bar and in back of the front face of said post.

19. A one-piece tubular spray head for dispensing material from an aerosol container comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, a cylindrically shaped exit orifice in fluid flow communication with said expansion chamber and in longitudinal alignment therewith, the outside diameter of said expansion chamber being substantially greater than the diameter of said exit orifice, said expansion chamber having a flat front face, a breakup bar, two oppositely disposed radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber to the back thereof, the back face of said breakup bar being substantially flat, a longitudinally extending post mounted on the outside end of said breakup bar and extending partially into said exit orifice, said post having a conically shaped front face with an outwardly disposed apex, a pair of radially extending fins mounted on the outside of said breakup bar and extending around the circumference of said breakup bar between said ribs respectively, the front faces of said fins being located in back of the front face of said post, the back faces of said fins being backwardly, inwardly tapered, and the outside diameter of said post being substantially smaller than the diameter of said exit orifice.

20. A spray head for dispensing material from an aerosol container comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, an exit orifice in fluid flow communication with said expansion chamber, said expansion chamber having a front face, a breakup bar and a pair of offset ribs for mounting said breakup bar in said expansion chamber.

21. A tubular spray head for dispensing material from an aerosol container comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, a cylindrically shaped exit orifice in fluid flow communication with said expansion chamber and in longitudinal alignment therewith, said expansion chamber having a front face, a breakup bar, two oppositely disposed offset, parallel, radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber a substantial distance into said expansion chamber.

22. A one-piece tubular spray head for dispensing material from an aerosol container comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, a cylindrically shaped exit orifice in fluid flow communication with said expansion chamber and in longitudinal alignment therewith, the outside diameter of said expansion chamber being substantially greater than the diameter of said exit orifice, said expansion chamber having a substantially flat front face, a breakup bar, two oppositely disposed offset, radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber a substantial distance into said expansion chamber, said ribs forming two oppositely disposed, offset, parallel channels, the front face of said breakup bar having a conical indentation, the back face of said breakup bar being substantially flat.

23. A spray head for dispensing material from an aerosol container comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, and exit orifice in fluid flow communication with said expansion chamber, the outside diameter of said expansion chamber being substantially greater than the diameter of said exit orifice, said expansion chamber having a front face and cylindrical sidewalls, a breakup bar having a front face and a back face, said breakup bar having two parallel flat sides, a pair of oppositely disposed radially extending ribs for mounting said breakup bar in said expansion chamber, both of said ribs extending from the front face of said expansion chamber substantially to the back face of the said breakup bar, the front face of said expansion chamber being located in front of the front face of said breakup bar, said exit orifice having an inner portion having two flat sides parallel to the two flat sides of said breakup bar.

24. A spray head for dispensing material from an aerosol container according to claim 23 wherein said expansion chamber and said breakup bar have flat front faces.

25. A spray head for dispensing material from an aerosol container according to claim 23 wherein the sides of said ribs are parallel to and have the same width as said breakup bar.

26. A spray head for dispensing material from an aerosol container according to claim 25, wherein the front face of said expansion chamber slopes in a direction parallel to the radially extending ribs, the face on one side of said ribs being sloped in one direction and the face on the other side of said ribs being sloped in the opposite direction.

27. A spray head for dispensing material from an aerosol container according to claim 26 wherein the front face of said breakup bar has two triangularly shaped projections with sloping front surfaces, one surface sloping in one direction and the other surface sloping in the opposite direction, said projections extending parallel to the flat sides of said breakup bar, each of said surfaces being parallel to its adjacent front face of said expansion chamber, each front face of said expansion chamber being located in front of the front surface of its adjacent triangular projection.

28. A spray head for dispensing material from an aerosol container according to claim 26, wherein the front face of said breakup bar has two triangularly shaped projections with sloping front surfaces, one surface sloping in one direction and the other surface sloping in the opposite direction, said projections extending parallel to the flat sides of said breakup bar, each of said surfaces sloping in the opposite direction with respect to its adjacent front face of said expansion chamber, each front face of said expansion chamber having a substantial portion thereof located in front of the front face of its adjacent triangular projection.

29. A spray head for dispensing material from an aerosol container comprising means for receiving the end of a discharge conduit, an expansion chamber in fluid flow communication with said discharge conduit, a cylindrically shaped exit orifice in fluid flow communication with said expansion chamber and in longitudinal alignment therewith, the outside diameter of said expansion chamber being substantially greater than the diameter of said exit orifice, said expansion chamber having a flat front face and cylindrical sidewalls, a breakup bar having a flat front face and a flat back face, said breakup bar having two parallel flat sides, a pair of oppositely disposed radially extending ribs for mounting said breakup bar centrally in said expansion chamber, both of said ribs extending from the front face of said expansion chamber to the back face of the said breakup bar and the sides thereof being parallel to the sides of said breakup bar and having the same width as said breakup bar, the front face of said expansion chamber being located in front of the front face of said breakup bar, said exit orifice having an inner portion having two flat sides parallel to the two flat sides of said breakup bar.

30. A spray head for dispensing material from an aerosol container according to claim 29, wherein the front face of said expansion chamber slopes in a direction parallel to the radially extending ribs, the face on one side of said ribs being sloped in one direction and the face on the other side of said ribs being sloped in the opposite direction.

31. A spray head for dispensing material from an aerosol container according to claim 30, wherein the front face of said breakup bar has two triangularly shaped projections with sloping front surfaces, one surface sloping in one direction and the other surface sloping in the opposite direction, said projections extending parallel to the flat sides of said breakup bar, each of said surfaces being parallel to its adjacent front face of said expansion chamber, each front face of said expansion chamber being located in front of the front surface of its adjacent triangular projection.

32. A spray head for dispensing material from an aerosol container according to claim 30, wherein the front face of said breakup bar has two triangularly shaped projections with sloping front surfaces, one surface sloping in one direction and the other surface sloping in the opposite direction, said projections extending parallel to the flat sides of said breakup bar, each of said surfaces sloping in the opposite direction with respect to its adjacent front face of said expansion chamber, each front face of said expansion chamber having a substantial portion thereof located in front of the front face of its adjacent triangular projection.

33. A spray head for dispensing material from an aerosol container comprising a recess for mounting on the upper portion of a container or overcap, an expansion chamber in fluid flow communication with said discharge conduit, an exit orifice in fluid flow communication with said expansion chamber, said expansion chamber having a front face, a breakup bar, rib means for mounting said breakup bar in said expansion chamber, said recess having four longitudinally extending spaced flattened sides for centering the spray head with respect to said container or overcap.

34. A spray head for dispensing material from an aerosol container according to claim 33 wherein a portion of the front face of said expansion chamber is tapered radially inwardly and forwardly.

35. A spray head for dispensing material from an aerosol container according to claim 33 wherein said rib means comprises two oppositely disposed radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber to a substantial distance back in said expansion chamber.

36. A spray head for dispensing material from an aerosol container according to claim 33 wherein said exit orifice has an outer portion of greater diameter than the inner portion thereof.

37. A spray head for dispensing material from an aerosol container according to claim 36, said breakup bar has flat sides and the width thereof is substantially equal to the width of the inner portion of said exit orifice.

38. A one-piece tubular spray head for dispensing material from an aerosol container comprising a recess for mounting on the upper portion of a container or overcap, an expansion chamber in fluid flow communication with said discharge conduit, a cylindrically shaped exit orifice in fluid flow communication with said expansion chamber and in longitudinal alignment therewith, said exit orifice having an outer portion of greater area than the inner portion thereof, said expansion chamber having a front face, a portion of said front face being tapered radially inwardly and forwardly, a breakup bar, two oppositely disposed radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber to a substantial distance back in said expansion chamber, the front face and the back face of said breakup bar being substantially flat, said recess having four longitudinally extending spaced flattened sides for centering the spray head with respect to said container or overcap, said breakup bar having flat sides and the width thereof being substantially equal to the inner portion of said exit orifice.

39. An actuator overcap for dispensing material from an aerosol container comprising sidewalls for engaging the top edge of said container, an integral spray head portion having means for receiving the upper end of said container in fluid-receiving attitude, a push button for deflecting the spray head to cause fluid to flow from said container, said spray head having an expansion chamber in fluid flow communication with said discharge conduit, an exit orifice in fluid flow communication with said expansion chamber, said expansion chamber having a front face, a breakup bar, rib means for mounting said breakup bar in said expansion chamber.

40. An actuator overcap according to claim 39 wherein a front portion of said spray head is disposed at an angle of about 20.degree. with respect to the remainder of the spray head.

41. An actuator overcap according to claim 39 wherein a portion of the front face of said expansion chamber is tapered radially inwardly and forwardly.

42. An actuator overcap according to claim 39 wherein said rib means comprises two oppositely disposed radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber back a substantial distance into said expansion chamber.

43. An actuator overcap according to claim 39 wherein said exit orifice has an outer portion having a larger area than an inner portion.

44. An actuator overcap according to claim 43 wherein the cross-sectional area of said breakup bar is substantially equal to the area of said inner portion of the exit orifice.

45. An actuator overcap according to claim 39 wherein the exit orifice has an outwardly diverging configuration.

46. An actuator overcap for dispensing material from an aerosol container comprising sidewalls for engaging the top edge of said container, an integral spray head having means for receiving the end of a discharge conduit, a pushbutton for deflecting the spray head to cause fluid to flow from said discharge conduit, said spray head having an expansion chamber in fluid flow communication with said discharge conduit, a cylindrically shaped exit orifice in fluid flow communication with said expansion chamber and in longitudinal alignment therewith, said exit orifice having an outer portion having a greater area than an inner portion, the cross-sectional area of said expansion chamber being substantially greater than the area of said exit orifice, said expansion chamber having a front face, a portion of said front face being tapered radially inwardly and forwardly, a breakup bar having a cross-sectional area substantially equal to the area of said inner portion, two oppositely disposed radially extending ribs for centrally mounting said breakup bar in said expansion chamber, said ribs extending from the front face of said expansion chamber back a substantial distance in said expansion chamber, the back face of said breakup bar being substantially flat, and a front portion of said spray head being disposed at an angle with respect to the remainder of the spray head.