AU2014239287B2

AU2014239287B2 - Aerosol valve with defined flow paths

Info

Publication number: AU2014239287B2
Application number: AU2014239287A
Authority: AU
Inventors: Geoffrey Brace; Michael Paul Downey; John B. Fore
Original assignee: Precision Valve Corp; Prec Valve Corp
Current assignee: Precision Valve Corp
Priority date: 2013-03-15
Filing date: 2014-03-14
Publication date: 2018-03-15
Anticipated expiration: 2034-03-14
Also published as: JP6309611B2; CN105263820B; WO2014152696A1; JP2016517374A; EP2969845B1; CN105263820A; EP2969845A1; EP2969845A4; ZA201506144B; AU2014239287A1; CA2905990A1; US20160009481A1; MX2015010781A; BR112015023731A2; ES2829501T3

Abstract

An aerosol valve having a valve stem, valve stem housing, compression spring, and a hard stop formed by the interaction of valve stem and valve stem housing is provided. The hard stop prevents the compression spring from becoming fully compressed, or coil-bound, when the valve stem is pressed to dispense a product formulation from the container, thereby creating open spaces between coils of the compression spring and providing a defined flow path for the product formulation. The aerosol valve increases mixing and turbulence of the product formulation that reduce agglomerations of solids that might otherwise block the flow paths. The additional defined flow path also directs more of the product to the valve stem aperture, further increasing dispensing of the product formulation from the container. A method of using the aerosol valve is provided.

Description

(87) WIPO No: WO14/152696 (30) Priority Data (31) Number (32) Date (33) Country

61/798,402 2013.03.15 US (43) Publication Date: 2014.09.25 (44) Accepted Journal Date: 2018.03.15 (71) Applicant(s)

Precision Valve Corporation (72) Inventor(s)

Fore, John B.;Downey, Michael Paul;Brace, Geoffrey (74) Agent / Attorney

Fisher Adams Kelly Callinans, Level 6 175 Eagle Street, BRISBANE, QLD, 4000, AU (56) Related Art

US 3219069 A US 3937368 A US 5906046 A (12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT) (19) World Intellectual Property Organization

International Bureau (43) International Publication Date 25 September 2014 (25.09.2014)

(10) International Publication Number

WIPOIPCT

WO 2014/152696 Al (51) International Patent Classification:

B65D 83/20 (2006.01) (21) International Application Number:

PCT/US2014/027630 (22) International Filing Date:

March 2014 (14.03.2014) (25) Filing Language: English (26) Publication Language: English (30) Priority Data:

61/798,402 15 March 2013 (15.03.2013) US (71) Applicant: PRECISION VALVE CORPORATION [US/US]; 800 Westchester Avenue, Ste C-700, Rye Brook, NY 10573 (US).

(72) Inventors: FORE, John, B.; 803 Marion St, Travelers Rest, SC 29690 (US). DOWNEY, Michael, Paul; 648 Nichole Place, Greer, SC 29651 (US). BRACE, Geoffrey; 520 Mountain View Drive, Columbus, NC 28722-4458 (US).

(74) Agent: RUGGIERO, Charles, N., J.; Chlandt, Greeley, Ruggiero & Perle, L.L.P., One Landmark Square, 10th Floor, Stamford, CT 06901-2682 (US).

(81) Designated States (unless otherwise indicated, for every kind of national protection available)·. AE, AG, AL, AM, AO, AT, AU, AZ, BA, BB, BG, BH, BN, BR, BW, BY, BZ, CA, CH, CL, CN, CO, CR, CU, CZ, DE, DK, DM, DO, DZ, EC, EE, EG, ES, FI, GB, GD, GE, GH, GM, GT, HN, HR, HU, ID, IL, IN, IR, IS, JP, KE, KG, KN, KP, KR,

KZ, LA, LC, LK, LR, LS, LT, LU, LY, MA, MD, ME,

MG, MK, MN, MW, MX, MY, MZ, NA, NG, NI, NO, NZ, OM, PA, PE, PG, PH, PL, PT, QA, RO, RS, RU, RW, SA, SC, SD, SE, SG, SK, SL, SM, ST, SV, SY, TH, TJ, TM, TN, TR, TT, TZ, UA, UG, US, UZ, VC, VN, ZA, ZM, ZW.

(84) Designated States (unless otherwise indicated, for every kind of regional protection available)·. ARIPO (BW, GH, GM, KE, LR, LS, MW, MZ, NA, RW, SD, SL, SZ, TZ, UG, ZM, ZW), Eurasian (AM, AZ, BY, KG, KZ, RU, TJ, TM), European (AL, AT, BE, BG, CH, CY, CZ, DE, DK, EE, ES, FI, FR, GB, GR, HR, HU, IE, IS, ΓΓ, LT, LU, LV, [Continued on next page] (54) Title: AEROSOL VALVE WITH DEFINED FLOW PATHS

WO 2014/152696 Al

FIG. 2 (57) Abstract: An aerosol valve having a valve stem, valve stem housing, compression spring, and a hard stop formed by the interaction of valve stem and valve stem housing is provided. The hard stop prevents the compression spring from becoming frilly compressed, or coil-bound, when the valve stem is pressed to dispense a product formulation from the container, thereby creating open spaces between coils of the compression spring and providing a defined flow path for the product formulation. The aerosol valve increases mixing and turbulence of the product formulation that reduce agglomerations of solids that might otherwise block the flow paths. The additional defined flow path also directs more of the product to the valve stem aperture, further increasing dispensing of the product formulation from the container. A method of using the aerosol valve is provided.

wo 2014/152696 Al lllllllllllllllllllllllllllllllllllll^

MC, MK, MT, NL, NO, PL, PT, RO, RS, SE, SI, SK, SM, TR), OAPI (BF, BJ, CF, CG, CI, CM, GA, GN, GQ, GW, KM, MF, MR, NE, SN, TD, TG).

Declarations under Rule 4.17:

— of inventorship (Rule 4.17 (iv))

Published:

— with international search report (Art. 21(3)) — before the expiration of the time limit for amending the claims and to be republished in the event of receipt of amendments (Rule 48.2(h))

WO 2014/152696

PCT/US2014/027630

AEROSOL VALVE WITH DEFINED FLOW PATHS

BACKGROUND OF THE DISCLOSURE

1. Field of the Disclosure [0001] The present disclosure relates to the field of aerosol valves for delivery of product formulations having solids. More particularly, the present disclosure relates to an aerosol valve having a valve stem, compression spring, and a hard stop that prevents full compression of the compression spring when the valve stem is pressed by the consumer to dispense the product formulations having solids, creating defined flow paths.

2. Description of Related Art [0002] Aerosol valve structures for product formulations that contain solids can fail because of agglomeration (clumping) of solids in the flow passages in the internal space of the valve stem housing. Conventional designs of aerosol valves often employ flow paths that have long, narrow channels, abrupt changes in flow direction, and areas of recirculation - any or all of which can cause solids in the product formulation to clump and clog the flow paths.

[0003] Also, conventional aerosol valves have a compression spring that is fully compressed (i.e., the individual spring coils are pressed tightly together) when the valve stem is fully pressed by a consumer to dispense or spray the product. However, the compressed spring coils form a barrier to the product formulation that is flowing upward, and so forces the product and propellant to follow a flow path that is nearly entirely along the outside of the fully-compressed spring coils, since there is little or no space between the spring coils to permit the product formulation and propellant to flow in between the spring coils or access the volume in the center of

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PCT/US2014/027630 the compression spring. A fully-compressed (i.e., coil-bound) compression spring in the conventional aerosol valve, therefore, provides little or no product mixing, or little surface to break up clumps of solids that may accumulate and clog flow paths.

[0004] Also, because the coil-bound compression spring coils form a barrier that keeps the majority of product flow on the outside, the aperture (vapor tap) only impinges a small portion of the product flow path and so does not take in the maximum potential amount of product or propellant.

SUMMARY OF THE DISCLOSURE [0005] The present disclosure provides an aerosol valve that provides an additional flow path for the product and propellant that improves mixing of the product formulation.

[0006] The present disclosure also provides such an aerosol valve that provides an additional flow path for the product and propellant that improves mixing of the product formulation, reduces agglomeration of solids in the product that might otherwise clog the flow paths in the aerosol valve, increases turbulence of the product formulation as it flows through the aerosol valve, and feeds more of the product directly to the aperture for better dispensing of the product.

[0007] The present disclosure further provides an aerosol valve having a valve stem, housing, compression spring, and a hard stop between the valve stem and housing. The hard stop prevents the compression spring from becoming fullycompressed (coil-bound) when the consumer presses on the valve stem to dispense a product, so that there are open spaces between adjacent coils of the compression spring.

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PCT/US2014/027630 [0008] The present disclosure still further provides that the resulting open spaces between the coils of the compression spring create an additional flow path for the product formulation and propellant that provides access to the product and propellant into the center space circumscribed by the compression spring.

[0009] The present disclosure also provides that the compression spring has these open spaces that can function as a baffle and a static mixer for the product formulation to improve the mixing of the solids in the product formulation as they flow through the aerosol valve.

[0010] The present disclosure further provides that the spaces between the coils of the compression spring also increase turbulence in the flow path, and can break up agglomerations of solids in the product formulation that might otherwise clog the flow path.

[0011] The present disclosure still further provides that the aerosol valve structure directs the ingress of the product to preferentially flow through the center of the spring diameter, and to exit as a cascade through the open coils over the upper end of the compression spring.

[0012] The present disclosure yet further provides that the aperture (vapor tap) is positioned adjacent to the open spring coils to maximize impingement of the product and propellant into the center of the fluid flow in the interior space formed by the compression spring.

[0013] The present disclosure also provides that the aerosol valve has a valve stem with large cross-section passageways that allow the product formulation to flow directly from the dip-tube through the center of the compression spring. This configuration allows the product flow to be gently deflected around the valve stem, which reduces back pressure (resistance).

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BRIEF DESCRIPTION OF THE DRAWINGS [0014] Figure 1 is a prior art aerosol valve in full stroke, illustrating the flow paths around the outside of the fully-compressed (coil-bound) compression spring.

[0015] Figure 2 is a side view of an exemplary embodiment of an aerosol valve of the present disclosure, with a cut-away showing some of the interior structures in the aerosol valve.

[0016] Figure 3 is a side view of the exterior of the valve stem portion of the aerosol valve in Figure 2.

[0017] Figure 4A is a side view of the valve stem housing portion of the aerosol valve in Figure 2. Figure 4B is a cut-away of a portion of Figure 4A to show some of the interior structures in the aerosol valve stem housing.

[0018] Figure 5 is a cross-section of an exemplary embodiment of an aerosol valve of the present disclosure in a closed position (resting mode), and seated in the top of an aerosol container.

[0019] Figure 6 is a cross-section of the aerosol valve in Figure 5 in an open (fully-actuated) position.

[0020] Figure 7 is an exploded view of a portion of the aerosol valve in Figure 6, illustrating the contacts between the valve stem and the compression spring, and the hard stop between the valve stem and the valve stem housing.

[0021] Figure 8 is an illustration showing how the gas and liquid mix in the aerosol valve.

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PCT/US2014/027630 [0022] Figures 9A, 9B, 9C, and 9D are cross-section perspective views of an exemplary embodiment of an aerosol valve of the present disclosure showing the primary and secondary flow paths at various positions of the aerosol valve stem. Figure 9A shows the aerosol valve in its closed position (resting mode). Figure 9B shows the aerosol valve when the valve is slightly cracked to an open position. Figure 9C shows the aerosol valve in a partially open position (mid-stroke). Figure 9D shows the aerosol valve in a fully-open position (full stroke).

[0023] Figures 10A, 10B, and 10C are further cross-section side views of an exemplary embodiment of an aerosol valve of the present disclosure, in a closed position (resting mode), a partially open position (mid-stroke), and a fully-open position (fully-actuated mode), respectively.

[0024] Figures 11 A, 11B, 11C, and 11D are cross-section perspective views of another exemplary embodiment of an aerosol valve of the present disclosure showing the primary and secondary flow paths at various positions of the aerosol valve stem. Figure 11A shows the aerosol valve in its closed position (resting mode). Figure 11B shows the aerosol valve when the valve is slightly cracked to an open position. Figure 11C shows the aerosol valve in a partially open position (midstroke). Figure 11D shows the aerosol valve in a fully-open position (full stroke).

[0025] Figures 12A, 12B, and 12C are cross-section side views of another exemplary embodiment of an aerosol valve of the present disclosure, in a closed position (resting mode), a partially open position (mid-stroke), and a fully-open position (fully-actuated mode), respectively.

[0026] Figures 13A, 13B, 13C, and 13D are cross-section perspective views of still another exemplary embodiment of an aerosol valve of the present disclosure showing the primary and secondary flow paths at various positions of the aerosol

WO 2014/152696

PCT/US2014/027630 valve stem. Figure 13A shows the aerosol valve in its closed position (resting mode). Figure 13B shows the aerosol valve when the valve is slightly cracked to an open position. Figure 13C shows the aerosol valve in a partially open position (midstroke). Figure 13D shows the aerosol valve in a fully-open position (full stroke).

[0027] Figure 14 is a cross-section view of yet another exemplary embodiment of an aerosol valve of the present disclosure in a closed position (resting mode).

[0028] Figures 15A and 15B are cross-section perspective views of yet another exemplary embodiment of an aerosol valve of the present disclosure showing the primary and secondary flow paths when the valve is open and closed. Figure 15A shows the aerosol valve in its closed position (resting mode). Figure 15B shows the aerosol valve when the valve is fully tilted (full stroke).

[0029] Figures 16A and 16B are cross-section perspective views of another exemplary embodiment of an aerosol valve of the present disclosure showing the primary and secondary flow paths when the valve is open and closed. Figure 16A shows the aerosol valve in its closed position (resting mode). Figure 16B shows the aerosol valve when the valve is fully tilted (full stroke).

[0030] Figure 17A is an illustration of CFD tests to show the flow streams of the product and propellant through and over the compression spring coils inside the valve stem housing of an embodiment of the aerosol valve of the present disclosure. Figure 17B is another view of the flow streams in Figure 17A, without the surrounding aerosol valve structures, so the flow streams are clearly shown.

[0031] Figure 18A is an illustration of CFD tests to show the flow streams of the product and propellant through the compression spring coils inside the valve stem housing of another embodiment of the aerosol valve of the present disclosure having the spring seat filled in. Figure 18B is another view of the flow streams in

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Figure 18A, without the surrounding aerosol valve structures, so the flow streams are clearly shown.

DETAILED DESCRIPTION OF THE DISCLOSURE [0032] Referring to the drawings and, in particular, Figure 1 that is a conventional or prior art aerosol valve generally represented by reference numeral 10. Valve 10, shown in Figure 1 in full stroke, shows the flow path of the product formulation around the outside of the compression spring before the formulation is able to enter the center hole (aperture) of the valve stem.

[0033] Aerosol valve 10 includes a dip tube 12, compression spring 14, valve stem 16, valve stem housing 18, mounting cup 20, and seal 22. Valve stem 16 is enclosed in valve stem housing 18. Valve stem 16 has a pair of apertures (not shown in Figure 1) through which a pressurized high-solids product formulation passes in order to enter center hole 24 of valve stem 16. Mounting cup 20 orients and stabilizes aerosol valve 10 in its proper position on the product. Valve stem 16 contacts compression spring 14 at contact point 26.

[0034] Compression spring 14 exerts an upward pressure on valve stem housing 18, which is pressed against seal 22 that is located on the inner aspect of mounting cup 20. Valve stem 16 has an upper portion that protrudes through seal 22 and mounting cup 20, and which is pressed by the consumer to spray the product formulation.

[0035] When valve stem 16 is pressed down by the consumer to spray the product, the product formulation flows upward through the internal space of valve stem housing 18 in a flow path 30.

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PCT/US2014/027630 [0036] As shown in Figure 1, compression spring 14 is fully compressed (i.e., fully-actuated), pushing together the individual coils of compression spring 14 so there is little or no space between any of the individual coils. In this configuration, the coils of compression spring 14 act as a barrier to the space that is inside the compression spring, requiring the product formulation to flow upwardly by a long path through valve stem housing 18 that is almost entirely along the outside of compression spring 14. This long, tortuous primary flow path 30 increases the probability that the solids in the product formulation will agglomerate and clog the flow path, causing the passage of the product formulation in the flow path to be slowed or blocked altogether, leading to product failure.

[0037] Figures 2 through 10 show several exemplary embodiments of an aerosol valve 40 of the present disclosure.

[0038] Figures 2 to 4 show a first embodiment of aerosol valve 40 that includes a dip tube 42, compression spring 44, valve stem 46, valve stem housing 48, mounting cup 50, and seal 52. Valve stem 46 is enclosed in valve stem housing 48. Valve stem 46 has a valve stem aperture 58 through which a pressurized high-solids product formulation passes in order to enter center hole 54 of valve stem 46.

[0039] Figures 5 and 6 show a mounting cup 50 that orients and stabilizes aerosol valve 40 in its proper position on the aerosol container. Compression spring 44 exerts an upward pressure on valve stem housing 48, which is pressed against seal 52 that is positioned on an inner aspect of mounting cup 50. Valve stem 46 has an upper portion that protrudes through seal 52 and mounting cup 50, and which is pressed by the consumer to dispense (spray) the product formulation.

[0040] Figure 7 shows that aerosol valve 40 has a hard stop 49 between valve stem 46 and valve stem housing 48. Valve stem 46 contacts compression spring 44 at contact point 56. Hard stop 49 prevents valve stem 46 from fully compressing

WO 2014/152696

PCT/US2014/027630 compression spring 44 so that, even when the consumer presses down fully on valve stem 46 to dispense (spray) the product formulation, the individual coils of compression spring 44 retain some space therebetween; i.e., even when valve stem 46 is fully-actuated, compression spring 44 does not become “coil-bound” (i.e., having little or no space between adjacent coils of the spring).

[0041] Aerosol valve 40 has fewer abrupt changes in flow direction, as compared with the flow paths of aerosol valves in the prior art. This reduces the propensity of the solids in the product formulation to agglomerate in the flow paths, by providing fewer loci at which the particles may accumulate, and thereby reduces product failures.

[0042] An embodiment of valve stem 46 has four (4) passageways (not shown) that are large in cross-section, to minimize drag and thereby reduce agglomeration of the solids in the product formulation as the product passes through, reducing the incidence of product failure.

[0043] The passageways readily allow the product formulation to flow directly from dip tube 42 through the center space inside compression spring 44, and to be gently deflected around valve stem 46. Valve stem 46 is preferably a thinned valve stem body. These structures and configuration reduce back pressure (resistance) to the flow of the product formulation before it reaches valve stem aperture(s) 58. This is an advantage over conventional valve flow paths, which require abrupt changes in flow direction and passage through long, narrow channels prior to arriving at the valve stem apertures.

[0044] As shown in Figures 5 and 6, compression spring 44, when not fully compressed, has open spaces 45 formed between adjacent coils of the compression spring. This permits the coils of compression spring 44 to function as a “baffle” and/or as a “static mixer” for the components of the product formulation.

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PCT/US2014/027630 [0045] Spaces 45 between the individual coils in compression spring 44 increase turbulence along the flow paths of the product and propellant. This turbulence can break up agglomerations of solids in the product formulation as it moves along the flow path, thereby reducing the likelihood that solids will agglomerate and clog any of the flow paths. In this way, the coils of compression spring 44 can “atomize” the solids in the product formulation; i.e., maintain the solids at their smallest individual particle size, on average, with few or zero “clumps” of solids.

[0046] Spaces 45 between the coils of compression spring 44 also improve the mixing of the product formulation as the solids flow through aerosol valve 40.

[0047] Spaces 45 between the coils of compression spring 44 (when open for spraying) also direct the ingress of the product formulation to preferentially flow through the center of compression spring 44 and exit as a cascade through the open coils and over the upper end of compression spring 44.

[0048] Spaces 45 between the coils of the compression spring 44 create an additional defined flow path for the product and propellant that improves mixing of the product formulation, reduces agglomeration of solids that might otherwise block the flow path, increases turbulence of the product formulation as it flows through the aerosol valve, and feeds more of the product directly to the aperture for better dispensing of the product.

[0049] Seal 52 is a flexible material that seals the space between mounting cup 50 and valve stem housing 48. Seal 52 is preferably made of rubber or similar flexible material. Seal 52 is preferably shaped as a gasket. A seal between seal 52, valve stem housing 48 and mounting cup 50 occurs by compression during crimping of cup 50. Pressing on valve stem 46 can somewhat deform the gasket-like seal

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PCT/US2014/027630 between seal 52 and valve stem housing 48 as well as between seal 52 and mounting cup 50.

[0050] Dip tube 42 is the access point for the stored product formulation in the container (not shown) to aerosol valve 40.

[0051] Aerosol valve 40 preferentially forms the largest possible flow path cross-sections that are viable, given the constraints of the valve stem housing, compression spring geometry, and valve stem molding capability (for strength and moldability).

[0052] Figure 8 shows how the liquid flow and gas mix together in the aerosol valves of the present disclosure (shown as aerosol valve 40, with valve stem housing 48 and center hole 54 labeled for reference).

[0053] Figures 9A, 9B, 9C, and 9D show the primary and secondary flow paths through aerosol valve 40 at various positions of valve stem 46. Figure 9A shows aerosol valve 40 in its closed position (resting mode) when there is no flow. Figure 9B shows aerosol valve 40 in a slightly cracked position, where valve stem 46 presses slightly on compression spring 44, creating a primary flow path 60 and a secondary flow path 62 between the individual coils in compression spring 44.

Figure 9C shows aerosol valve 40 in a partially open position (mid-stroke), illustrating primary flow path 60 and secondary flow path 62 as valve stem 46 presses somewhat more fully on compression spring 44. Figure 9D shows primary flow path 60 and secondary flow path 62 when aerosol valve 40 is in a fully-open position (full stroke). Valve stem 46 is fully actuated and reaches a hard stop (not shown) to partially, but not completely, compress compression spring 44. The hard stop can be, but does not have to be, part of the interior surface of valve stem housing 48 that interacts with (e.g., contacts) valve stem 46. Compression spring 44

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PCT/US2014/027630 does not become coil-bound, and some space is maintained between the individual coils of the compression spring to form a flow path for the product and propellant.

[0054] Figures 10A, 10B and 10C show cross-sections of an embodiment of aerosol valve 40 in its various stages as the valve stem is pressed by the consumer. Figure 10A shows aerosol valve 40 an unactuated, closed position (resting mode). Figure 10B shows aerosol valve 40 in a partially-open position (mid-stroke). Figure 10C shows aerosol valve 40 in a fully-open position (fully-actuated mode).

[0055] Figures 11 A, 11B, 11C, and 11D show the primary and secondary flow paths through another embodiment of aerosol valve 40 at various positions of valve stem 46. Figure 11A shows aerosol valve 40 in its closed position (resting mode), when there is no flow. Figure 11B shows aerosol valve 40 in a slightly cracked position, where valve stem 46 presses slightly on compression spring 44, creating a primary flow path 60. Figure 11C shows aerosol valve 40 in a partially open position (mid-stroke), illustrating primary flow path 60 as valve stem 46 presses somewhat more fully on compression spring 44. Figure 11D shows primary flow path 60 when aerosol valve 40 is in a fully-open position (full stroke). In this position, valve stem 46 is fully actuated and reaches a hard stop (not shown) so as to partially compress compression spring 44. As noted above, the hard stop can be, but does not have to be, part of the interior of valve stem housing 48 that contacts valve stem 46.

[0056] Figures 12A, 12B and 12C show cross-sections of yet another embodiment of an aerosol valve of the present disclosure, represented generally as aerosol valve 70. Aerosol valve 70 is shown in its various stages as the valve stem is pressed by the consumer. Figure 12A shows aerosol valve 70 an unactuated, closed position (resting mode). Figure 12B shows aerosol valve 70 in a partiallyopen position (mid-stroke). Figure 12C shows aerosol valve 70 in a fully-open position (fully-actuated mode).

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PCT/US2014/027630 [0057] Figures 13A, 13B, 13C, and 13D show the primary and secondary flow paths through aerosol valve 70 at various positions of valve stem 76. Figure 13A shows aerosol valve 70 in its closed position (resting mode) when there is no flow. Figure 13B shows aerosol valve 70 in a slightly cracked position, where valve stem 76 presses slightly on compression spring 74, creating a primary flow path 80 and a secondary flow path 82 between the individual coils of compression spring 74.

Figure 13C shows aerosol valve 70 in a partially open position (mid-stroke), illustrating primary flow path 80 and secondary flow path 82 as valve stem 76 presses somewhat more fully on compression spring 74. Figure 13D shows primary flow path 80 and secondary flow path 82 when aerosol valve 70 is in a fully-open position (full stroke). As before, in this position, valve stem 76 is fully actuated and reaches a hard stop (not shown) to partially compress compression spring 74. However, compression spring 74 does not become coil-bound, and some space is maintained between the individual coils of the spring to form a flow path for the product and propellant.

[0058] Figure 14 shows yet another embodiment of an aerosol valve of the present disclosure, represented generally as aerosol valve 90. Aerosol valve 90 is shown in an unactuated, closed position (resting mode).

[0059] Figure 15A and Figure 15B show the primary and secondary flow paths through another embodiment of the aerosol valve when aerosol valve 90 is in a closed position and in a fully-open position (tilted), respectively. In this embodiment, aerosol valve 90 is actuated by tilting the valve stem. As used in this application, “tilted” means the valve stem is inclined away from its vertical position at rest, and “tilting” means pushing against the top portion of the valve stem so that the valve stem is inclined away from its vertical position at rest. For example, the valve stem can be tilted between about 5% and about 10% from the vertical position to actuate the aerosol valve. Figure 15A shows valve stem 96 in its closed position (resting mode), and there are no flow paths. Figure 15B shows the aerosol valve when valve

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PCT/US2014/027630 stem 96 is fully tilted (i.e., full stroke), and the resulting primary flow path 100 and secondary flow path 102.

[0060] Similarly, Figure 16A and Figure 16B show another embodiment of aerosol valve 90 when the aerosol valve is in a closed position and in a fully-open position (valve stem is tilted), respectively. Figure 16A shows the aerosol valve and valve stem 96 in a closed position (resting mode), and there are no flow paths. Figure 16B shows the aerosol valve when the valve stem 96 is fully tilted (i.e., full stroke), and the resulting primary flow path 100 and secondary flow path 102.

[0061] In another embodiment, the product formulation of the present disclosure is a mixture of two types of media, such as a mixture of a powder (solids) and propellant.

[0062] A method of using the aerosol valve described above for delivery of a product formulation is also provided. The method uses the aerosol valve having a hard stop that prevents full compression of the compression spring when the valve stem is pressed by the consumer to dispense the product. The resulting spaces between the coils of the compression spring create an additional flow path for the product and propellant and can act as a baffle and/or static mixer. The method improves mixing of the product formulation, reduces agglomeration of solids that might otherwise block the flow path, increases turbulence of the product formulation as it flows through the aerosol valve, and feeds more of the product directly to the aperture for better dispensing of the product. The aerosol valve structure also permits loading the product and propellant into the aerosol container in a single production line, increasing the manufacturing rate, and reducing material usage.

EXPERIMENTAL

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PCT/US2014/027630 [0063] Testing the proposed aerosol valve with high-solids product formulations has resulted in no recordable instances of failure of the product to dispense throughout full-life testing. This is in contrast to laboratory testing with known, existing aerosol valve designs that failed due to agglomeration with a highsolids formulation that showed a propensity to agglomerate.

[0064] Figures 17A and 17B provide the results of a CFD test that show the flow streams of the product and propellant through and over the compression spring coils inside the valve stem housing of an embodiment of the aerosol valve of the present disclosure. Primary flow path 60 shows the flow of product and propellant as passing in and through compression springs 44 and valve stem housing 48 when valve stem 46 is pressed (opened) for the test). Figure 17B is another view of the flow streams in Figure 17A, without the surrounding aerosol valve structures, so the flow streams are shown clearly.

[0065] Figures 18A and 18B provide the results of another CFD test that shows the flow streams of the product and propellant through the compression spring coils inside the valve stem housing of another embodiment of the aerosol valve of the present disclosure that has the spring seat filled in. Primary flow path 60 shows the flow of product and propellant as passing in and through compression springs 44 and valve stem housing 48 when valve stem 46 is pressed (opened) for the test). Figure 18B is another view of the flow streams in Figure 18A, without the surrounding aerosol valve structures, so the flow streams are shown clearly.

[0066] As used in this application, the word “about” for dimensions, weights, and other measures means a range that is ± 10% of the stated value, more preferably ± 5% of the stated value, and most preferably ± 1 % of the stated value, including all subranges therebetween.

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PCT/US2014/027630 [0067] It should be understood that the foregoing description is only illustrative of the present disclosure. Various alternatives and modifications can be devised by those skilled in the art without departing from the present disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications, and variances that fall within the scope of the present disclosure.

2014239287 22 Jan 2018

Claims

1. An aerosol valve for dispensing a product formulation from a container, the aerosol valve comprising:

a mounting cup on the container for orientating the aerosol valve on the container;

a seal positioned on the mounting cup;

a valve stem housing defined by an inner chamber that has a base, an upper portion defined by a first diameter, a lower portion defined by a second diameter that is less than the first diameter, and a middle portion of a varying diameter decreasing between the upper portion and the lower portion, the valve stem housing positioned below the mounting cup and adjacent the seal, the middle portion of the valve stem housing having a surface along an entire inner circumference of the valve stem housing, the surface slanted to connect the upper portion to the lower portion to create an annular stop surface;

a valve stem, the valve stem having a top portion that protrudes through and above the seal and a bottom portion in the valve stem housing, the valve stem further comprising a valve stem aperture and a center hole, the valve stem being movable from a top position when the aerosol valve is in an unactuated, closed position to a bottom position when the aerosol valve is fully actuated;

a compression spring positioned in the valve stem housing and contacting the valve stem, the compression spring comprising:

a spring coil disposed on the base that, in a first position, forms a plurality of spaces with each space between adjacent coils of the spring coil; and a center space circumscribed by the spring coil with a center space diameter, wherein the annular stop surface interacts with the valve stem to form a hard stop that prevents full compression of the coils of the spring coil so that the spring coil and the valve stem housing define a first flow path and a second flow path when the product formulation in the reservoir flows upwardly under pressure,

3509120v1

2014239287 22 Jan 2018 wherein the first flow path is into and through the center space of the spring coil of the compression spring, around the outside of the valve stem, entering the valve stem aperture, and into the center hole, and wherein the second flow path is into and through the coils of the spring coil and the spaces therebetween.

2. The aerosol valve according to claim 1, wherein the second flow path increases mixing of the product formulation and breaks up agglomerations of solids in the product formulation by an interaction of the product formulation with the compression spring.

3. The aerosol valve according to claim 1, wherein the second flow path reduces incidences of blockage and thereby decreases a product failure rate of the aerosol valve by an increased mixing of the product formulation and breaking up of agglomerations of solids at the spring coil.

4. The aerosol valve according to claim 1, wherein the annular stop surface of the valve stem housing has an area that inclines inward to form the hard stop, and wherein the hard stop is a physical barrier to further downward movement of the valve stem.

5. The aerosol valve according to claim 4, wherein the hard stop is a position that allows the valve stem to attain the bottom position, and wherein the bottom position partially, but not completely, compresses the coils of the spring coil.

6. The aerosol valve according to claim 1, wherein the first flow path has few abrupt changes in flow direction to decrease resistance and back pressure of flow of product formulation therethrough.

7. The aerosol valve according to claim 1, wherein the first flow path has few loci at which the product formulation can agglomerate and impede the flow of the product formulation.

8. The aerosol valve according to claim 1, wherein the second flow path is turbulent.

9. The aerosol valve according to claim 1, wherein the coils and the spaces

3509120v1

2014239287 22 Jan 2018 therebetween direct the product formulation to flow into and upward through the center space of the compression spring, so that the product formulation exits as a cascade through an upper end of the compression spring where it enters the valve stem aperture and flows into the center hole, thereby increasing an amount of the product formulation entering into the valve stem aperture and the center hole.

10. The aerosol valve according to claim 1, wherein the first flow path and the second flow path form a single flow path before entering the valve stem aperture.

11. The aerosol valve according to claim 1, wherein all, or substantially all, of the product formulation flows in and through the spaces between the coils of the spring coil before entering the valve stem aperture.

12. The aerosol valve according to claim 1, wherein the bottom portion of the valve stem is shaped to form a flow passageway through which the product formulation flows when the aerosol valve is actuated.

13. The aerosol valve according to claim 1, wherein the product formulation comprises a mixture of a chemical composition and a propellant.

14. The aerosol valve according to claim 13, wherein the chemical composition comprises a powder.

15. The aerosol valve according to claim 14, wherein the product formulation is a highsolids product formulation.

16. An aerosol valve for dispensing a product formulation from a container, comprising:

a mounting cup on a top portion of the container; a seal positioned on the mounting cup;

a valve stem housing positioned below the mounting cup and adjacent the seal, the valve stem housing having a base and an interior surface along an entire interior circumference of the valve stem housing, the interior surface slanted inward;

3509120v1

2014239287 22 Jan 2018 a dip tube positioned below the valve stem housing, the dip tube being connected to a reservoir of the product formulation in the container;

a valve stem being in the valve stem housing, the valve stem having a top portion that protrudes through and above the seal and a bottom portion in the valve stem housing, the valve stem further comprising a valve stem aperture and a center hole; and a compression spring positioned in the valve stem housing and contacting the valve stem, the compression spring comprising:

a spring coil disposed on the base and that, in a first position, forms a plurality of spaces with each space between adjacent spring coils; and a center space circumscribed by the spring coil with a center space diameter, wherein the valve stem is in a vertical position prior to actuation, and is tilted away from the vertical position by pressing sideways on the valve stem to form a tilted valve stem that can actuate the aerosol valve, wherein the interior surface has an area that inclines inward and interacts with the tilted valve stem to form a hard stop so that the tilted valve stem partially, but not completely, compresses the spring coil when the aerosol valve is actuated, wherein when the aerosol valve is actuated, the product formulation in the reservoir flows upwardly under pressure through the dip tube, wherein the product formulation has a first portion that flows into and through the center space of the spring coil of the compression spring, around the outside of the valve stem body, enters the valve stem aperture, and flows into the center hole to dispense the product formulation from the container, forming a first flow path, wherein the product formulation has a second portion that flows into and through the spring coils and the spaces therebetween, forming a second flow path, wherein the interaction of the product formulation with the spring coils of the second flow path increases mixing of the product formulation and breaks up agglomerations of solids in the product formulation.

17. The aerosol valve according to claim 16, wherein the increased mixing of the 20

3509120v1

2014239287 22 Jan 2018 product formulation and breaking up of agglomerations of solids in the second flow path reduce the incidence of blockages to decrease a product failure rate of the aerosol valve.

18. The aerosol valve according to claim 16, wherein the valve stem is tilted between about 5% and about 10% from a vertical position on the mounting cap to actuate the aerosol valve.

19. A method for using an aerosol valve to dispense a product formulation from a container, the method comprising:

pressing a valve stem of the aerosol valve to actuate the aerosol valve to dispense the product formulation, wherein the aerosol valve comprises:

a mounting cup on the container that orientates the aerosol valve on the container;

a seal positioned on the mounting cup;

a valve stem housing defined by a base and an inner chamber that has an upper portion defined by a first diameter, a lower portion defined by a second diameter that is less than the first diameter, and a middle portion of a varying diameter decreasing between the upper portion and the lower portion, the valve stem housing positioned below the mounting cup and adjacent the seal the middle portion of the valve stem housing having a surface along an entire inner circumference of the valve stem housing that is slanted to connect the upper portion to the lower portion; the valve stem housing having a valve stem, the valve stem comprising a valve stem aperture and a center hole, the valve stem being movable from a top position when the aerosol valve is in an unactuated, closed position to a bottom position when the aerosol valve is fully actuated;

a compression spring positioned in the valve stem housing on the base and contacting the valve stem, the compression spring comprising:

a spring coil that, in a first position, forms a plurality of spaces with each space between adjacent coils; and a center space circumscribed by the spring coil with a center space diameter,

3509120v1

2014239287 22 Jan 2018 wherein the interior surface of the valve stem housing interacts with the valve stem to form a hard stop that prevents full compression of the spring coil, wherein the coils of the spring coil and the valve stem housing define a first flow path and a second flow path when the product formulation in the reservoir flows upwardly under pressure, wherein the first flow path is into and through the center space of the spring coil of the compression spring, around the outside of the valve stem, entering the valve stem aperture, and into the center hole, and wherein the second flow path is into and through the coils and the spaces therebetween; and releasing the valve stem to stop dispensing the product formulation.

20. The method according to claim 19, wherein the second flow path reduces incidences of blockage and thereby decreases a product failure rate of the aerosol valve by an increased mixing of the product formulation and breaking up of agglomerations of solids at the spring coil.

3509120v1

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FIG. 1

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230

FIG. 2

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FIG. 3

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FIG. 4 A

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Gas Flow

Liquid Flow

FIG. 8

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FIG. 9A

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FIG. 9B

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FIG. 9C

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FIG. 9D

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FIG. 10A

FIG. 10B

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FIG. 11A

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FIG. 11B

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FIG. 11C

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2014239287 30 Sep 2015

FIG. 11D

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FIG. 12A

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FIG. 12C

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FIG. 13A

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FIG. 13B

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FIG. 13C

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FIG. 13D

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FIG. 15B

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FIG. 16A

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FIG. 16B

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g

EC

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