GB2554745A

GB2554745A - Aerosol spray device

Info

Publication number: GB2554745A
Application number: GB1617114.2A
Authority: GB
Inventors: Guy Goldberg Thomas; Nasr Ghasem; Tulloch Greig; Hawthorne Gary
Original assignee: Plasvalco Ltd
Current assignee: Plasvalco Ltd
Priority date: 2016-10-07
Filing date: 2016-10-07
Publication date: 2018-04-11
Anticipated expiration: 2036-10-07
Also published as: GB2554745B; WO2018065780A1; GB201617114D0

Abstract

A closure for a container comprising a mounting cup 109 and an aerosol valve assembly 110. The aerosol valve assembly has a threaded portion 103a located on the outside of the housing for engagement with a corresponding threaded portion 103b on the mounting cup allowing the valve assembly to be screwed into the mounting cup. An aerosol spray device 100 is also described which comprises a container 108 mechanically coupled to the described closure preferably by a screw fitting 104. Any of the mounting cup, valve housing 105, 107, valve stem 101 and container may be formed from plastic, preferably polyethylene terephthalate (PET). The threaded portions 103a, 103b, 104a and 104b may comprise vents to allow for the relief of excess pressure from the container. Either or both of the screw fittings may have a ratchet mechanism 106 to resist disengagement of the valve assembly from the mounting cup and of the mounting cup from the container. Gaskets may be included to provide a seal between the valve assembly and mounting cup in the closure and/or between the mounting cup and the container in the aerosol device.

Description

(54) Title of the Invention: Aerosol spray device Abstract Title: Aerosol spray device (57) A closure for a container comprising a mounting cup 109 and an aerosol valve assembly 110. The aerosol valve assembly has a threaded portion 103a located on the outside of the housing for engagement with a corresponding threaded portion 103b on the mounting cup allowing the valve assembly to be screwed into the mounting cup. An aerosol spray device 100 is also described which comprises a container 108 mechanically coupled to the described closure preferably by a screw fitting 104. Any of the mounting cup, valve housing 105, 107, valve stem 101 and container may be formed from plastic, preferably polyethylene terephthalate (PET). The threaded portions 103a, 103b, 104a and 104b may comprise vents to allow for the relief of excess pressure from the container. Either or both of the screw fittings may have a ratchet mechanism 106 to resist disengagement of the valve assembly from the mounting cup and of the mounting cup from the container. Gaskets may be included to provide a seal between the valve assembly and mounting cup in the closure and/or between the mounting cup and the container in the aerosol device.

100

104a

106

109

Fig. 1

103b

105 B~103a

107

108

At least one drawing originally filed was informal and the print reproduced here is taken from a later filed formal copy.

1/4

100 /

CM

Ο

CM

Fig. 1

2/4

12 17

105

103a

107

Fig. 2

3/4

12 17

300 /

Fig. 4

4/4

12 17

L L

Fig. 5a Fig. 5b Fig. 5c

Fig. 6

AEROSOL SPRAY DEVICE

Field of the Invention

The present invention relates to an aerosol spray device for discharging a liquid product (e.g. a household product such as an air freshener) in the form of a spray. In particular, the present invention relates to an aerosol spray device which may be made substantially of plastic and, more particularly, to a closure for such an aerosol spray device.

Background to the Invention

Broadly speaking, aerosol spray devices comprise a container holding a liquid to be discharged and an outlet nozzle associated with a valving arrangement which is selectively operable to allow discharge of the liquid as a spray from the nozzle by means of propellant gas also provided within the container. The valving arrangement is conventionally coupled to the container via what is known as a mounting cup.

Conventional containers for aerosol spray devices are made of metal as are conventional mounting cups. Conventional valve assemblies are made primarily of plastic, with some components, such as springs, made of metal, and some components, such as seals/gaskets, made of rubber.

In order to assemble such an aerosol spray device, the valve assembly is crimped to the mounting cup by deforming surfaces of the mounting cup around the valve assembly in such a way that the valve assembly is retained in the mounting cup and a seal is formed between the mounting cup and the valve assembly, as is commonly known in the art. The mounting cup with the valve assembly crimped to it acts as a closure for the container.

The mounting cup with the valve assembly crimped to it is then itself clinched to the metal container such that a seal is created between the mounting cup and the container.

The seal created by the crimping of the valve assembly to the mounting cup and the seal created by the clinching of the mounting cup to the container needs to be strong enough to withstand a pressure of 10 bar or more within the closed system defined by the container and the mounting cup and valve assembly closure.

Where a metal mounting cup and plastic valve assembly undergo mechanical and pneumatic crimping actions during assembly, there are inevitable problems with regard to maintaining the required tolerances with respect to variations in the height and the diameter of the crimp. The required tolerances are conventionally ± 0.01mm which, if not adhered to, can adversely affect the valve functionality and the spray performance of the device. If the crimping is not correct, or falls outside of this tolerance, leakage could occur meaning the propellant gas and/or the product to be dispensed will be depleted upon actuation, often before the product reaches consumers.

Similar issues can arise when the tolerances required when clinching a metal mounting cup to a metal container are not met.

As such, there is a need to overcome the above issues with conventional aerosol spray devices.

Summary of the Invention

According to a first aspect of the invention, there is provided a closure for a container comprising: a mounting cup; and an aerosol valve assembly, the aerosol valve assembly comprising: a housing comprising internal walls defining a valve chamber and having at least one inlet; a valve stem received within the housing, the valve stem comprising an outlet; wherein an outer surface of the housing comprises a first threaded portion, wherein the mounting cup comprises a second threaded portion adapted to engage with the first threaded portion of the valve assembly so as to secure the valve assembly to the mounting cup, and wherein the valve stem is moveable between: an open position in which a flow path is provided between the at least one inlet of the housing and the outlet of the valve stem; and a closed position in which the flow path is closed off.

Advantageously the threaded portions provide a precise fit which will not vary during the assembly operation, as is commonly the case with conventional crimped closures. Thus improved product quality and better control of the overall manufacturing process is provided.

Preferably, at least one of the first and second threaded portions comprises one or more vents adapted to allow the passage of gas through the first and second threaded portions when engaged with each other when a pressure difference across the closure exceeds a predetermined threshold.

Preferably, the closure further comprises a ratchet mechanism adapted to resist disengagement of the valve assembly from the mounting cup when the first and second threaded portions are engaged.

Preferably, the closure further comprises at least one protrusion located on one of the mounting cup and the valve assembly and at least one corresponding recess located on the other one of the mounting cup and the valve assembly adapted to resist disengagement of the valve assembly from the mounting cup when the first and second threaded portions are engaged.

Preferably, at least one of the mounting cup, housing and valve stem are made of plastic, preferably polyethylene terephthalate.

Preferably, the closure further comprises a gasket adapted to form a sealing engagement between the mounting cup and the valve assembly.

According to a second aspect of the invention, there is provided an aerosol spray device comprising: a container; and the closure of the first aspect, wherein the closure is secured to the container via a mechanical coupling so as to form a closed system.

Preferably, the container is made of plastic, preferably polyethylene terephthalate.

Preferably, the mounting cup comprises a third threaded portion and, the container comprises a fourth threaded portion arranged to engage with the third threaded portion so as to provide the mechanical coupling.

Preferably, at least one of the third and fourth threaded portion comprises one or more vents adapted to allow passage of gas through the at least one of the third and fourth threaded portions when engaged with each other when a pressure in the closed system exceeds a predetermined threshold.

Preferably, the aerosol spray device further comprises a ratchet mechanism adapted to resist disengagement of the mounting cup from the container when the third and fourth threaded portions are engaged.

Preferably, the aerosol spray device further comprises at least one protrusion located on one of the mounting cup and the container and at least one corresponding recess located on the other of the mounting cup and the container adapted to resist disengagement of the container from the mounting cup when the third and fourth threaded portions are engaged.

Preferably, the aerosol spray device further comprises a gasket adapted to form a sealing engagement between the mounting cup and the container.

Brief Description of Drawings

The invention will be further described by way of example only with reference to the accompanying drawings, in which:

Figure 1 depicts an aerosol spray device;

Figure 1a depicts a ratchet portion;

Figure 2 depicts a valve housing;

Figure 3 depicts an alternative embodiment of an aerosol spray device;

Figure 4 depicts a cross section of the mounting cup according to the alternative embodiment depicted in Figure 3;

Figures 5a, 5b and 5c depict various shaped protrusions;

Figure 6 depicts a further alternative embodiment.

Detailed Description

Figure 1 depicts an aerosol spray device 100. The aerosol spray device 100 comprises a container 108, a mounting cup 109 and a valve assembly 110. The valve assembly 110 comprises a valve stem 101, a top housing portion 105, a bottom housing portion 107 coupled to the top housing portion 105 so as to form a valve housing. Also depicted are an inner gasket 102 located between the mounting cup 109 and the valve assembly 110, an outer gasket 111 located between the mounting cup 109 and the container 108, a dip tube 112 connected to the bottom housing portion 107 and a ratchet mechanism 106.

The container 108 is in the form of a plastic aerosol bottle. The valve stem 101, top housing portion 105 and bottom housing portion 107 of the valve assembly 110 are also be made of plastic. The mounting cup 109 is also made from plastic. Preferably they are all made from polyethylene terephthalate. It is noted that crimping and clinching of plastic components is not possible. All of the attachment mechanisms described herein enable plastic components to be used as the need for crimping and/or clinching is obviated.

It will be understood that the components of the aerosol spray device 100 may be made from other materials, such as a metal, for example aluminium, but that plastic is the preferred material.

The outer surface of the top housing portion 105 comprises a first threaded portion 103a. The mounting cup 109 comprises a second threaded portion 103b arranged to engage with the first threaded portion 103a in such a way that the valve assembly 110 can be attached via a screw fit to the mounting cup 109 without the need for any valve crimping. When the valve assembly 110 is screwed into the mounting cup 109, the two components form a closure for the container 108.

The mounting cup 109 comprises a third threaded portion 104a. The container 108 comprises a fourth threaded portion 104b arranged to engage with the third threaded portion 104a in such a way that the mounting cup can be attached via a screw fit to the container 108 without the need for any clinching actions.

The threads of each of the threaded portions 103a, 103b, 104a and 104b may be sloped (for example, as shown in Figure 2 described below) so as to provide enhanced engagement between the various components of the aerosol spray device 100.

The ratchet mechanism 106 comprises at least one ratchet portion located on an inner surface of the mounting cup 109 which is arranged to engage with a corresponding ratchet portion on an opposing outer surface of the container 108. Figure 1a depicts an example container 108 comprising a fourth threaded portion 104b and a ratchet portion 106 on an outer surface of the container 108. The corresponding ratchet portions are configured to engage one another during assembly of the aerosol spray device 100 at the point where the mounting cup 109 has been fully screwed onto the container 108 and in such a way that mounting cup 109 can no longer be removed from the container 108. In other words, removal of the mounting cup 109 from the container 308 is resisted by the ratchet mechanism.

Any suitable ratchet mechanism may be used such as corresponding opposing protrusions on each of the mounting cup 109 and the container 108 in the form of asymmetrical teeth, such as those of the ratchet portion 106b depicted in Figure 1a. Each tooth may have a sloped profile ending in a wall such that the opposing protrusions may pass each other in a first direction as the sloped edges are able to pass over one another, usually by a slight deformation of the plastic teeth, but are prevented from passing each other in a second opposite direction as the walls abut against each other. A series of ratchet portions may be provided on each of the mounting cup 109 and the container 108, as depicted in the container 108 of Figure 1a.

An equivalent ratchet mechanism (not shown) may be provided to ensure that the valve assembly 110, once screwed into the mounting cup 109, can no longer be removed from the mounting cup 109. Equivalent ratchet portions may be provided on the outer surface of the valve housing and on the corresponding inner surface of the mounting cup 109.

The valve assembly 110 may be of the type described in PCT Patent Applications (Publication) Nos. WO 2011/061531, WO 2011/128607, WO 2015/185904, WO 2011/042751, WO 2011/061481, and WO 2011/042752, all of which are incorporated by reference. The valve stem 101 is moveable between an open position, in which a flow path is provided between an at least one inlet of the valve housing and an outlet of the valve stem, and a closed position, in which the flow path is closed off.

The inner gasket 102 is arranged to provide seal between an outer surface of the valve stem 101, the mounting cup 109 and the top housing portion 105 of the valve housing when the valve assembly 110 is screwed into the mounting cup 109.

The outer gasket 111 is arranged to provide seal between the mounting cup 109 and the container 108 when the mounting cup 109 is screwed onto the container 108.

The assembled aerosol spray device 100 is designed to safely contain compressed air of up to 10 bar in pressure.

Figure 2 depicts a side view of the top housing portion 105 and bottom housing portion 107 of the valve assembly 110. The first threaded portion 103a is clearly visible. Also visible are vents 202 in the first threaded portion 103a which allow the venting of gas if the pressure is high. Similar vents may also be provided in any one of the second threaded portion 103b, third threaded portion 104a and/or fourth threaded portion 104b. These vents are configured such that when pressure within the aerosol spray device 100 reaches greater than a predetermined amount, for example 10 bar, the plastic material of the various components of the aerosol spray device is deflected opening a flow path between the interior and the exterior of the aerosol spray device 100 to allow gas to bleed from the device, specifically during the filling process. When the pressure inside the devices returns to the desired 10 bar or lower, the plastic material of the various components of the aerosol spray device is returns to its original position closing the flow path.

This is an important safety feature as it prevents the aerosol spray device 100 from becoming over pressurised and prevents any likelihood of the aerosol spray device 100 bursting during filling, where pressures of 45 bar and above are used.

Also depicted in Figure 2 is a hole 204 in the valve housing top housing portion 105. The hole 204 provides a further safety feature, namely pressure equalisation during filling of the aerosol spray device 100 which, in turn allows for faster filling. Essentially, the hole 204 replicates the natural gaps which occur between the valve assembly and the mounting cup in conventional aerosol spray devices when the valve assembly is crimped to the mounting cup, which also enable quicker filling.

Such a hole may additionally or alternatively be provided between the threads 104a of the mounting cup 109.

It is important to note that filling of the aerosol spray device 100 is performed at pressures of around 45 bar or more. The inner gasket 102 is bent inwards and gas flows into the container and pressure across the device is equalised by the hole 204. Once the aerosol spray device 100 is filled with gas up to a pressure of 10 bar, the inner gasket 102 returns to its original position providing the aforementioned seal between the outer surface of the valve stem 101, the mounting cup 109 and the top housing portion 105 of the valve housing, thereby preventing gas from leaving the aerosol spray device 100. The gasket 102 is designed to withstand pressures of 10 bar, but is designed to be deformed at filling pressures of 45 bar.

The above described the screw fit between the mounting cup 109 and the valve assembly 110, as well as the screw fit between the mounting cup 109 and the container 108, has significant advantages in relation to the assembly of the aerosol spray device 100. The need for the mechanical crimping or clinching together of two inert materials, specifically of the plastic valve to the metal cup of conventional aerosol spray devices, is alleviated. The provided threaded portions provide a precise fit which will not vary during the assembly operation, thus providing improved product quality and better control of the overall manufacturing process. The aerosol spray device 100 may also be assembled much more rapidly as the screwing together of the components is a much quicker operation than an operation which requires crimping and clinching.

The various components of the aerosol spray device 100 are made of plastic and, as such, the threaded portions can be formed easily and to a very high degree of accuracy via an injection moulding process.

The seal between the valve assembly 110 and the mounting cup 109 is more effective than a conventional crimped seal. Moreover, screwing the valve assembly 110 into the mounting cup 109 obviates the need for a pedestal (or turret) to be provided on the mounting cup 109 to enable crimping of the valve assembly 110 to the mounting cup 109. This prevents the occurrence of distortion of the inner gasket 102 against the pedestal (or turret), which can arise when a conventional valve assembly is crimped to the pedestal of a conventional metal mounting cup and which can result in gas leakage. Distortion of the inner gasket 102 occurs particularly when the crimping operation is carried out in a non-vertical plane as the gasket will tend to impinge on the crimping dramatically affecting the quality of the crimp and often causing leakage. As the need for crimping is obviated in the aerosol spray devices described herein, this problem does not arise.

In addition, the injection moulding of the components enables the dimensions of the components to be controlled to a high level of accuracy. In particular, the internal venting provided can be precisely dimensioned to enable gas bleeding through the components during filling, as described above, to be controlled more precisely. For example, the various vents and holes described above can be dimensioned such that the gas bleed occurs at a predetermined pressure, e.g. at greater than 10 bar. The thread fit mechanism also enables the components of the aerosol spray device 100 to be attached together while at the same time exceeding the tolerances required for the corresponding standard crimping of the valve assembly to the mounting cup in conventional aerosol spray devices. This manufacturing process of the aerosol spray device 100 can more easily be controlled to within the required ± 0.1mm tolerance.

Assembly

The assembled valve assembly 110 with vented first screw threads 103a has the advantage over conventional crimped devices in that there is a reduced risk of gasket movement during the assembly process, which tends to occur in conventional crimping assembly processes. Also, no mechanical process is involved in the operation and no crimping or clinching of the various components, as described above, is required. Clinching of conventional mounting cups to containers currently varies by +/- 0.5mm whereas the present screw thread will be able to obtain variations of +/- 0.05mm or less.

Furthermore, the addition of locking down the various thread engagements via the aforementioned ratchet mechanisms allow for a near perfect non-removable seal and the component parts of the aerosol spray device 100 can be held in robust and accurate positions without lateral or radial movements, as can commonly occur when components are crimped or clinched together. The venting system also allows the closure to release pressure and vent out excess air which reduces the risk of the container bursting.

Another advantage of the screw thread is a quicker filling process compared with conventional filling. The filling can be 350 aerosol spray devices 100 per minute or greater. The mounting cup 109 and valve assembly 110 offers a form fill seal system, specifically where the container is a plastic bottle. Furthermore, the outer threads and the inner threads are easily engageable and accurately assembled and fitted together during the filling process without any leakage.

Figure 3 depicts an alternative embodiment of an aerosol spray device 300. Where like reference numerals are used in Figure 3, the components are the same as those of the embodiment depicted in Figure 1. Only the mounting cup 309 and the container 308 are different in this embodiment.

Figure 4 depicts a cross section of the mounting cup 309 according to the alternative embodiment. The aerosol spray device 300 comprises all of the same components as the aerosol spray device 100, except that the mounting cup 309 is not permanently attached to the container 108 via a ratchet mechanism 106. Instead, as can be seen in Figure 4, protrusions 401 are formed on an inner surface of the mounting cup 309. Corresponding recesses (not depicted) are formed on the opposing outer surface of the container 308. The protrusions and recesses are arranged such that, as the mounting cup 309 is fully screwed onto the container 308, the protrusions 401 are brought into alignment with their corresponding recesses in the container 308 and snap into place, thereby permanently attaching the mounting cup 309 the container 308 in such a way that the removal of the mounting cup from the container 308 is resisted by the protrusions and recesses. The location of the protrusions 401 and the corresponding recesses can be reversed, such that the protrusions 401 are located on the container 308 and the recesses are located on the mounting cup 309.

Other shapes of protrusions and corresponding recesses may be used such as those depicted in Figures 5a, 5b and 5c, namely chevron (Figure 5a), rib (Figure 5b) and dome (Figure 5c) shaped protrusions may be used with corresponding recesses.

An equivalent arrangement of protrusions and recesses (not shown) may be provided to ensure that the valve assembly 110, once screwed into the mounting cup 309, can no longer be removed from the mounting cup 309. Equivalent protrusions or recesses may be provided on the outer surface of the valve housing and on the corresponding inner surface of the mounting cup 309 and the location of the protrusions may be on the valve assembly and the location of the recesses may be on the mounting cup or vice versa.

Figure 6 depicts a further alternative embodiment. An aerosol spray device 600 is depicted which provides an alternative mechanism of attaching a valve assembly 610 to a mounting cup 609 and of attaching the mounting cup 609 to the container 608. The aerosol spray device 600 comprises no threaded portions. Instead the valve assembly 610 is attached to the mounting cup 609 via two continuous beads 614 (although one bead 614 or greater than two beads 614 may be used) located on the valve assembly 610. Corresponding recesses are provided in the mounting cup 609. The location of the beads 614 and recesses may be reversed. The mounting cup 609 is attached to the container

608 via two continuous beads 616 (although one bead 616 or greater than two beads 616 may be used) located on the container 608. Corresponding recesses are provided in the mounting cup 609. The location of the beads 614 and recesses may be reversed. The various components are then welded together via an ultrasonic of RF (Radio Frequency) welding process.

The beads 614 and 616 may be shaped like any of the protrusions depicted in Figures 5a, 5b and 5c and the recesses may be correspondingly shaped.

Claims

1. A closure for a container comprising: a mounting cup; and an aerosol valve assembly, the aerosol valve assembly comprising:

a housing comprising internal walls defining a valve chamber and having at least one inlet;

a valve stem received within the housing, the valve stem comprising an outlet;

wherein an outer surface of the housing comprises a first threaded portion, wherein the mounting cup comprises a second threaded portion adapted to engage with the first threaded portion of the valve assembly so as to secure the valve assembly to the mounting cup, and wherein the valve stem is moveable between:

an open position in which a flow path is provided between the at least one inlet of the housing and the outlet of the valve stem; and a closed position in which the flow path is closed off.

2. The closure of claim 1, wherein at least one of the first and second threaded portions comprises one or more vents adapted to allow the passage of gas through the first and second threaded portions when engaged with each other when a pressure difference across the closure exceeds a predetermined threshold.

3. The closure of claim 1 or claim 2, further comprising a ratchet mechanism adapted to resist disengagement of the valve assembly from the mounting cup when the first and second threaded portions are engaged.

4. The closure of any one of claims 1 to 3, further comprising at least one protrusion located on one of the mounting cup and the valve assembly and at least one corresponding recess located on the other one of the mounting cup and the valve assembly adapted to resist disengagement of the valve assembly from the mounting cup when the first and second threaded portions are engaged.

5. The closure of any preceding claim, wherein at least one of the mounting cup, housing and valve stem are made of plastic, preferably polyethylene terephthalate.

6 The closure of any preceding claim, further comprising a gasket adapted to form a sealing engagement between the mounting cup and the valve assembly.

7. An aerosol spray device comprising: a container; and the closure of claim 1 to 6, wherein the closure is secured to the container via a mechanical coupling so as to form a closed system.

8. The aerosol spray device of claim 7, wherein the container is made of plastic, preferably polyethylene terephthalate.

9. The aerosol spray device of claim 7 or claim 8, wherein the mounting cup comprises a third threaded portion and, wherein the container comprises a fourth threaded portion arranged to engage with the third threaded portion so as to provide the mechanical coupling.

10. The aerosol spray device of claim 8, wherein at least one of the third and fourth threaded portion comprises one or more vents adapted to allow passage of gas through the at least one of the third and fourth threaded portions when engaged with each other when a pressure in the closed system exceeds a predetermined threshold.

11. The aerosol spray device of any of claims 7 to 10, further comprising a ratchet mechanism adapted to resist disengagement of the mounting cup from the container when the third and fourth threaded portions are engaged.

12. The aerosol spray device of any of claims 7 to 11, further comprising at least one protrusion located on one of the mounting cup and the container and at least one corresponding recess located on the other one of the mounting cup

5 and the container adapted to resist disengagement of the container from the mounting cup when the third and fourth threaded portions are engaged.

13. The aerosol spray device of any of claims 7 to 12, further comprising a gasket adapted to form a sealing engagement between the mounting cup and

10 the container.

Intellectual

Property

Office

Application No: GB1617114.2