Aerosol Dispenser With Sealed Actuator

The invention relates to an aerosol spray container and dispenser for holding materials which must normally be maintained in separated conditions until immediately prior to use.

Many compounds would be advantageously used if they could be dispensed from an aerosol container. Some of these compounds have a relatively short life and cannot be intermixed until just prior to use. Aerosol containers that include a frangible secondary container have been used to hermetically separate two chemical ingredients that must be mixed together immediately prior to spraying, such as a resinous paint and a catalyst. An inertia means, such as a steel ball, has been placed in the secondary container so that by shaking the entire aerosol container the inertia means shatters the secondary container allowing the two chemicals to be mixed together allowing a chemical mixture to be sprayed to a desired location. An example of this structure is shown by Cronan in U.S. Pat. No. 4,121,772.

An aerosol package shown and described in Aerosol Age April 1986 has an ampule that keeps the reactive compounds in the system separated until ready for use. When the valve is actuated, the sample is broken and its contents mix with other chemicals and/or a propellant. The ampule is made of a frangible material, such as glass. A rod extends from the valve downwardly into the container. The lower end of the rod has a saddle that traps the ampule transversly against the bottom of the container. When the valve stem is depressed, the rod shatters the ampule. This aerosol system allows one to use an aerosol spray containing material such as cyanoacrylate adhesives. This material causes rapid deteriation of gaskets and has a relatively short shelf life. Actuating the valve to shatter the ampule causes the contents of the container and ampule to immediately begin flowing out through the valve and the container. This may result in the waste of expensive materials and environmental contamination. Dangerous substances may be inadvertantly released. The adhesives may unexpectedly come into contact with the user's fingers in concentrated form causing them to bond together. The contents of the container is released before the material in the ampule and the other chemicals and/or propellant have had an adequate opportunity to mix. The amount of the two substances may be in a precise ratio necessary for effective application. This ratio may be upset if sufficient mixing of the substances is not allowed before releasing the contents of the container.

The invention is directed to an aerosol dispenser that has a container for storing a propellant and materials, such as liquids and chemicals that are to be sprayed to a desired location. The dispenser stores two or more separated materials that are mixed together within the container immediately prior to use. A wide range of ratios of material can be selected by using different size ampules for storing secondary materials. The dispenser can be effectively used with an aerosol spray containing cyanoacrylates. Ampule breaking structure associated with the spray control valve is manually operated to fracture the ampule thereby allowing the materials in the ampule and container to mix with each other. An actuator button mounted on the valve stem seals the open top of the valve stem eliminating inadvertant release of the materials and allowing the materials to mix thoroughly before release. This also maintained proper mixing ratios of the materials in the container. The container can be made of transparent materials to permit visual inspection of the integrity of the ampule.

The container has an open top that is closed with a cap that supports a normally closed control valve. The control valve has a moveable tubular member which can be manually moved into the container to open the valved to allow propellant and material to be dispensed therefrom. An actuator button frictionally mounted on the outer end of the moveable member seals the valve. A frangible ampule is located within the container for storing a second material separated and isolated from the first material. The ampule is an elongated closed glass vessel that is positioned transversly along the bottom wall of the container. The ampule is broken by a rod which extends from the movable member downwardly into the container and entraps the ampule against the bottom wall of the container. The rod and ampule have cooperating surfaces so that when pressure is applied to the actuator button, the movable member is moved into the chamber of the container causing the rod to depress and crush or break the ampule between the bottom wall of the container and the rod. This allows the second material to be mixed with the first material in the chamber. The inwardly movement of the movable member and rod to break the ampule also unseats the valve. However, the actuator button traps the air inside the moveable member and does not allow propellant and material to escape from the container. After the propellant and material have been properly mixed and the desired application area has been targeted, the button is removed from the top of the valve stem with the valve closed and replaced with a valve actuator cap and nozzle. The actuator cap and nozzle and valve are operated in a normal manner to dispense the mixed materials to a selected location.

A preferred embodiment of the aerosol dispenser has an elongated cylindrical transparent glass container having a bottom wall, an open top, and a chamber for storing a propellant and material such as a liquid. A cap mounted on the container closes the open top and supports a normally closed control valve. The control valve has an upwardly directed tubular stem that can be moved relative to a seal to open the valve. An actuator button is mounted on the outer end of the stem in a tight fitting relationship actuator so that the propellant and the material cannot be dispensed from the container.

An elongated frangible ampule is located within the chamber for storing a second material separate and isolated from the first material. The second material in the ampule being separated and isolated from the first material in the container increases the shelf life of the product and minimizes the deteriation of the gasket and seal structures of the control valve. A rod having a saddle shaped foot accommodates the mid section of the sample to hold the ampule adjacent the bottom wall of the container. The rod is connected to the inner end of the tubular stem. When the actuator button is depressed, the tubular stem and rod are moved inwardly to force the saddle foot into the ampule to break the ampule. The second material in the ampule flows into the chamber where it is mixed with the first material and propellant. The inward movement of the tubular stem opens the valve. The actuator button is friction sealed to the outer end of the stem to prevent the propellant and materials from being dispensed from the container when the valve is first opened. This avoids product waste and inadvertant application of the materials to undesired areas. The proper mixing ratios of the propellant and materials is maintained as one of the substances is not discharged before combining with the other substances. Also, potential environmental contamination is reduced. When the mixed materials and propellant are ready to be dispensed from the container, the button is replaced with a valve actuator cap having an opening or nozzle to allow the release of the contents of the container. A dip tube having a filter at the lower end thereof carries the mixed materials and propellant into the valve when the valve is open thereby allowing the mixed materials to be dispensed to a desired location. The valve actuator is provided with an elongated tube which allows the materials to be accurately dispensed to a desired location.

The objects and advantages of the aerosol dispenser of the invention are embodied in the dispenser structure and functions as shown in the drawing and described in the specification of the preferred embodiment thereof.

FIG. 1 is a perspective view of the aerosol dispenser invention equipped with an actuator button and a cap with nozzle, partly sectional, having a dispensing tube for directing mixed materials to a desired location in lieu of the actuator button;

FIG. 2 is an enlarged front elevational view of the dispenser of FIG. 1;

FIG. 3 is a top plan view of FIG. 2;

FIG. 4 is a view taken along the line 4--4 of FIG. 2;

FIG. 5 is a sectional view taken along the line 5--5 of FIG. 3 showing the unbroken ampule stored in the container;

FIG. 6 is a sectional view similar to FIG. 5 showing the broken ampule; and

FIG. 7 is an enlarged sectional view taken along the line 7--7 of FIG. 6.

Referring to FIGS. 1, 2, 3 and 4, there is shown the aerosol dispenser 10 of the invention for delivering mixed materials with a propellant to a desired location. The materials within dispenser 10 are mixed immediately prior to use so that corrosive materials have a minimum effect on gaskets and sealing elements of the control valve. The dispenser 10 has substantial shelf life since there is little or no reaction within the container prior to the mixing of the materials within the container. The dispenser can be used with materials such as cyanoacrylates and pharmaceutical drugs.

Dispenser 10 has an external bottle or container 11 made out of transparent material such as glass, plastic or the like. Bottle 11 has a cylindrical side wall 12 joined to a generally flat bottom wall 13. The top of side wall 12 has an annular rim or bead 14 surrounding the opening or mouth into chamber 16 of container 11. A material 17 such as a liquid, is normally stored in a chamber 16 along with a propellant which maintains materials 17 under pressure within chamber 16. The open top of the container 11 is closed with a cap 18 that supports a normally closed control valve indicated generally at 19.

As shown in FIGS. 5 and 6, control valve 19 has a generally upright tubular stem 21 that projects upwardly from cap 18. The lower portion of stem 21 has an elongated body 22 having an outwardly directed annular flange 23. Stem 21 has a passage 24 open to the top of the step and open to a side port 26 that allows the propellant and the material to flow into passage 24. An annular diaphram 27 surrounding stem 21 is normally aligned with the side port 26 to maintain the valve in a closed position. A coil spring 28 engages flange 23 to hold stem 21 in an up or closed position. The lower or inner end of coil spring 28 bears against an annular shoulder 29 of a generally cup-shaped housing 31 that surrounds stem body 22. Housing 31 has an internal chamber 32 that allows the propellant and material to flow upwardly to the side port 26 when control valve 19 is in the open position. Spring 28 biases stem 21 in a closed position as shown in FIG. 5. The upper end of housing 31 has an outwardly directed annular lip 33 that bears against the bottom of diaphram 27. Cap 18 is provided with an inwardly directed annular crimp 34 to hold lip 33 in engagement with diaphram 27. This also holds housing 31 on cap 18. An annular gasket 36 surrounds housing 31 and bears against the top of the bead 14 of container 11. Cap 18 is turned about or clamped over the gasket 36 and bead 14 to seal cap 18 on container 11.

The lower portion of housing 31 has a laterally and downwardly directed nipple 38 that is secured to an elongated dip tube 39. Tube 39 extends to adjacent the bottom wall 13 of container 11. A cup-shaped filter 41 fits over the lower end of dip tube 39 to prevent particulates, such as glass particles and the like, from flowing into the valve and being dispensed from the dispenser. Filter 41 is a porous polyethylene generally cylindrical member. The pore size of filter 41 is in the range of 45 to 75 microns. The bottom of filter 41 has a semi-spherical shape. The lower end of dip tube 39 fits into a hole extended down into filter 41. Other types of filters can be used with dip tube 39 to prevent foreign particles from interferring with the operation of control valve 19.

The lower portion of body 22 is secured to a downwardly directed compression or push rod 42. Push rod 42 is an elongated rigid member having a smooth outer cylindrical outer surface joined to the bottom part of stem 21 so that rod 42 moves with stem 21. Rod 42 is a stainless steel wire rod having a continuous and smooth cylindrical outer surface. Other types of materials can be used to make rod 42. The upper end of rod 42 fits into a hole or recess 43 in the bottom of body 22. Rod 42 extends downwardly through a hole 47 in bottom wall 48 of housing 31. Rod 42 is in a close sliding fit relation with bottom wall 48 to prevent foreign particles from entering passage 32. Spring 28 also serves as a stop to limit the depression or inward movement of stem 21. Stem body 22 has a diameter that is smaller than the diameter of passage 32 so that the propellant and liquid can freely flow to side port 26 when port 26 is moved below diaphram 27.

As shown in FIGS. 4 to 6, the bottom of rod 42 has a saddle shaped foot 44. Foot 44 is adapted to partially encircle and trap an elongated cylindrical frangible ampule 49 against the bottom wall 13 of container 11. Ampule 49 has a sealed chamber 51 storing a second material 52 such as liquid, chemical, powders, and the like that is desired to be mixed with material 17 in chamber 16 immediately prior to use of the dispenser. Ampule 49 is a glass vessel located generally transversly along the bottom wall 13 of container 11. The diameter of ampule 49 is smaller than the diameter of the opening into chamber 16. The length of ampule 49 can be substantially the same as the transverse length or diameter of bottom wall 13. The size of ampule 49 is selected to provide the desired ratio of volumes of material 17 to material 52.

Ampule 49 is retained in its generally transverse position with foot 44. As seen n FIG. 4, foot 44 is located contiguous to the mid-section of ampule 49. Ampule 49 is not broken so that the material 52 therein is isolated from material 17 in chamber 16. The structural condition of ampule 49 can be visually observed through the transparent material of container 11.

The upper end of stem 22 accommodates a generally circular button or closure member 57 that closes passage 24. Button 57 has a centrally located hole 56. Valve stem 21 is located in a close friction fit relation with hole 56 to effectively seal passage 24, as shown in FIG. 7. Button 57 is used to apply force as indicated by arrow 63 in FIG. 5 in a downward direction on stem 21. This moves valve 19 to the open position and rod 42 in a downward direction. Continued downward movement of rod 42 continues to exert force on the ampule 49 and wedges the ampule 49 between the bottom wall 13 of container 11 and foot 44. This force of foot 44 against ampule 49 in FIG. 6, fractures or breaks ampule 49 thereby releasing material 52 into chamber 16 where it is mixed with material 17. The mixing of the materials can be facilitated by shaking dispenser 10. Button 57 prevents the materials 17 and 52 from being discharged from the chamber 16. This eliminates wasted or unexpected discharge of the materials which could be expensive or dangerous. Drugs and other pharmaceutical aerosols that require exact mixing ratios to be effective would lose their effectiveness if material 17 was partially discharged before mixing with material 52 thereby upsetting the mixing ratio. Cyanoacrylate adhesives inadvertently discharged on a user's hands causes fingers to bond together and is painful and time consuming to unglue. These problems are avoided when button 57 is used on dispenser 10 while fracturing ampule 49.

After ampule 49 is broken, the external force 63 on button 57 can be removed. Spring 28 will then move stem 21 to its closed position as shown in FIG. 5. Button 57 is then removed from stem 21 and replaced with a cap actuator 58. As shown in FIG. 1, cap actuator 58 has a elongated lateral tube 59 having a discharge orifice 60. The bottom of cap 58 has a bore 61 that telescopes over the top of stem 21. Bore 61 is open to a passage 62 that leads laterally to tube 59. Other types of cap actuators and discharge nozzles can be used with stem 21 to direct the aerosol spray to desired locations.

Dispenser 10 is stored and transported in the manner shown in FIGS. 1 and 2. A cover (not shown) can be placed over button 57 and fitted on cap 18. The control valve 19 is closed thereby confining the liquid 17 and propellant to chamber 16. Ampule 49 being a hermetically sealed vessel separates and isolates the material 52 from the material from the material 17 and propellant in chamber 16. This substantially increases the shelf life of the liquids 17 and 52 and minimizes deteriation of the seal materials of the control valve 19. The separation of the first and second materials also allows the dispenser to use cyanoacrylates.

The sealed ampule 49 containing liquid 52 is placed in chamber 16 through the top opening before the cap 18 is attached to rim 14. Cap 18 and control valve 19 are placed on top of container 11 as a unit. The rod 42 extends down into chamber 16 to locate foot 44 adjacent the mid-section of ampule 49. Material 17 can be placed in chamber 16 before cap 18 is placed on container 11. Propellant can be introduced into chamber 16 through stem 21 by opening valve 19.

In use the operator applies force 63 on button 57 to move stem 21 down into container 11. This moves foot 44 down into ampule 49 to break ampule 49, as shown in FIG. 6. The material 52 in ampule 49 mixes with material 17. Button 57 prevents the materials 17 and 52 from escaping through stem passage 24. Button 57 is replaced with cap actuator 58. Dispenser is now ready for use to dispense a spray or jet of mixed materials and propellant to a location.

While there has been shown and described of preferred embodiment of the aerosol dispenser of the invention it is understood that changes in the structures, arrangement of structures, and materials may be made by those skilled in the art without departing from the invention. The invention is defined in the following claims.