[0001] Aerosol sprays are now widely used, particularly in the cosmetic, topical pharmaceutical
and detergent fields, for delivery of an additive such as a cosmetic, pharmaceutical,
or cleaning composition to a substrate such as the skin or other surface to be treated.
Aerosol compositions are widely used as antiperspirants, deodorants, and hair sprays
to direct the products to the skin or hair in the form of a finely-divided spray.
[0002] Much effort has been directed to the design of valves and valve delivery ports, nozzles
or orifices which are capable of delivering finely-divided sprays, of which U.S. patents
Nos. 3, 083, 917 and 3, 083, 918 patented April 2, 1963, to Abplanalp et al, and No.
3,544,258 dated December 1, 1970, to Presant et al, are exemplary. The latter patent
describes a type of valve which is now rather common, giving a finely atomized spray,
and having a vapor tap, which includes a mixing chamber provided with separate openings
for the vapor phase and the liquid phase to be dispensed into the chamber, in combination
with a valve actuator or button of the mechanical breakup type. Such valves provide
a soft spray with a swirling motion. Another design of valve of this type is described
in U.S. patent No. 2,767,023. Valves with vapor taps are generally used where the
spray is to be applied directly to the skin, since the spray is less cold.
[0003] Marsh U.S. patent No. 3,148,127 patented September 8, 1964 describes a pressurized
self-dispensing package of ingredients for use as a hair spray and comprising isobutane
or similar propellant in one phase and an aqueous phase including the hair setting
ingredient. The isobutane is in a relatively high proportion to the aqueous phase,
and is exhausted slightly before the water phase has been entirely dispensed. A vapor
tap type
Qf valve is used having a 0.030 inch vapor tap orifice, a 0..30 inch liquid tap orifice,
and a 0.018 inch valve stem orifice, with a mechanical breakup button. There is no
disclosure of the relative proportions of propellant gas to liquid phase being dispensed.
[0004] Rabussier U.S. patent No. 3,260,421 patented July 12, 1966 describes an aerosol container
for expelling an aqueous phase and a propellant phase, fitted with a vapor tap valve,
and capillary dip tube. To achieve better blending of the phases before expulsion,
the capillary dip: tube is provided with a plurality of perforations 0.01 to 1. 2
mm in diameter over its entire length, so that the two phases are admitted together
in the valve chamber from the capillary dip tube, instead of the gas being admitted
only through a vapor tap orifice, and the liquid through a dip tube as is normal.
The propellant is blended in the liquid phase in an indeterminate volume in proportion
to the aqueous phase in the capillary dip tube.
[0005] Presant et al in patent No. 3,544,258, referred to above, discloses a vapor tap valve
having a stem orifice 0.018 inch in diameter, a vapor tap 0.023 Inch in diameter with
a capillary dip tube 0.050 inch in diameter. The button orifice diameter is 0.016
inch. The composition dispensed is an aluminum antiperspirant comprising aluminum
chlorhydroxide, water, alcohol and dimethyl ether. The aluminum chlorhydroxide is
in solution in the water, and there is therefore only one liquid phase. The dimensions
of the orifices provided for this composition are too small to avoid clogging, in
dispensing an aluminum antiperspirant composition containing dispersed astringent
salt particles.
[0006] The vapor tap type of valve is effective in providing fine sprays. However, it requires
a high proportion of propellant, relative to the amount of active ingredients dispensed
per unit time. A vapor tap requires a large amount of propellant gas, because the
tap introduces a volume of propellant gas into each squirt of liquid. Such valves
therefore require aercsol compositions having a rather high proportion of propellant.
A high propellant proportion is dangerous and undesirable, however, when the propellant
is flammable. For this reason, the art has preferred nonflammable propellants, such
as the fluorocarbons. With the imminent banning of fluorocarbon propellants, how ever,
it is now necessary for the art to turn to the flammable propellants, such as hydrocarbons
and low boiling ethers, and the resulting flame hazard poses a considerable problem.
The flame hazard is increased if liquefied propellant is delivered with gaseous propellant,
since the liquid contains more flammable material per unit volume.
[0007] Vapor tap valves normally have a rather large valve chamber, in the walls of which
are placed the vapor tap and liquid tap orifices. The valve chamber houses the bias
means tending to hold the valve in a closed position, and at the same time furnishes
blending space for the liquid and gaseous components of the aerosol compositions before
delivery when the delivery valve is opened. The liquid tap and vapor tap orifices
in the valve chamber are normally open to free entry of both liquid aerosol composition
and liquefied propellant or propellant gas at all times, even when the delivery valve
is closed. When the aerosol container is shaken up to provide a uniform distribution
of two liquid phases or of liquid and solid phases, the valve chamber can and usually
does fill with liquid propellant via at least the vapor tap orifice. Upon opening
of the delivery valve, the volume of liquefied propellant in the valve chamber is
dispensed first, within the first few seconds, This initial delivery of liquefied
propellant when the propellant is flammable poses a considerable flame hazard, if
the container is used in the vicinity of a flame.
[0008] A further problem peculiar to vapor tap valves arises when the container is inclined
from the normally upright position to below the horizontal, or even inverted. If the
container is inclined or tipped below the horizontal, or inverted, the gas propellant
phase can pass through the liquid tap orifice, and the liquefied propellant and liquid
aerosol composition can pass through the vapor tap orifice. Since the liquid tap orifice
and the vapor tap orifice normally differ in restriction to flow, the ratio of gas
to liquid is likely to be completely changed, and the proportion of flammable liquid
propellant may be greatly increased, with a resulting increase in flammability of
the spray that is dispensed. In this case, an extremely flammable spray can be obtained.
[0009] Aerosol containers are commonly filled so that the liquid phase occupies about 60%
of the total container capacity at 21°C. With this fill in a container with minimum
doming, a straight dip tube, and a vapor tap or if ice about 0.6 mm in diameter, off-center
and positioned downward when the container is horizontal, both vapor and liquid tap
orifices will be covered by liquid when the container is positioned so that the valve
is in the range of about -5
0 (below horizontal) to +5° (above horizontal). If the dip tuba bends downward when
the container is horizontal, the range in valve position in which both taps are covered
by liquid may extend to about -30° (below the horizontal) to about + 5 (above the
horizontal). The extent or span of this range will depend on the dimensions of the
container. The larger the ratio of diameter: height, the wider the span of the range.
[0010] In accordance with the invention of Serial No. 754,471, the fire hazard posed when
aerosol containers equipped with conventional vapor tap valves are tipped from the
upright position to the horizontal or even inverted position, is overcome by including,
in combination with the delivery valve, an overriding shut-off valve which, although
normally open when the container is upright, automatically closes off flow of liquid
through the delivery valve from the container to the delivery port at some limiting
angle at or below the horizontal as the top of the container is brought below the
horizontal, towards the fully inverted position. The shut-off valve will normally
have closed fully before the container is fully inverted. The angle to the horizontal
at which the valve must close is of course the angle at which liquid can flow to the
delivery port and escape as liquid from the container, without benefit of a high gas
ratio. This can be within the range from 0° (i.e. hortzontal) to -90°, and preferably
is from -5° to -45°, below the horizontal.
[0011] In this type of container, it is generally not possible to dispense the liquid contents
of the container by opening the delivery valve unless the container is so oriented
that a sufficient ratio of gas is expelled with the liquid phase. The container must
be held in a fully upright position, or at least in a position with the valve above
the horizontal. Otherwise, the liquid phase cannot flow through the open delivery
valve, because the shut-off valve is closed.
[0012] The aerosol container in accordance with the invention of Serial No. 754,471 comprises',
in combination, a pressurizable container having at least one storage compartment
for an aerosol composition and a liquefied propellant in which compartment propellant
can assume an orientation according to orientation of the container between a horizontal
and an upright position, and a horizontal and inverted position; a delivery valve
movable manually between open and closed positions, and including a valve stem and
a delivery port; an aerosol-conveying passage in flow connection at one end with the
storage compartment and at the other end with the delivery port, manipulation of the
delivery valve opening and closing the passage to flow of aerosol composition and
propellant from the storage compartment to the delivery port; and a shut-off valve
responsive to orientation of the container to move automatically between positions
opening and closing off flow of liquefied propellant to the delivery port, the shut-off
valve moving into an open position in an orientation of the container between
' a horizontal and an upright position, and moving into a closed position in an orientation
of the container between the horizontal and an inverted. position.
[0013] A preferred embodiment of delivery valve Is of the vapor tap type, comprising a valve
movable manually between open and closed positions, a valve stem and a delivery port;
a valve stem orifice in the valve stem, in 'flow connection at one end with a blending
space, and at the other end with an aerosol-conveying valve stem passage leading to
the delivery port; bias means for holding the delivery valve in a closed position;
means for manipulating the valve against the bias means to an open position, for expulsion
of aerosol composition via the valve stem orifice to the delivery port; wall means
defining a blending space, and separating the blending space from liquid aerosol composition
and propellant within the container; at least one liquid tap orifice through the wall
means; at least one vapor tap orifice through the wall means; and a shut-off valve
means movable between a closed position closing off the valve stem passage and an
open position allowing aerosol composition to pass through the valve stem passage,
the shut-off valve being in the open position at least when the container is fully
upright, and being in the closed position at least when the container is fully inverted,
and moving from the open to the closed position at an angle therebetween beyond the
horizontal at which liquid propellant can flow to and through the vapor tap orifice
and escape through the delivery port via the aerosol conveying valve stem passage
when the delivery valve is in the open position.
[0014] The containers of Serial No. 754,471 do not however overcome the problem of delivery
even when the container is upright, or inclined but above the horizontal, of a highly
flammable spray composed predominantly of liquefied flammable propellant when the
container is shaken just before the delivery valve is opened, arising from the filling
of the valve chamber during shaking with liquefied propellant just before delivery.
This is a problem similar to that arising when the container is inverted or held at
an angle to the vertical below the horizontal, even though the container may be held
fully upright, because the shaking at least partially fills the valve chamber with
the liquid phase.
[0015] In accordance with the present invention, this difficulty is overcome by providing
a vapor tap valve for aerosol containers comprising, in combination, a delivery valve
movable manually between open and closed positions and including a valve stem, a delivery
port, and a valve chamber; bias means in the valve chamber biasing the delivery valve
towards a closed position; a liquid tap orifice in flow communication with the valve
chamber; a vapor tap orifice in flow communication with the valve chamber; and a shut-off
valve linked to and movable with the delivery valve, closing off the vapor tap orifice
against entry of liquefied propellant therethrough into the valve chamber when the
delivery valve is closed, and opening the vapor tap orifice when the delivery valve
is manually moved to the open position, against the biasing force of the bias means.
[0016] In a preferred embodiment, the vapor tap valve is combined with a second shut-off
valve responsive to orientation of the aerosol container to move automatically between
positions opening and closing off flow of propellant to the delivery port via the
valve chamber, the shut-off valve moving into an open position in an orientation of
the container between a horizontal and an upright position, and moving into a closed
position in an orientation of the chamber between the horizontal and an inverted position.
[0017] This preferred embodiment of vapor tap valve Including first and second shut-off
valves inhibits delivery of liquefied propellant under all conditions to which the
container may be subjected.
[0018] The vapor tap valve has a valve housing which may also include or is in flow connection
with wall means defining the valve chamber or blending space. The valve chamber is
of limited volume, ipsufficient to constitute a foam chamber, and only as large as
required for thorough blending of gas and liquid therein before reaching the valve.
A delivery valve is movably disposed for movement between open and closed positions,
away from and towards a valve seat at the inner end of the valve stem passage, with
which the valve chamber is in flow connection when the delivery valve is open...
[0019] The valve chamber can be small in volume, and no larger than the volume needed for
full movement of a delivery valve therein. It can also be a narrow passage, large
enough at one end for the delivery valve, and merging indistinguishably with the dip
tube or tail piece passage. Any conventional mixing chamber in a vapor tap valve will
serve.
[0020] The volume of the valve chamber does not usually exceed 1 cc, and can be as small
as 0.01 cc, but it is preferably from 0.05 to 0.2 cc.
[0021] The liquid tap orifice communicates the valve chamber directly or indirectly with
a capillary dip tube or a standard dip tube. A standard or capillary dip tube normally
extends into the liquid composition or phase in the aerosol container, and may reach
to the bottom of the container. A tail piece may be provided (but is not essential)
at the valve housing as a coupling for linking the dip tube to the valve chamber within
the valve housing. The tail piece when present has a through passage In fluid flow
connection with the liquid composition or phase in the container, via the dip tube,
and thence into the valve chamber.
[0022] The liquid tap orifice in this embodiment is an orifice or constriction in the passage,
at the blending space end, at the dip tube end, or intermediate the ends. The orifice
can also be in direct communication with the dip tube, in the event the tail piece
is omitted. When the dip tube communicates directly with the liquid tap orifice, the
liquid tap orifice can be at the end opening of the dip tube.
[0023] In the special case when a capillary dip tube is used, no liquid tap orifice as such
is required. The capillary dip tube serves as the liquid tap orifice. However, the
size parameters for the capillary dip tube and vapor tap orifice in that event are
different, because of the unique flow restriction of the capillary dip tube.
[0024] The vapor tap orifice is in fluid flow connection with the propellant or gas phase
of the aerosol container, and admits gas into the valve chamber before the valve stem
delivery passage. Normally, therefore, it is in the wall defining the valve chamber,
and above the liquid tap orifice, although this is not essential. The vapor tap orifice
can be in a wall beside or above the shut-off valve, but it is of course upstream
of the shut-off valve.
[0025] The vapor tap valve delivery system of an aerosol container downstream of the vapor
tap delivery valve normally includes an actuator which . operates the delivery valve,
and movable between open and closed positions against the biasing force at a bias
means, with a valve stem and an aerosol composition-conveying valve passage therethrough,
in flow connection with a delivery port.
[0026] When the valve chamber has a small capacity, e.g., less than about 0.2 cc, it is
advantageous that when the first shut-off valve, which is linked with the delivery
valve, is in an open position it is in flow communica- tion with both the vapor tap
orifice and the liquid tap orifice. This facilitates mixing of the gas and liquid
phases which occurs in the valve chamber, before these pass to the delivery valve,
and the diameters of the vapor tap and liquid tap orifices as well as the valve passages
and orifices with which they are in communication are selected within the stated ranges
to provide, in the valve chamber, a gas: liquid volume ratio within the range from
about 8: 1 to about 40: 1, and preferably from about 15:1 to about 30: 1. It will
be appreciated that for a given size of these openings, the gas: liquid ratio obtained
from gas and liquid fed therethrough from the supply in the container will vary with
the particular propellant or propellants and the composition of the liquid phase.
The viscosity of the liquid is a factor in determining the proportion that can flow
through the liquid tap orifice per unit time, when the valve is open.
[0027] In a preferred embodiment of this type of valve, where particulate solids are either
absent or present in too small a size or concentration to constitute a potential clogging
problem, the valve stem orifice has a diameter within the range from about 0. 3 to
about 0.35 mm, at least one liquid tap orifice having a cross-sectional open area
within the range from about 0.1 to about 0.8 mm
2, and at least one vapor tap orifice having a cross-sectional open area within the
range from about 0.1 to about 0.8 mm
2, the ratio of liquid tap orifice to vapor tap orifice cross-sectional open area being
within the range from about 0.5 to about 2.5; the open areas of the liquid tap orifice
and vapor tap orifice being selected within the stated ranges to provide a volume
ratio of propellant gas: liquid aerosol composition within the range from about 8:1
to about 40:1, limiting the delivery rate of liquid aerosol composition from the container
when the valve is open.
[0028] In a preferred embodiment of this type of valve, where particulate solids are present
with a particle size and concentration that could clog small orifices, the valve stem
orifice has a diameter within the range from about 0.5 to about 0. 65 mm, at least
one liquid tap orifice having a cross-sectional open area within the range from about
0.4 to about 0.8 mm
2, and at least one vapor tap orifice having a cross-sectional open area within the
range from about 0.3 to about 0.8 mm
2, the ratio of liquid tap'orifice to vapor tap orifice cross-sectional open area being
within the range from about 0. 5 to about 2.3; the open areas of the liquid tap orifice
and vapor tap orifice being selected within the stated ranges to provide a volume
ratio of propellant gas: liquid aerosol composition within the range from about 8:
1 to about 40:1, limiting the delivery rate of liquid aerosol composition from the
container when the valve is open.
[0029] In the special case where the liquid tap orifice is a capillary dip tube, and particulate
solids are not present in size or amount to clog small orifices, the cross-sectional
open area thereof is within the range from about 0.1 to about 1.8 mm
2, for flow of liquid aerosol composition into the valve chamber, and at least one
vapor tap orifice through the wall has a cross-sectional open area within the range
from about 0.1 to about 0.8 mm
2 for flow of propellant gas into the blending space; and the ratio of capillary dip
tube to vapor tap orifice cross-sectional open area is within the range from about
1. 0 to about 3.2.
[0030] In the special case where the liquid tap orifice is a capillary dip tube, where the
solids are present in size or amount to clog small orifices, the cross-sectional open
area thereof is within the range from about 0.6 to about 1. 8 mm
2, for flow of liquid aerosol composition into the valve chamber, and at least one
vapor tap orifice through the wall has a cross-sectional open area within the range
from about 0.3 to about 0.8 mm
2 for flow of propellant gas into the valve chamber; and the ratio of capillary dip
tube to vapor tap orifice cross-sectional open area is within the range from about
1 to about 3.2.
[0031] The controlling orifices to achieve the desired proportion of gas and liquid in the
blend dispensed from the container are the vapor tap orifice, the liquid tap orifice
(or in the case of a capillarly dip tube, the capillary dip tube), and the valve stem
orifice. The open areas of these orifices and the ratio of liquid tap orifice to vapor
tap orifice open area should be controlled within the stated ranges. However, these
dimensions are in no way critical to the operation of the shut-off valve, which can
be used advantageously with delivery valves having other dimensions.
[0032] The valve delivery system normally includes, in addition to the valve stem orifice,
an actuator orifice at the end of the passage through the actuator of the valve. The
valve delivery system from the valve chamber through the valve stem and actuator to
the delivery port thus includes, in flow sequence towards the delivery end, the valve
stem orifice, the valve stem passage, and the actuator orifice. The controlling orifice
in this sequence is the valve stem orifice, and the actuator orifice will normally
have a diameter the same as or greater than the valve stem orifice, but not necessarily.
[0033] In the unlikely event that the actuator orifice has an open area that is less than
the valve stem orifice, then the actuator orifice becomes the controlling orifice,
downstream of the blending chamber, and its diameter may in that event be within the
range from about 0.3 to about 0.65 mm when solids are not present, and from about
0.45 to about 0. 65 mm when solids are present in sufficient amount or size to clog
small orifices.
[0034] The orifice ranges given are applicable to dispersion-type antiperspirant aerosol
compositions. Other orifice ranges may be used with other types of aerosol compositions.
[0035] The invention is also applicable to aerosol containers which have at least two compartments,
a first aerosol composition compartment and a second liquefied propellant gas compartment,
the propellant compartment and the valve and chamber being communicated by at least
one vapor tap orifice, which is across the line of flow through the valve chamber
to the valve delivery port from the propellant compartment. A liquid aerosol composition
to be foamed and then expelled from the container is placed in the first compartment
of the container, which is in flow communication via a liquid tap orifice with the
valve chamber, so as to admit liquid aerosol composition into the valve chamber across
the line of propellant gas flow via the gas orifice or orifices to the delivery valve.
When the delivery valve is opened, the propellant passes in gaseous form through the
vapor tap orifice(s) and propels the liquid aerosol composition to and through the
open delivery valve passage out from the container.
[0036] The overall dimensions of the vapor tap and the liquid tap orifice(s) are selected
according to the required product delivery rate (including propellant expelled).
[0037] Both the vapor tap and liquid tap orifices are in a wall or walls defining the valve
chamber or housing The liquid tap orifice is placed so that liquid aerosol composition
entering the valve chamber is disposed across the line of flow from the vapor tap
orifice into the valve chamber and out from the container. The liquid tap orifice
can be below, above, or on a line with the vapor tap orifice.
[0038] The function of the shut-off valve of the invention is to prevent liquid aerosol
composition containing flammable liquefied propellarit.irorri entering the valve chamber
when the container is shaken. This liquid composition readily enters the valve chamber
through the vapor tap orifice as well as through a liquid tap orifice communicating
with a standard dip tube. In the case where the liquid tap orifice is a capillary
dip tube of narrow bore, very little liquid will enter the valve chamber through the
capillary, but it can enter through the vapor tap orifice.
[0039] Thus, it is always essential that the shut-off valve close off the vapor tap orifice.
While it may also be necessary that it close off the liquid tap orifice to entry of
liquefied propellant into the valve chamber if that orifice is large, it is usually
unnecessary, and therefore optional to do so.
[0040] The shut-off valve of the invention can be placed at any convenient location across
the line of flow of propellant liquid or gas through the vapor tap orifice into the
valve chamber of the vapor tap valve. Thus, it can be placed directly across or beside
the vapor tap orifice. It can also be placed in the valve chamber downstream of the
liquid tap orifice in the valve chamber. If it is downstream of the liquid tap orifice,
it of course closes off the valve chamber to filling with liquid propellant from both
liquid tap and vapor tap orifices, while if it is across only the vapor tap orifice,
it prevents entry of liquefied propellant into the valve chamber, but only through
the vapor tap orifice. If the liquid propellant can readily enter the valve chamber
through both the vapor tap and the liquid tap orifices by shaking, it is of course
desirable to put the shut-off valve downstream of both the liquid tap and vapor tap
orifices in the valve chamber.
[0041] It is sufficient to close off the vapor tap orifice when the liquid tap orifice is
a capillary dip tube with a small inside diameter, e.g., 0,4 mm.
[0042] It 'is necessary that the shut-off valve be linked to the delivery valve, so that
when the delivery valve is opened, the shut-off valve is opened as well, thus making
possible the passage of both liquid and gas into the valve chamber and through the
delivery system to the delivery port.
[0043] Accordingly, a preferred emmbodiment of shut-off valve has both shut-off valve and
delivery valve means attached to a valve stem, and movable therewith between open
and closed positions, opening and closing together at least both the vapor tap orifice
and the delivery valve.
[0044] In a preferred embodiment, both the delivery valve and the shut-off valve are slide
valves, movable together into the open position against the biasing force of the bias
means by manual manipulation of the valve actuator. The shut-off valve is in the form
of a reciprocable shaft or cylinder, with at least one flow passage therethrough movable
therewith between an open position in which at least both the valve chamber and the
vapor tap orifice are linked in fluid flow communication via the passage, and a closed
position in which the passage is not in registration with the valve chamber and the
vapor tap orifice; and bias means holding the shut-off valve in the closed position.
[0045] The valve accordingly prevents entry of liquefied propellant through the vapor tap
orifice when the container is shaken, because when the container is shaken the delivery
valve is closed, and with it the vapor tap orifice. The vapor tap orifice is normally
closed, and is opened only when the delivery valve is also opened, for delivery of
aerosol composition from the container.
[0046] In order to prevent delivery of flammable liquefied or gaseous propellant when the
container is in an inclined or inverted position, the vapor tap valve of the invention
and aerosol containers including the same can also include a second shut-off valve,
of the type described in Serial No. 754,471. This second shut-off valve can be placed
in any convenient location across the line of flow of liquid to the delivery port.
[0047] Thus, it can be at or in the passage leading directly to the delivery port, downstream
or upstream of the delivery valve, in the valve chamber, or at or in the vapor tap
orifice.
[0048] It is sufficient to close off the vapor tap orifice, if there be a dip tube leading
to the liquid tap orifice, since this will prevent escape of liquid. Hcwever, the
shut-off valve can also. be arranged to close off the valve stem orifice, or the valve
chamber, or the valve stem passage. In all such cases, all flow is cut off, even if
the manipulatable valve be open.
[0049] The second shut-off valve in accordance with the invention can take any of several
forms.
[0050] A preferred emboutment of shut-off valve has a valve means which is free to roll
with gravity, such as a cylinder or ball, which can roll freely along an inclined
guide, chute or support, into a position at the valve seat closing off the valve passage
when the container is in any position between a few degrees less than horizontal to
fully inverted, i. e. , from -2 ° to -90° below the horizontal, but which normally
is drawn by gravity into an at-rest position in which the shut-off valve is open when
the top of the container is in any position between a few degrees below the .horizontal
to fully upright, i. e., +90°. As the container is brought from an upright position
toward the horizontal, the ball or cylinder can roll down towards the valve seat,
and at some angle near the horizontal will roll into position on the valve seat, closing
off flow to the valve passage. The flammability hazard is eliminated when the container
is in any position.
[0051] This embodiment is especially suitable for disposition in a valve chamber, or across
a delivery valve stem passage or orifice, including a vapor tap valve in the ball
housing.
[0052] Another embodiment of the shut-off valve of the invention is a slide valve, slidable
along a guide between open and closed positions. In the. open position, the slide
valve is away from the valve seat and the valve passage is open. As the container
is brought into a fully inverted position at an angle at about 10° or so beyond the
horizontal, the slide valve slides along the guide into contact with the valve seat,
closing off the valve passage.
[0053] The slide valve can for example be tubular and arranged to slide along a concentric
tubular guide, the guide constituting a dip tube, or a wall enclosing the valve chamber.
The vapor tap or valve stem orifice extends radially through the tubular guide, or
is disposed axially at one end of the tubular guide. In the former case, the side
of the tubular slide valve can be arranged to close off the orifice through the tubular
guide. In the latter case, the end of the slide valve can be arranged to close off
the orifice, when brought into abutting relation therewith.
[0054] Another form of slide valve has a disc with a flanged outer periphery, movable along
the concentric tubular guide. The orifice or passage to be closed off is axially disposed,
in a wall of a valve chamber. It can for example be a vapor tap orifice through the
bottom wall of the valve chamber. The vapor tap orifice is accordingly closed off
when the disc comes into abutment with the bottom wall, guided in this position by
the tubular guide.
[0055] Other variations will be apparent to those skilled in this art.
[0056] Preferred embodiments of aerosol containers in accordance with the Invention are
illustrated in the drawings, in which:
Figure 1 representa a fragmentary sectional view of an.aerosol container having therein
one embodiment of vapor tap valve in accordance with the invention, including a vapor
tap orifice and a liquid tap orifice. in the form of a capillary dip tube in fluid
flow connection with the shut-off valve of the invention arranged as a reciprocable
slide valve at one end of the valve stem of the delivery valve, and movable within
an aperture in a valve plate extending all the way across the valve chamber, closing
off the valve chamber whichin the closed position, and showing the shut-off valve
in the closed position.
Figure 1A represents a detailed view of the vapor tap valve of Figure 1, showing the
shut-off valve in the open position;
Figure 2 represents a cross-sectional view taken along the line 2-2 of Figure 1;
Figure 3 represents a fragmentary longitudinal sectional view of another embodiment
of vapor tap valve in accordance with the invention, including a capillary dip tube
in fluid flow connection with the liquid tap orifice;
Figure 4 represents a cross-sectional view taken along the line 4-4 of Figure 3;
Figure 5 represents a longitudinal sectional view of another embodiment of vapor tap
valve in accordance with the invention, designed for use with a pressure bottle, rather
than an aerosol can;
Figure 6 represents a cross-sectional view taken along the line 6-6
Figure 7 represents a longitudinal sectional view of another embodiment of vapor tap
valve in accordance with the invention, arranged to close off the valve chamber at
one end, downstream of both the liquid tap and vapor tap orifices, and
Figure 8 represents a cross-sectional view taken along the line 8-8 of Figure 7.
[0057] In principle, the preferred aerosol containers of the invention utilize a container
having at least one compartment for propellant gas and liquid aerosol composition,
communicated by at least one vapor tap orifice and at least one liquid tap orifice
to a valve chamber of a vapor tap valve which is across the line of flow to the valve
delivery port. A liquid aerosol composition to be blended with propellant gas and
then expelled from the container is placed in this compartment of the container, in
flow communication via the liquid tap orifice with the valve chamber, so as to admit
liquid aerosol composition into the valve chamber, while propellant gas flows into
the valve chamber via the vapor tap orifice or orifices to the valve.
[0058] The aerosol containers in accordance with the invention can be made of metal or plastic,
the latter being preferred for corrosion resistance. However, plastic-coated metal
containers can also be used, to reduce corrosion. Aluminum, anodized aluminum, coated
aluminum; zinc-plated and cadmium-plated steel, tin, and acetal polymers such as Celcon
or Delrin are suitable container materials.
[0059] The aerosol container 1 shown in Figures 1, 1A and 2 has a vapor tap valve 4 of the
invention comprising a valve poppet 8 combining in one member a delivery valve poppet
8a and a shut-off slide valve 8b. The delivery valve poppet 8a seats against the sealing
face 19 of a sealing gasket 9. The shut-off slide valve 8b reciprocates through and
against the inside wall of the aperture constituting a valve seat 29 of a valve plate
28. The valve plate extends all the way across the valve chamber 5, .separating a
lower portion 5b into which open the vapor tap orifice 2 and liquid tap orifice 5a.
The poppet 8a is open at the inner end, and defines a socket 8c therein for the reception
of a coil spring 18. The passage 13 is separated from the socket 8c within the poppet
8a by the divider wall 8d.
[0060] Adjacent the divider wall 8d in a side wall of the stem 11 is a valve stem orifice
13a. The gasket 9 has a central opening 9a therethrough, which receives the valve
stem 11 in a sliding leak-tight fit, permitting the stem to move easily in either
direction through the opening without leakage of propellant gas or liquid from the
container.
[0061] When the valve stern is in the outwardly extended position shown in Figure 1, tie
surface of the poppet portion 8a contiguous with wall 8d is in sealing engagement
with the inner face of the gasket 9, closing off the orifice 13a and the passage 13
to outward flow of the contents of the valve chamber 5.
[0062] The slide valve 8b has a solid shaft tip, with a central groove 27 open on one side,
and considerably longer than the thickness of the valve plate 28. With the valve 8b
and the valve stem 11 in the position shown in Figure 1, the groove is entirely within
the valve chamber 5, and therefore access from the chamber 5 to the space 5b below
the valve plate 28 is closed off by the valve 8b. When however the valve stem 11 is
moved inwardly by the, buton actuator 12, the groove 27 is also moved inwardly, and
in the fully depressed position of the valve stem, the groove 27 provides a flow communication
between the valve chamber 5 and the space 5a below the valve plate 28. With the valve
in the position shown in Figure 1, entry into chamber 5 of both gas and liquid passing
through the gas and liquid tap orifices 2 and 5a is prevented by the valve 8b, and
thus the valve 8b closes off the valve chamber 5 to outward flow of all of the contents
of the container, upstream- . of the valve 8b.
[0063] The outer end portion 11a of the valve stem 11 is received in the axial socket 16
of the button actuator 12, the tip engaging the ledge 16a of the socket. The stem
is attached to the actuator by a press fit. The axial socket 16 is in flow communication
with a lateral passage 17, leading to the actuator (valve delivery) orifice 14 of
the button 12.
[0064] The compression coil spring 18 has one end retained in the socket 8c of the valve
poppet 8a, and is based at its other end upon valve plate 28. The spring 18 biases
the poppet 8a towards the gasket 9, engaging it in a leak-tight seal at the valve
seat 19. When the valve poppet is against the valve seat 19, the orifice 13a leading
into the passage 13 of the valve stem is closed off.
[0065] The delivery valve is however reciprocably movable towards and away from the valve
seat 19 by pressing inwardly on the button actuator 12, thus moving the valve stem
11 and with it poppet 8a against the spring 18. When the valve is moved far enough
away from the seat 19, into the position shown in detail in Figure 1A, the orifice
13a is brought beneath the valve gasket 9, and a flow passage is therefore open from
the valve chamber 5 defined by the valve housing 6 to the delivery port 14.
[0066] At the same time, the shut-off valve 8b is moved inwardly in aperture 29 so that
the groove 27 is brought into registry at one end with valve chamber 5 and at the
other. end with the space 5b below the chamber, and a flow passage is therefore opened
through the groove 27 from the space 5b into the valve chamber 5 defined by the valve
housing 6, and thence to the delivery port 14 via the open valve stem orifice 13a.
[0067] The limiting open position of the valve poppet 8a and shut-off valve 8b is fixed
by the spring 18, which can be compressed at most to the position where the coils
of the spring are in contact with each other.
[0068] The valve stem orifice 13a when in the open position communicates the stem passage
13 with the actuator passages 16, 17 and the valve delivery orifice 14, and thus depressing
the actuator 12 permits fluid flow past the shut-off valve 8b and the valve stem orifice
13a via the valve chamber 5, to be dispensed from the container at delivery port 14.
[0069] Thus, the spring 18 ensures that the valve poppet 8a and the shut-off valve 8b are
normally in a closed position, and that the two valves are open only when the button
actuator 12 is moved manually against the force of the spring 18.
[0070] The valve housing 6 has an expanded portion 6a upon which is the sealing gasket 9,
and retained in position at the upper end of the housing. The expanded portion 6a
and the sealing gasket 9 are retained by the crimp 23b in the center of the mounting
cup 23, with the valve stem 11 extending through an aperture 23a in the cup. The cup
23 is attached to the container dome 24, which in turn is attached to the main container
portion 25.
[0071] Through the bottom wall 7 of the valve housing 6 is a vapor tap orifice 2, which
is in flow connection with the upper portion 20 of the space 21 within the container
1, and therefore with the gas phase of propellant, which rises into this portion of
the container. Below the valve plate 28 the space 5b of the valve housing 6 terminates
in a passage 5a, enclosed in the projection 6c of the housing 6. In the passage 5a
is inserted one end of the capillary dip tube 32, which extends all the way to the
bottom of the container, and thus dips into the liquid phase of the aerosol composition
in portion 21 of the container. Liquid aerosol composition accordingly enters the
space 5b at the passage 5a, via the capillary dip tube 32, so that the dip tube serves
as a long liquid tap orifice, while gas enters the space 5b through the gas tap orifice
2.
[0072] In the valve shown, the diameter of the actuator (valve delivery) orifice 14 is 0.5
mm. The valve stem orifice 13a is 0.6 mm. The diameter of the vapor tap orifice 2
is 0.95 mm, and the inside diameter of the capillary dip tube 32 is 1.0 mm. The valve
chamber 5 has a length of 1 cm, . and an inside diameter of 0.78 cm. The stem shaft
11 has a diameter of 0. 3 cm, ard extends almost to the bottom of the space 5b when
the valves 8a, 8b are opened. The groove 27 in the valve stem 11 has a rectangular
shape, 0.08 cm deep, with a length of 0.4 cm and a width of 0.08 cm, starting 0.1
cm from the bottom of the stem shaft. The shaft 11 fits snugly in a leak-tight fit
in the aperture 29 of the valve plate 28. The aperture has an inside diameter of 0.3
cm, the same as the outside diameter of the valve stem. The valve plate 28 is located
0.2 cm above the bottom wall of the valve chamber 5 and is held in position, spaced
from the lower wall 6b of the valve chamber 5, by the spring 18 and the lugs 31.
[0073] The volume of the valve chamber 5 is about 0.4 cc, and the volume of the space 5b
between the valve plate and the capillary dip tube is-about 0.1 cc.
[0074] In operation, button 12 is depressed so that the valve stem 11 and with it valve
poppet 8a, orifice 13a, and shut-off valve 8b are manipulated to the open position,
away from the valve seats 19 and 29. Liquid aerosol composition is thereupon drawn
up via the capillary dip tube 32 and the passage 5a into the space 5b, whence it flows
through the aperture 29 into the valve chamber 5, and then up around the poppet 8a
towards the valve stem orifice 13a. Propellant gas passes through the vapor tap orifice
2, and is blended with liquid aerosol composition in the spaces 5b and 5, which it
enters via the aperture 29 as it flows past the valve plate 28, and then flows around
the poppet 8a through the valve stem orifice 13a and the valve stem passage 13 and
valve button passages 16, 17, through the delivery orifice 14. The dimensions of the
orifices 2, 32 are such that at least 8 volumes of gas enter through the vapor tap
orifice 2 for each volume of liquid entering through the liquid tap orifice, which
is the capillary dip tube 32.
[0075] This embodiment of container includes a second shut-off valve, slide valve 3, arranged
to close off the vapor tap orifice 2 when the container is inverted, or inclined below
the horizontal. The slide valve 3 has a valve body of plastic, for example polyethylene
or polypropylene, with an annular rim 3a and a central disc valve 3b. The rim defines
twin recesses 3c and 3d, of which recess 3c is wide enough and deep enough to receive
the end 6b of the valve housing 6, and all of wall 7. When it does so, the disc valve
3b eventually abuts and covers over the bottom wall 7 of the valve housing 6, thus
effectively closing off the vapor tap orifice 2, when the valve 3 is in the uppermost
position. Accordingly, the valve in this position closes off the vapor tap orifice
2.
[0076] The disc valve 3b has a central aperture 15 through which passes loosely the projection
6c of the valve housing 6. The loose fit prevents binding of the disc against the
projection 6c. The annular rim 3a is long enough to engage the housing 6 over the
entire travel of the valve along projection 6c between the closed position abutting
the bottom wall 7 of the housing 6, and the open position abutting the stops 6d on
the projection 6c. In the open position, the valve disc 3b is in the lowermost position,
and rests against the stop 6d, as shown in Figure 1. In this'position, the container
is upright and the valve under the force of gravity remains in this position.
[0077] It will be apparent, however, that when the container is inverted, the valve will
tend to slide along the projection 6c into the newly lowermost position (corresponding
to the closed position) shown in Figure 1A, with the valve disc 3b closing off the
vapor tap orifice 2. This effectively prevents liquid from escaping from the container
via the vapor tap orifice, even though the liquid is now on the other side of the
container. The dip tube 32 now taps the gas phase, and thus it is quite impossible
for liquid to escape from the container. Accordingly, a flammability hazard due to
the escape of flammable liquid is avoided.
[0078] At the same time, the shut-off valve 8b prevents a flame hazard due to the entry
of liquefied propellant into the valve chamber 5 when the container is shaken before
opening the delivery valve. With the valve 8b closing off the aperture 29 in the valve
plate 28, both liquid through the liquid tap orifice 5a and gas or liquefied propellant
through the vapor tap orifice 2 are prevented from entering the valve chamber 5, so
that the valve chamber is kept relatively free of aerosol composition when the container
is shaken to distribute or disperse insoluble material more uniformly through the
composition, before opening the delivery valve. Since the valve Chamber 5 is empty,
or virtually so, liquefied flammable propellant is not delivered from the valve when
the delivery valve is opened, during the first few seconds of the delivery. Thus,
again, a flame hazard due to the escape of flammable liquid propellant is avoided.
[0079] This container is capable of delivering a dispersion type aerosol antiperspirant
composition of conventional formulation at a delivery rate of about 0.4 g/second,
about 40% of the normal delivery rate of 1 g/second. Accordingly, in order to obtain
the same delivery of active ingredients (such as active antiperspirant) per squirt
of a unit time, it is necessary to considerably increase the concentration of active
antiperspirant composition. Normally, such compositions contain less than 5% active
antiperspirant, because of clogging problems usin;; standardized aerosol container
valve systems and dimensions. In this container, however, it is possible to deliver
at a low delivery rate about 0. 3 to about 0.7 g/second of aerosol antiperspirant
composition containing from about 8% to about 20% active ingredient as suspended or
dispersed solid material without clogging, because of the high proportion of gas to
liquid.
[0080] The vapor tap valve 40 shown in Figures 3 and 4 is generally similar to that of Figures
1, 1A and 2, and consequently like reference numerals are used for like parts. In
this embodiment, the shut-off valve 45 of the invention reciprocates in aperture 44
in the bottom wall 6b of the valve chamber 5, and the valve plate 28 is eliminated.
The shut-off valve 45 is downstream of both the liquid tap orifice 41 and the vapor
tap orifice 42, and consequently all flow from either orifice into the valve chamber
5 is prevented when the shut-off valve is in the closed position, closing aperture
44 as shown in Figures 3 and 4.
[0081] In this container the vapor tap valve 40 of the invention has a valve stem 11 having
a valve button 12 attached at one end, with valve button passages 16, 17 and a delivery
orifice 14 therethrough, and a valve housing 6 pinched by crimp 23b in the aerosol
container cap 23. The valve housing 6 has a valve chamber 5, and an aperture 44 in
bottom wall 6b, the walls of which serve as a valve seat for the shut-off valve tip
45 of the valve stem 11. The delivery valve portion of the valve stem 11 is in the
form of a valve poppet 8d. The valve stem orifice 13a is closed off by the poppet
when the delivery valve is in the closed position, seen in Figure 3. The valve poppet
8d is reciprocably mounted on the valve stem 11, as also is the shut-off valve 45,
and both are biased by the spring 18 against the valve seat 19 on the inside face
of the gasket 9, in the normally closed position. When the valve poppets 8d and 45
are away from their seats, the valve stem orifice 13a is in flow corimunication via
the valve chamber with the liquid tap orifice 41 and the vapor tap orifice 42.
[0082] The valve housing 6 in the portion below the shut-off valve 45 is provided with a
tapered passage 46 which is shaped to receive the end 32a of the-capillary dip tube
32.
[0083] The liquid aerosol composition is stored in the lower portion 21 of the container,
and the di
p tube 32 extends from the lower portion 21 of the container into the passage 5c of
the valve housing 6 in which it is press fitted in place. The dip tube puts the liquid
phase in the bottom of the container in flow connection with the liquid passage 41.
[0084] The second slide valve 3 has a valve body of metal, for example, stainless steel
or aluminum, with an annular rim 3a and a central disc valve 3b. The rim defines a
recess 3d which is wide enough to embrace and conform to the cylindrical tail piece
6f of the valve housing 6. When the valve 3 is in the uppermost position, on the end
6d of the valve housing, the disc valve 3b covers over vapor tap orifice 42 and abuts
the bottom wall 6b of the valve housing 6, thus effectively closing off the vapor
tap orifice 2a. When the valve 3 is in its lowermost position, it engages the stop
6h on the tail piece 6f.
[0085] The disc valve 3b has a central aperture 15, which fits. loosely over the tail piece
6f of the valve housing 6. The loose fit prevents binding of the disc against the
tail piece 6f. In the open position, the valve disc 3b-rests against the stop 6d,
as shown in the Figure. In this position, the container is upright, vapor tap orifice
42 is open, and the second shut-off valve under the force of gravity remains in the
lowermost position.
[0086] It will be apparent however that when the container is inverted, the valve 3 will
tend to slide along the tail piece 6f, into the newly lowermost position corresponding
to the closed position, with the valve disc 3b closing off the vapor tap orifice 42.
This effectively prevents liquid from escaping from the container via the vapor tap
orifice, even though the liquid is now on the other side of the container. The dip
tube 32 now taps the gas phase, and thus it is quite impossible for liquid propellant
to escape from the container. Accordingly, a flame hazard when the container is inverted
due to the escape of flammable liquid is avoided.
[0087] In the aerosol container shown in Figures 5 and 6, the vapor tap valve of the invention
is employed in a pressure bottle. In this embodiment, the delivery valve 60 is the
same as that of Figures 3 and 4, and the shut-off valve 55 is similar. Upstream of
the shut-off valve 55 and the vapor tap orifice 51 is a capillary dip tube flow passage
53 through the housing 6, in flow communication at one end with the upper end of the
capillary dip tube 52 and at the other end with the valve chamber 61.
[0088] Upstream of the vapor tap orifice 51 within the valve housing 6 in a chamber 54 between
the two sections of the vapor tap orifice 51 is a second shut-off valve 65, designed
to close off the vapor tap orifice 51. when the container is inclined to below the
horizontal, or inverted.
[0089] This shut-off valve comprises a ball 58 of inert noncorrodible metal such as aluminum,
stainless steel, or brass, which is free to roll within the valve chamber 54 . The
valve seat is defined by the concave recess 59 in the wall of the chamber adjacent
the two sections of orifice 61. The recess 59 is tapered sufficiently to guide the
ball 58 and permit it to lodge against the orifice 51, closing it off, when the container
is inverted or inclined below the horizontal.
[0090] In the normal upright position of the container, as shown in Figure 5, the ball 58
is at the bottom of the chamber 54. Accordingly, when the actuator button 12 is depressed,
the shut-off valve 55 is opened, as well as the delivery valve 60, and liquid aerosol
composition can be drawn up through the dip tube 52 into the valve chamber 61, while
vapor phase propellant gas from the head space 62 can enter the valve chamber 61 through
the vapor tap orifice 51. Thus, the container acts normally when it is in this position,
and in fact in all positions above the horizontal, since the ball then tends under
gravity to remain in the position shown.
[0091] When however the container is inverted so the delivery valve 60 is below the horizontal,
the ball 58 is free to roll along the side walls of the chamber 54, and when it does
so, it moves against the gas tap orifice 51, closing it off. It is guided thereby
the concave walls of the recess 59. It is held in this position by gravity. This prevents
the escape of liquid propellan through the vapor tap orifice 51 into the passage 53
and from there to the valve stem passage and delivery port, thus avoiding a flame
hazard.
[0092] In this embodiment the pressure bottle has a much smaller opening for the valve assembly
than an aerosol can; in this case, 1. 2 cm in diameter as compared to a 2.5 cm opening
for an aerosol can. The vapor tap valve oi the invention is mounted across this opening
in the cap for the pressure bottle, as in the can embodiments illustrated previously.
The upper neck of the bottle is provided with a bulge, and the pressure bottle cap
is crimped at its lower edge to retain the cap and the valve to the bottle in a leak-tight
seal provided by the rubber gasket.
[0093] The vapor tap valve shown in Figures 7 and 8 utilizes a slide valve as the shut-off
valve. As seen in Figures 7 and 8, the valve housing 70 has a valve chamber 71 at
the upper portion, and a blending chamber or space 72 below the valve chamber. A wall
73 with a central opening 74 separates the valve chamber from the blending space.
[0094] The vapor tap valve 75 has a valve stem 76 with a valve stem orifice 77 therethrough
in flow communication with the valve chamber 71 when the delivery valve is in the
open position. In the closed position, the valve stem orifice 77 is sealed off by
the gasket 9.
[0095] Beyond the valve stem orifice 77, the valve stem 76 extends as a solid rod. In the
other direction the valve stem 76 includes a valve stem passage 78, which is in fluid
flow connection with valve button passages 16 and 17 of the valve button 12 and a
delivery orifice 14 at the end of the valve button passage 17. The solid portion 79
of the valve stem extends all the way across the valve chamber 71, and through the
aperture 74. At the tip end of the stem 79 is a slot 80, which when the valve is in
the open position as shown in dashed lines in Figures 7 and 8 registers with and communicates
the blending space 72 with the valve chamber 71. In the closed position shown in solid
lines, the lower portion of the slot 80 is closed off by the wall 73. Consequently,
all flow from the blending space 72 into the chamber 71 is closed off when the delivery
valve is in the closed position, and the valve chamber cannot therefore be filled
with either gas or liquid from the blending space 72.
[0096] Through the wall of the housing 70 is a vapor tap orifice 81, and a liquid tap orifice
82 in the form of the open capillary passage through a capillary dip tube 83 extending
to the bottom of the container. Since the valve stem 79 is downstream of both the
vapor tap and the liquid tap orifices, neither gas nor liquid can pass into the valve
chamber 71 when the valve is. closed.
[0097] Slidably retained within the blending space 72 is a shut-off valve 85, in the form
of an annular ring, with a central aperture 86 therethrough. The ring is free to slide
within the blending space 72. When the valve is in the upright position, as shown
in Figures 7 and 8, the ring is at the lower portion of the blending space. When the
valve is inverted, the ring falls by gravity to the other end of the blending space,
abutting the solid portion 79 of the valve stem.
[0098] The liquid aerosol composition is stored in the portion 21 of the container, and
the dip tube 83 extends through the lower portion 21 of the container into blending
space 72, being inserted into one end of this space through the open end of the valve
housing 70. The dip tube puts the liquid phase 29 in the bottom of the container in
flow connection with the blending space 72. The vapor tap orifice 81 communicates
the upper portion 22 of the container with the blending space 72, and thus puts the
gas phase in the upper portion of the container in flow connection with the blending
space 72.
[0099] The slide valve 85 has a valve body of metal, for example, stainless steel or aluminum,
and the central opening 86 is just wide enough to accommodate the tip end 79 of the
valve stem in sealing relationship. The valve 85 is long enough so that when the valve
is inverted and the valve stem 79 is pushed inwardly b' the button actuator 12 as
far as it can go, the slot 80 is still not in flow communication with the blending
space 72, being closed off by the ring 85. Thus, when the valve is in the inverted
position, with the slide valve 85 at the upper end of the blending space 72, the valve
85 effectively closes off the slot 80, and prevents passage of both liquid and gas
from the blending space 72 into the valve chamber 71, and thence eventually through
the delivery port 14. Accordingiy, a flame hazard when the container is inverted due
to escape of flammable liquid is avoided.
[0100] The vapor tap valve of the invention can be used in any kind of aerosol container
to deliver any aerosol composition in the form of a spray. The range of products that
can be dispensed is diverse, and includes pharmaceuticals for spraying directly into
oral, nasal and vaginal passages, antiperspirants, deodorants, hair sprays, fragrances
and flavors, body oils, insecticides, window cleaners and.other cleaners, spray starches
and polishes for autos, furniture and shoes.