Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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SPRAY DEVICES
TECHNICAL FIELD
One aspect of the invention relates generally to hand holdable spray devices.
Another aspect
of the invention relates generally to hand holdable spray devices containing a
composition and a
propellant.
BACKGROUND OF THE INVENTION
There are a number of situations where it may be desirable to spray a
composition
comprising one or more particulates. Some non-limiting examples include
paints, surface cleaners,
polishes and personal care compositions (e.g., an antiperspirant composition).
In some instances, it
may be desirable to utilize one or more of a propellant at a low concentration
to pressurize the
composition, a low composition flow rate, and/or a high particulate
concentration in the composition
to be sprayed. In these and other instances, it may be quite desirable to
reduce or minimize the
potential for clogging within the spray device, and more particularly within a
valve assembly of the
spray device.
USPNs 5,082,652 and 4,396,152 illustrate some examples of spray devices. While
these
designs might work well for their intended purpose, there is a continuing
desire to improve the flow
path design within valve assemblies of spray devices to minimize the potential
for clogging.
Further, there is a continuing desire to improve the flow path design within a
valve assembly in a
manner that is simple to manufacture.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a hand held spray device is
disclosed. The spray
device includes a body with a reservoir, an actuator having a discharge
orifice, a composition stored
within the reservoir that is sprayable from the discharge orifice, a means for
pressurizing the
composition, and a valve assembly attached to the body in fluid communication
with the reservoir.
The valve assembly includes a housing, a valve stem slidably disposed within
the housing and
having a valve bore that is in fluid communication with the discharge orifice,
a valve that seals the
valve bore, and a spring biasing the valve stem and surrounding a lower
portion of the valve stem.
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The valve stem includes a plurality of channels, each channel having an
entrance adjacent a proximal
end of the valve stem and an exit spaced downstream from the distal end of the
spring.
BRIEF DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims, it is believed that the same
will be better
understood from the following description taken in conjunction with the
accompanying drawings
wherein like numbers illustrate like elements throughout the views and in
which:
FIG. 1 is a cross-sectional side view of one example of a spray device;
FIG. 2 is a perspective view of the valve assembly shown in FIG. 1;
FIG. 3 is a side elevation view of the valve assembly of FIG. 2;
FIG. 4 is a cross-sectional side view of the valve assembly of FIG. 3, taken
along line 4-4
thereof;
FIG. 5 is a perspective view of the valve stem shown in FIG. 4;
FIG. 6 is a side elevational view of the valve stem shown in FIG. 5;
FIG. 7 is a cross-sectional side view of the valve stem shown in FIG. 6, taken
along line 7-7
thereof;
FIG. 8 is a bottom plan view of the valve stem shown in FIG. 5;
FIG. 9 is a perspective view of the seal shown in FIG. 4;
FIG. 10 is a cross-sectional view of the valve stem, spring and housing of
FIG. 4, taken
along line 10-10 thereof
FIG. 11 is a perspective view of the valve stem and a portion of the spring
shown in FIG. 4;
and
FIG. 12 is a cross-sectional view of the valve stem and housing of FIG. 4,
taken along line
12-12 thereof;
FIG. 13 is a cross-sectional side elevational view of another embodiment of
the valve
assembly of FIG. 3;
FIG. 14 is a bottom plan view of the cup-shaped insert shown in FIG. 13;
FIG. 15 is a bottom plan view of an alternate embodiment of the cup-shaped
insert shown in
FIG. 13;
FIG. 16 is a cross-sectional side view of an another embodiment of a valve
stem comprising
two valve bores arranged at an angle; and
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FIG. 17 is a cross-sectional plan view of yet another embodiment of a valve
stem, the valve
stem comprising a plurality of scallops and wherein the view is taken at the
same location as line 12-
12 of FIG. 4.
DETAILED DESCRIPTION
A spray device, container, composition, propellant, etc. may comprise, consist
essentially of,
or consist of, various combinations of the materials, features, structures,
and/or characteristics
described herein.
Reference within the specification to "embodiment(s)" or the like means that a
particular
material, feature, structure and/or characteristic described in connection
with the embodiment is
included in at least one embodiment, but it does not mean that all embodiments
incorporate the
material, feature, structure, and/or characteristic described. Furthermore,
materials, features,
structures and/or characteristics may be combined in any suitable manner
across different
embodiments, and materials, features, structures and/or characteristics may be
omitted or substituted
from what is described.
The term "antiperspirant composition" refers to any composition containing an
antiperspirant
active and which is intended to be sprayed onto skin, exclusive of the
propellant. An antiperspirant
composition may be provided in the form of a liquid dispersion (including
suspensions, colloids, or
solutions).
The term "bulking or suspending material" refers to a material which is
intended to reduce
settling of a particulate from a liquid and/or reduce the severity of
particulate caking post settling.
Some non-limiting examples of common bulking or suspending agents include, but
are not limited
to, colloidal silicas and clays.
The term "clogging" refers to either a blocked passage, orifice, hole or other
opening
resulting in little or no mass flow out of a container when the actuator is
activated or a valve stuck at
least partially open from accumulated composition, resulting in semi-
continuous or continuous
leakage of the composition and/or a propellant from a spray device.
The term "composition" refers to any composition intended to be sprayed from a
spray
device, exclusive of propellant.
The term "container" and derivatives thereof refers to the package that is
intended to store
and dispense a composition in a spray type form. A container may typically
comprise at least one
reservoir for storing the composition, a valve for controlling flow of the
composition, and an
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actuator by which a user can actuate the valve. A container may or may not be
configured to store a
propellant.
The term "controlling orifice" refers to the orifice(s), hole(s) or other
opening(s) which
principally control or meter the mass flow of the composition thru container.
In some instances, the
controlling orifice may comprise a plurality of orifices, holes or openings
which are arranged in a
generally parallel fashion with respect to the mass flow of the composition
and which in
combination principally control or meter the mass flow thru the container. The
controlling orifice is
typically the smallest opening(s) thru which the composition flows. The
controlling orifice may
sometimes be the valve opening.
The term "particulate", as used herein, refers to a material that is solid or
hollow or porous
and which is substantially or completely insoluble in the liquid materials of
a composition.
The term "propellant" refers to a gas that is compressed, liquefied or
dissolved under
pressure for the purpose of pressurizing the composition to facilitate egress
of the composition from
container. A propellant may or may not be used to atomize the composition upon
exiting the
container.
The term "spray device" refers to the combination of a container and a
composition that is
intended to be sprayed from the spray device. A spray device may or may not
contain a propellant.
The term "substantially free" refers to an amount of a material that is less
than 1%, 0.5%,
0.25%, 0.1%, 0.05%, 0.01%, or 0.001% by weight of a composition.
The term "total fill" refers to the total amount of materials added to or
stored within a
reservoir(s) of a container. For example, total fill includes the propellant
and composition stored
within a spray device after completion of filling and prior to first use.
Various spray devices, containers, and compositions will now be described. The
spray
devices and containers incorporate a novel valve stem and spring arrangement
within a valve
assembly that may reduce or minimize clogging within the valve assembly.
I. SPRAY DEVICES
Referring to FIG. 1, one non-limiting example of a spray device is shown. The
spray device
100 comprises a container 102, a liquid propellant 104, and a composition 106
that is sprayable from
the spray device. It will be appreciated that the propellant 104 and
composition 106 are merely
shown for purposes of illustration in FIG. 1, and FIG. 1 is not intended to
limit in any way the
arrangement of the propellant and composition within the container 102. For
example, in some
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instances the propellant and the composition are miscible such that distinct
layers may not be visible.
The spray device 100 may be shaped and configured so that it is hand-holdable.
The container 102
comprises a body 108, an actuator 110 having a discharge orifice 112, and a
valve assembly 114 in
fluid communication with a reservoir 118 storing the composition 106 and/or
liquid propellant 104.
5 Optionally, a dip tube 119 may extend into the reservoir 118. A gaseous
propellant 120 may fill the
headspace of the reservoir 118.
While reservoir 118 may be defined by one or more interior surfaces of the
body 108, it will
be appreciated that other reservoir arrangements may be provided. For example,
the reservoir may
be provided as a separate structure apart from the body 108. In one
embodiment, the reservoir may
be provided in the form of a collapsible bag that is disposed within the body
108 as a reservoir for
storing the composition, sometimes referred to as a "bag on valve"
arrangement. In this
arrangement, the reservoir (bag) may store the composition 106 but no
propellant. The collapsible
bag (and hence the composition) may be pressurized by a propellant stored
under pressure exterior to
the bag (e.g., in the space between bag the interior surface of the body 108)
so as to exert pressure on
the bag. In another arrangement, the elasticity of the bag may be sufficient
to pressurize the
composition without using a propellant. Bag on valve arrangements may or may
not include a dip
tube. While one reservoir is shown in the FIG. 1, a plurality of reservoirs
may also be provided.
The body 108, actuator 110 and valve assembly 114 may be provided in a wide
variety of
configurations, shapes, and sizes.
VALVE ASSEMBLIES
The valve assemblies described hereafter are suitable for use in variety of
spray devices,
including spray devices where a mixture of a liquid propellant and a
composition flow thru the valve
assembly; or a mixture of a liquid propellant, a gaseous propellant and a
composition flow thru the
valve assembly; or a composition only flows thru the valve assembly; or a
mixture of a composition
and a gaseous propellant flow thru the valve assembly. For example, in
embodiments where a liquid
propellant is combined with a composition in a single reservoir, such as shown
in FIG. 1, a mixture
of the composition and liquid propellant typically flows up the dip tube, thru
the valve assembly, and
out of the discharge orifice of the actuator. The liquid propellant vaporizes
upon exiting the
actuator, resulting in atomization of the composition. In contrast, in a bag
on valve type
embodiment, the composition (but typically no propellant) flows thru the valve
assembly and out of
the discharge orifice of the actuator.
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Referring to FIGS. 1 to 4, one non-limiting example of a valve assembly 114
which may be
attached to the body 108 is shown. The valve assembly 114 comprises a slidably
disposed valve
stem 124 to which the actuator 110 attaches, a mounting flange 128 for
attaching the valve assembly
114 to the body 108 (such as by crimping), and a housing 130 attached to the
mounting flange 128.
The housing 130 may be attached by a variety of means to the mounting flange,
as known in the art,
including by a press fit, positive latching, welding, etc. The housing 130
contains a spring 132 that
biases the valve stem 124. The spring 132 may comprise a plurality of coils or
be provided in other
forms, such as an elastomeric bellows.
Turning to FIGS. 5 to 8, one non-limiting example of a novel valve stem will
now be
described. The valve stem 124 comprises a core 142 having an upper portion 144
and a lower
portion 146. The upper portion 144 has a distal end 148 and is configured to
be attachable to the
actuator 110. The lower portion 146 is configured to position at least a
portion of the spring 132
there about. The lower portion 146 has a proximal end 150. The proximal end
150 may have a flat
surface thereat, may be tapered, may be formed by a combination of the
foregoing, or may have
some other conformation which preferably minimizes the potential for
accumulation of a
composition at the proximal end 150. One or more valve bores 152 (two being
shown in the FIGS.)
may be disposed between the upper portion 144 and the lower portion 146. The
valve bore 152 is
shown, for purposes of illustration only, arranged in a radial direction with
respect to the
longitudinal axis of the valve stem 124. The one or more valve bores 152 open
into a wall 154 of a
groove 156 and communicate with an axial bore 158 that extends from the one or
more valve bores
152 to the distal end 148 of the upper portion 144. It will be appreciated
that the terms "radial" and
"axial", and derivatives thereof (e.g., radially and axially), are intended to
merely refer to a general
direction with respect to a feature or structure, and these terms are
intended, unless expressly stated
otherwise, to be fully inclusive of directions that are not purely radial or
axial, such as substantially
radial/axial directions and combinations of radial and axial directions where
the net overall
directional effect is more radial than axial or vice versa. The axial bore 158
in turn communicates
with the actuator 110 when it is attached to the valve stem 124.
The one or more valve bores 152 may function as a controlling orifice that
principally
controls the mass flow of the composition or a mixture of the composition and
a propellant thru the
container. It will be readily appreciated that other openings, passages or
holes in the valve stem or
elsewhere may function as the controlling orifice. The one or more valve bores
may have a total
cross-sectional area from about 0.01 mm2 to about 1 mm2, or about 0.03 mm2 to
about 0.5 mm2, or
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about 0.06 mm2 to about 0.1 mm2. The one or more valve bores may have a
maximum dimension,
typically a diametrical dimension, from about 0.1 mm to about 1 mm, or from
about 0.2 mm to about
0.8 mm, or from about 0.3 mm to about 0.5 mm. In a specific embodiment, the
valve stem 124
comprises one valve bore 152 having a diameter from about 0.3 mm to about 0.4
mm.
Referring to FIGS. 4 and 9, mating sealing surfaces formed by an inner wall
160 of a
substantially flat seal 162 and the wall 154 of the groove 156 form a valve
that seals the valve bore
152. The seal 162 may be formed from an elastomeric material, such as nitrile
butadiene rubber
(sometimes referred to as Buna-N). The seal 162 may be disposed about the core
142 of the valve
stem and sandwiched between the mounting flange 128 and the housing 130, as
shown by way of
example in FIG. 4. The sealing surfaces are mated when the valve stem is not
depressed, as shown
in FIG. 4, thereby preventing flow of the composition or a mixture of the
composition and a
propellant thru the valve bore 152. When the actuator 110 is depressed, the
sealing surfaces
separate, thereby permitting the composition or a mixture of the composition
and a propellant to
flow through the valve bore 152 to the axial bore 158 and onto the actuator
110. As used herein, the
term valve (as opposed to valve assembly) is intended to merely refer to the
mating sealing surfaces
that permit or prevent flow of the composition or a mixture containing the
composition from the
reservoir 118 to the actuator 110. The mating sealing surfaces may be provided
in configurations
other than shown in the FIGS and described herein. In some specific
embodiments, the valve may
be a continuous flow valve, meaning there is flow through the valve for as
long as the actuator is
depressed. In contrast, a non-continuous or metered valve allows only
predetermined amount of
flow thru the valve regardless how long the actuator is depressed.
Referring again to FIGS. 5 to 8 and to FIG. 10, the core 142 further comprises
one or more
channels 160, the channel 160 having an entrance 162 disposed at or adjacent
to the proximal end
150 and an exit 164. The channels 160 may extend axially along the valve stem
124. The core 142
may comprise from about 2 to about 8 channels or from about 4 to about 6
channels, although more
channels may be provided if desired. The channels may be equi-spaced about the
circumference of
the core 142. The exit 164 of the channel 160 is located at terminal end of
the channel 160. In some
specific embodiments, at least a portion of the channel 160 may be configured
to direct the
composition or a mixture comprising the composition and a propellant from an
interior annular
volume 166 (FIG. 10) to an outer surface of the valve stem 124, such as for
example cylindrical
surface 168 (FIG. 5) of ring 169, that is disposed downstream of the spring
132. The interior
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volume 166 may be defined by at least a portion of the spring 132 and the
lower portion 146 of the
core 142. At least a portion of the spring 132 surrounds at least a portion of
the channels 160.
A wide variety of channel configurations may be provided. The channel 160 may
be formed
or defined in part by a pair of walls 170, which may extend radially from the
valve stem core as
shown in the FIGS. The walls 170 transmit a portion of the spring force to the
ring 169, the latter
providing additional structural integrity to the walls 170. The ring 169 also
provides a load bearing
surface to act against the seal 160 to return it to a closed or sealed
position when the actuator is
released. The valve stem 124 may comprise 3, 4, 5, 6, 7, 8 or more radially
extending walls. Each
wall 170 may have a bearing surface 171 that centers the valve stem 124 within
the housing 130 and
which slidably engages the housing 130. The bearing surface 171 may be
substantially flat and
rectangular in shape, although other shapes and surface contours may be
provided. It is believed that
a slidable valve stem 124 having too few walls 170 may not center very well
within the housing 130,
and a valve stem 124 having too many walls may reduce the cumulative exit area
of the channels too
much, thereby potentially increasing the risk of clogging. In some instances,
the walls 170 may have
an overall length L (FIG. 6) from about 2 mm to about 9 and a width W (FIG. 8)
from about 0.25
mm to about 1.3 mm.
Each wall 170 may have a notch 172 that receives a distal end or a portion 174
of the spring
132, the distal end 174 of the spring being located closest to the valve
compared to a proximal end of
the spring 132 which is located furthest from the valve. In other words, the
distal end of the spring is
located downstream of the proximal end of the spring and the valve is in turn
located downstream of
the distal end of the spring. While only a portion (e.g., about 3 coils) of
spring 132 is shown in FIG.
4 within the notch 172 (when the valve stem is not depressed), it will be
appreciated that in some
embodiments more of the spring or even the entire spring 132 may be received
within the notch 172.
In some specific embodiments, the notch 172 may be configured to receive from
about two to about
six coils of the spring 132 (when the valve stem is not depressed), wherein a
last coil of the spring
132 bottoms on a surface 176 of the notch 172 of the wall 170. The surface 176
may be
substantially flat. The last coil of the spring 132 may have one or more free
portions 178 (FIG. 11)
extending between the walls 170, wherein the free portion does not bottom on a
surface (e.g., surface
176) of the valve stem 124. The notch 172 may have a notch depth D (FIG. 7)
from about 0.4 mm
to about 1 mm and a notch length NL (FIG. 11) from about 0.5 mm to about 3.5
mm.
At least a portion of a channel 160, together with its exit 164, may be
disposed axially
downstream of the notch 172 and/or the last coil/distal end of the spring 132.
In other words, the
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exit 164 of the channel 160 may be spaced apart from the last coil of the
spring 132 and/or the notch
172 so that at least a portion of the composition or a mixture of the
composition and propellant may
exit from the interior volume 166 without passing between a pair of adjacent
coils of the spring
and/or between the last coil of the spring 132 and the surface upon which it
bottoms. The exit 164
may be disposed between the notch 172 and the valve and/or valve bore 152. For
example, the exit
164 of the channel 160 may be located from about 1 mm to about 5 mm from the
last coil of the
spring 132 and/or the notch 172. In other instances, exit 164 of the channel
160 may be located at or
adjacent to the last coil of the spring 132 and/or the notch 172.
A channel 160 may have an exit area from about 0.6 mm2 to about 3 mm2,
although it will be
appreciated that larger or smaller exit areas may be provided. As used herein,
the term exit area with
respect to a channel 160 refers to the cross-sectional area at the exit 164
that is defined by the walls
170, inner surface 180 (FIG. 12) of the housing 130 that is adjacent the exit
164, and channel bottom
surface 182 at the exit 164. The cumulative exit area for all of the channels
160 of the valve stem
124 may be from about 2.5 mm2 to about 12 mm2, although it will be appreciated
that larger or
smaller cumulative exit areas may be provided.
In some embodiments, at least a portion of the channel bottom surface 182 may
have a shape
or conformation that directs the flow of the composition or a mixture of the
composition and a
propellant toward the outer surface 168 of the ring 169. In some embodiments,
at least some,
substantially all, or all of the channel bottom surface 168 may have a concave
type conformation for
directing the flow from the interior volume 166 to the exterior of the stem
124. FIG. 5 illustrates
one non-limiting example of a channel having a bottom surface that is
partially concave.
An annulus or gap 184 (FIG. 12) may be provided downstream of the exit 164 of
the channel
160 that allows the composition (or a propellant/composition mixture) exiting
the channels 160 to
flow downstream to the valve. The annulus 184 may be defined by the outer
surface 168 of the
valve stem 124 and the inner surface 180 of the housing 130. The outside
diameter of the outer
surface 168 may be from about 1.5 mm to about 11 mm while the outside diameter
defined by the
walls 170 may be slightly less, although it will be appreciated that larger or
smaller dimensions may
be provided. The inside diameter of the inner surface 180 may be from about
2.5 mm to about 12
mm. The annulus 184 may have a cross-sectional area from about 3 mm2 to about
10 mm2. The
annulus 184 may have a radial dimension there across from about 0.25 mm to
about 10 mm.
The novel valve stem configuration allows the composition (or a propellant
containing
mixture thereof) to flow from the reservoir, thru the interior volume 166, and
exit downstream of the
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last coil the spring 132 and into the annulus 184. It is believed that this
flow path, which minimizes
the amount of composition exiting between the spring coils, may reduce the
accumulation of
composition about the spring and thereby potentially minimize the risk of
clogging, particularly
where the composition comprises a high concentration of particulates, a low
propellant concentration
5
is utilized and/or a low composition mass flow rate is desired. Composition
mass flow rates less
than 0.3 g/sec, or from about 0.1 g/sec to about 0.3 g/sec, may be
particularly suitable for use with
the valve assemblies and spray devices described herein. Further, the novel
valve stem and spring
arrangement may advantageously permit a more open flow path past the lower
portion 146 of the
core 142 to the valve, as structures used to center the valve stem 124 within
the housing 130 (e.g.,
10
the bearing surface 171) are independent of or do not otherwise form part of
the flow path as in some
conventional valve assemblies.
In another embodiment, the valve assembly 114 may further comprise a vapor tap
for mixing
gaseous propellant from the headspace of the reservoir 118 with the
composition. Some non-
limiting vapor tap configurations suitable for use are described in USPN
4,396,152. Referring to
FIGS. 13 to 15, the housing 230 may comprise a one or more holes 186 for
permitting gaseous
propellant to pass from the reservoir 118 into the interior of the housing
230. A cup-shaped insert
188 may be installed within the housing 230 between the dip tube and the valve
stem 124. The cup-
shaped insert 188 may be press-fit within the housing 230 or otherwise
retained within the housing
by other means known in the art. The cup-shaped insert 188 may receive one end
of the spring 132.
An insert bore 192 may be provided in a bottom wall of the cup-shaped insert
188, thereby
permitting the composition to flow from the dip tube 116 into the interior of
the cup-shaped insert
188. Referring to FIGS. 14 and 15, one or more passages 194 may be provided in
the bottom wall
of the cup-shaped insert to direct gaseous propellant from the interior of the
housing 130 into the
insert bore 192, where it mixes with the composition. The passages 194 may be
aligned tangentially
with the insert bore 192, as shown by way of example in FIG. 14, or the
passages 194 may be
aligned radially with the insert bore 192, as shown by way of example in FIG.
15. The passages 194
may also be aligned in other configurations with the insert bore 192, such as
intermediate between a
tangential arrangement and a radial arrangement. While a vapor tap arrangement
may be useful in
some instances, the valve assembly need not comprise a vapor tap or a cup
shaped insert.
While the passages 194 are shown as generally rectangular in cross-sectional
shape, it will be
appreciated that the passages 194 may be provided in other shapes and sizes.
Similarly, the various
bores, holes, and orifices may be provided in shapes and sizes other than
shown/described herein.
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Further, while the vapor tap arrangements shown in FIGS. 13 to 15 permit
gaseous propellant to mix
with the composition upstream of the valve, other vapor tap arrangements (or
no vapor tap) may be
implemented as known in the art. For example, a vapor tap arrangement may be
provided where the
gaseous propellant mixes downstream of the valve, perhaps still within the
valve assembly 114 or
within the actuator 110. Multiple vapor tap arrangements may also be provided.
For example, a first
vapor tap arrangement might provide for mixing of gaseous propellant and the
composition upstream
of the valve 138 while a second vapor tap arrangement might provide for mixing
of additional
gaseous propellant and the composition downstream of the valve.
While the valve assembly 114 is shown herein as comprising a variety of
components, it is
contemplated that these components may be changed, combined, deleted, or other
components or
structures substituted therefor without departing from the spirit and/or scope
of the various
invention(s) described herein. For example, FIG. 16 illustrates a valve stem
comprising two valve
bores 352 that are angled relative to the longitudinal axis of the valve stem,
and FIG. 17 illustrates a
valve stem comprising a ring with one or scallops 496 disposed within the
outer surface of the ring.
Each of the scallops is aligned with the exit of one of the channels so as to
further increase the exit
area of the channel, thereby further reducing the likelihood of clogging. In
this later embodiment,
the composition exits the channels, flows thru the scallops 169 and/or the
annulus 184 and onto the
valve.
PROPELLANTS
A spray device may optionally comprise a propellant. The propellant may be
stored in a
reservoir containing the composition to be sprayed, or the propellant may be
stored separately, as in
the case of bag on valve type arrangement. A propellant may be utilized to
pressurize the
composition, thereby providing a means to drive the composition thru and out
of the spray device.
The propellant may also be used to atomize the composition upon exiting the
spray device, as is
typical in an aerosol type application. A propellant may also mix with the
composition to produce a
mousse or foam upon spraying. Alternatively, a non-propellant compressed or
liquefied gas may be
incorporated in the composition for producing a mousse or foam upon spraying.
For example, a first
compressed or liquefied gas might be provided for producing a foaming
composition while a second
compressed or liquefied gas might function as a propellant. If a vapor tap
arrangement is provided,
gaseous propellant from the head space of the reservoir may also be used to
swirl or break up the
composition within the valve assembly.
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The propellant may have a concentration from about 3%, 10%, 20%, 30%, 32%, 34%
36%,
38%, 40%, or 42% to about 85%, 75%, 65%, 60%, 54%, 52%, 50%, 48%, 46%, 44%, or
42% by
weight of the total fill of materials (i.e., propellant and composition)
stored within the spray device.
The novel valve stems described herein may be particularly useful in aerosol
type spray devices
utilizing low liquid propellant concentrations (e.g., from about 30% to about
60% of the total fill), as
lower propellant concentrations may result in less dilution of the composition
thereby potentially
increasing the risk of clogging compared to higher propellant concentrations.
This risk of clogging
may be further compounded in instances where the composition also comprises a
high particulate
concentration.
A wide variety of propellants may be used with the spray devices and
compositions described
herein. Some propellants may have a boiling point (at atmospheric pressure)
within the range of
from about ¨45 C. to about 5 C. The propellants are may be liquefied when
packaged in the
container under pressure. Suitable propellants may include chemically-inert
hydrocarbons such as
propane, n-butane, isobutane and cyclopropane, and mixtures thereof, as well
as halogenaed
hydrocarbons such as dichlorodifluoromethane (propellant 12) 1,1-dichloro-
1,1,2,2-tetrafluoroethane
(propellant 114), 1-chloro-1,1-difluoro-2,2-trifluoroethane (propellant 115),
1-chloro-1,1-
difluoroethylene (propellant 142B), 1,1-difluoroethane (propellant 152A),
dimethyl ether and
monochlorodifluoromethane, and mixtures thereof. Some propellants suitable for
use include, but
are not limited to, A-46 (a mixture of isobutane, butane and propane), A-31
(isobutane), A-17 (n-
butane), A-108 (propane), AP70 (a mixture of propane, isobutane and n-butane),
AP40 (a mixture of
propane, isobutene and n-butane), AP30 (a mixture of propane, isobutane and n-
butane), HF01234
(trans ¨ I ,3,3,3-tetrafluoropropene) and 152A (1,1 diflouroethane).
COMPOSITIONS
A wide variety of compositions may be sprayed from a spray device. While the
discussion
hereafter is primarily directed to antiperspirant compositions for purposes of
illustration, it will be
appreciated that this is a non-limiting example of only one type of
composition suitable for use with
the containers and spray devices previously described. Further, it will be
appreciated that the
ingredients, concentrations, and other features described with respect to the
antiperspirant
compositions described hereafter may be applicable in whole or part to other
compositions suitable
for use with the containers and spray devices described herein. Some non-
limiting examples of
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antiperspirant compositions are set forth in commonly assigned application
USSN 61/701,201 filed
September 14, 2012.
An antiperspirant composition may comprise one or more liquid materials. In
some specific
embodiments, an antiperspirant composition may comprise at least one non-
volatile or volatile
silicone fluid as a liquid carrier for the one or more antiperspirant actives
and/or other ingredients of
the antiperspirant composition. Preferably, the antiperspirant composition
comprises a non-volatile
silicone fluid. As used herein, the term "non-volatile" refers to a material
that has a boiling point
above 250 C (at atmospheric pressure) and/or a vapor pressure below 0.1 mm Hg
at 25 C. A non-
volatile silicone fluid may advantageously improve adherence of the
antiperspirant active to a skin
surface, thereby possibly improving the efficacy of the antiperspirant
composition. Further, an
antiperspirant composition comprising a non-volatile silicone fluid may reduce
the risk of clogging,
as the antiperspirant composition is less susceptible to drying within the
valve assembly. However,
high concentrations of a non-volatile silicone fluid in an antiperspirant
composition may lead to the
perception of a wet feel in use, which may be undesirable for some consumers.
The total concentration of non-volatile, silicone fluids may be from about
40%, 45%, 50% to
about 70%, 65%, 60%, or 55% by weight of an antiperspirant composition. In
some embodiments,
the total concentration of non-volatile, silicone fluids may be from about 45%
to about 55% by
weight of an antiperspirant composition. The liquid materials of the
antiperspirant composition may
consist essentially of or are primarily formed from one or more non-volatile,
silicone fluid(s). Some
non-volatile, silicone fluids that may be used include, but are not limited
to, polyalkyl siloxanes,
polyalkylaryl siloxanes, and polyether siloxane copolymers, and mixtures
thereof. Some preferred
non-volatile silicone fluids may be linear polyalkyl siloxanes, especially
polydimethyl siloxanes
(e.g., dimethicone) having the molecular formula of (C2H60Si)11. These
siloxanes are available, for
example, from Momentive Performance Materials, Inc. (Ohio, USA) under the
tradename Element
14 PDMS (viscosity oil). Silicones Fluids from Dow Corning Corporation
(Midland, Mich., USA)
available under the trade name Dow Corning 200 Fluid series (e.g., 10 to 350
cps). Other non-
volatile silicone fluids that can be used include polymethylphenylsiloxanes.
These siloxanes are
available, for example, from the General Electric Company as SF 1075 methyl
phenyl fluid or from
Dow Corning as 556 Fluid. A polyether siloxane copolymer that may be used is,
for example, a
dimethyl polyoxyalkylene ether copolymer fluid. Such copolymers are available,
for example, from
the General Electric Company as SF-1066 organosilicone surfactant. The non-
volatile, silicone fluid
may have an average viscosity from about 5 centistokes, 10 centistokes, 20
centistokes, or 50
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centistokes to about 900 centistokes, 500 centistokes, 350 centistokes, 100
centistokes or 50
centistokes at 25 C. In some specific embodiments, the silicone fluid may have
a viscosity about 50
cs.
While it may be desirable for the liquid materials of the antiperspirant
composition to consist
essentially of or be primarily formed from non-volatile silicone fluids, other
liquid materials may be
included in an antiperspirant composition. Some non-limiting examples include
a silicone gum or a
liquid perfume material. The liquid materials of the antiperspirant
composition may comprise less
than 30%, 20%, 10%, or less than 5% by weight of liquid materials other than
non-volatile, silicone
fluids. Said in another way, the liquid materials of the antiperspirant
composition may comprise
more than 70%, 75%, 80%, 85%, 90% or about 100% by weight of non-volatile
silicone fluids.
Some suitable silicone gums include silicone polymers of the dimethyl
polysiloxane type,
which may have other groups attached, such as phenyl, vinyl, cyano, or
acrylic, but the methyl
groups should be in a major proportion. Silicone polymers having a viscosity
below about 100,000
centistokes (molecular weight below about 100,000) at 25 C. are not
considered silicone gums here
but are rather, typically, considered a silicone fluid. One non-limiting
example of silicone gum
suitable for use is a silicone/gum fluid blend comprising a dimethiconol gum
having a molecular
weight form about 200,000 to 4,000,000 along with a silicone fluid carrier
with a viscosity from
about 0.65 to 100 mm2 s-1. An example of this silicone/gum blend is available
from Dow Corning,
Corp. of Michigan, USA under the trade name DC-1503 Fluid (85% dimethicone
fluid/15%
dimethiconol). Other silicone gum materials include SF1236 Dimethicone, SF1276
Dimethicone,
and CF1251 Dimethicone available from Momentive Performance Materials, Inc. of
NY, USA.
An antiperspirant composition may also optionally comprise one or more liquid
fragrance
materials. Liquid fragrance materials are typically a mixture of perfume or
aromatic components
that are optionally mixed with a suitable solvent, diluent or carrier. Some
suitable solvents, diluents
or carriers for the perfume components may include ethanol, isopropanol,
diethylene glycol
monoethyl ether, dipropylene glycol, diethyl phthalate, triethyl citrate, and
mixtures thereof. An
antiperspirant composition may comprise from about 0.5%, 0.75% or 1% to about
4%, 3%, 2%, or
1.5% of a liquid fragrance material. The perfume component may be any natural
or synthetic
perfume component known to one skilled in the art of creating fragrances.
It may also be desirable to include a high concentration of particulates in an
antiperspirant
composition. Incorporating a high concentration of particulates is one means
believed to improve
the skin feel of an antiperspirant composition comprising a high concentration
of a non-volatile
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silicone fluid. It is believed that an antiperspirant composition comprising a
total non-volatile liquid
material to total particulate material ratio (L/P ratio) from about 0.6, 0.8,
1, 1.2, or 1.4 to about 2.3,
2.2, 2.1, 2, 1.9, 1.8 or 1.6 may balance the tradeoff between enough
particulates to provide
acceptable skin feel while minimizing the appearance of residue. An
antiperspirant composition
5 may have a total particulate concentration from about 30%, 35%, or 40% to
about 60%, 55%, or
50% by weight of the antiperspirant composition, in keeping with the total
liquid to total particulate
(L/P) ratios previously described. While increasing the concentration of
particulates may improve
skin feel, it may also lead to an increased risk of clogging. The novel valve
assemblies previously
described may be particularly suited for use with these types of
antiperspirant compositions to
10 reduce or minimized the likelihood of clogging.
Some examples of particulate materials that may be included in an
antiperspirant
composition include but are not limited to antiperspirant actives, powders
(such as tapioca starch,
corn starch), encapsulated fragrance materials and bulking or suspending
agents (e.g., silicas or
clays). Other types of particulates may also be incorporated in an
antiperspirant composition.
15 An antiperspirant composition may comprise from about 16%, 18%, 20%,
22%, or 24% to
about 34%, 32%, 30%, 28%, or 26% by weight of a particulate antiperspirant
active. These
antiperspirant active concentrations refer to the anhydrous amount that is
added. Some examples of
suitable antiperspirant actives include astringent metallic salts,
particularly including the inorganic
and organic salts of aluminum. Some exemplary aluminum salts that can be used
include aluminum
chloride and the aluminum hydroxyhalides having the general formula Al2(OH)
aQbXH20 where Q is
chloride, bromide, or iodide (preferably chloride), a is from about 2 to about
5, and a+b=about 6, and
a and b do not need to be integers, and where X is from about Ito about 6, and
X does not need to be
an integer. Particularly preferred are the aluminum chlorhydroxides referred
to as "5/6 basic
chlorhydroxide" wherein "a" is 5 and " 2/3 basic chlorhydroxide" wherein "a"
is 4. Aluminum salts
of this type can be prepared in the manner described more fully in USPNs
3,887,692; 3,904,741; and
4,359,456. Preferred compounds include the 5/6 basic aluminum salts of the
empirical formula
Al2(OH)5DI2H20; mixtures of AIC136H20 and Al2(OH)5Cl2H20 with aluminum
chloride to
aluminum hydroxychloride weight ratios of up to about 0.5.
Some other non-limiting particulate materials that may be optionally included
in an
antiperspirant composition include, but are not limited to, native starches
such as tapioca, corn, oat,
potato and wheat starch powders. These particulates may be hydrophilic or
hydrophobically
modified (the later tending to only be moderately hydrophobic). One
particulate material believed to
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be particularly suitable for use is a hydrophilic or hydrophobically modified
tapioca material,
preferably a hydrophilic tapioca material. Tapioca is a starch which may be
extracted from the
cassava plant, typically from the root, which may then be processed or
modified as known in the art.
Tapioca starches are, advantageously, substantially non-allergenic. One non-
limiting example of a
hydrophobically modified tapioca material suitable for use comprises a
silicone grafted tapioca
starch, which is available under the trade name Dry Flo TS from AkzoNobel of
the Netherlands.
The INCI name is tapioca starch polymethylsilsesquioxane and may be produced
by a reaction of
methyl sodium siliconate (polymethylsilsesquioxane) and tapioca starch. This
silicone grafted
tapioca starch is commercially available as CAS No. 68989-12-8. The silicone
grafted tapioca starch
can be formed using any known means, including, but not limited to those
methods described in
USPNs 7,375,214, 7,799,909, 6,037,466, 2,852,404, 5,672,699, and 5,776,476.
Other non-limiting
examples of hydrophobically modified tapioca starch materials that are
suitable for use include Dry
Flo AF (silicone modified starch from Akzo Nobel), Rheoplus PC 541 (Siam
Modified Starch),
Acistar RT starch (available from Cargill) and Lorenz 325, Lorenz 326, and
Lorenz 810 (available
from Lorenz of Brazil).
In some specific embodiments, the tapioca material may be hydrophilic in order
to facilitate
release of the antiperspirant active during use. One non-limiting example of a
hydrophilic tapioca
starch material suitable for use is available under the trade name Tapioca
Pure available from Akzo
Nobel. A tapioca starch material may have a concentration from about 2%, 4%,
6%, 8%, 10%, or
15% to about 40%, 35%, 30%, 25% or 20% by weight of the antiperspirant
composition.
An antiperspirant composition may optionally comprise one or more encapsulated
fragrance
materials for masking malodors, absorbing malodors, or which otherwise provide
the antiperspirant
compositions with a desired aroma during use. As used herein, the phrase
"encapsulated fragrance
material" refers to the combination of a perfume component and a carrier for
encapsulating the
perfume component. Encapsulated fragrance materials also refer to "empty"
carriers (e.g., an
uncomplexed cyclodextrin material) capable of absorbing a fragrance or malodor
in use. The
encapsulated perfume components may be released by moisture whereby upon being
wetted, e.g., by
perspiration or other body fluids, the encapsulated perfume component is
released. Alternatively or
in addition thereto, the perfume components may be released by fracture of the
carrier, such as by
the application of pressure or a shearing force. Encapsulated fragrance
materials may be provided in
a particulate form which would be considered part of the total particulate
concentration of the
antiperspirant composition. An antiperspirant composition may comprise from
about 0.25% to about
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5%, or from about 0.5% to 5%, or from about 0.5% to about 4% by weight of the
antiperspirant
composition of an encapsulated fragrance material. Examples of some carriers
suitable for
encapsulating a perfume component include, but are not limited to,
oligosaccharides (e.g.,
cyclodextrins), starches, polyethylenes, polayamides, polystyrenes,
polyisoprenes, polycarbonates,
polyesters, polyacrylates, vinyl polymers, silicas, and aluminosilicates.
Some examples of
encapsulated fragrance materials are described in US PNs 2010/0104611;
2010/0104613;
2010/0104612; 2011/0269658; 2011/0269657; 2011/0268802; 5,861,144; 5,711,941;
8,147,808; and
5,861,144.
An antiperspirant composition may optionally comprise one or more particulate
bulking or
suspending agents. While it may be desirable to include some amount of a
particulate bulking or
suspending agent, such as a clay and/or a silica material, it is believed that
a total concentration by
weight of the antiperspirant composition of less than 2%, 1.5%, 1%, 0.5%, or
0.25% of a particulate
bulking or suspending agent is preferred in order to minimize clogging and
achieve an appropriate
overall viscosity. The bulking or suspending agent may be hydrophobic,
hydrophilic, or comprise
mixtures thereof. In some specific embodiments, these materials may be
hydrophilic in order to
facilitate release of the antiperspirant active during use. Some examples of
silica materials that may
be used include, but are not limited to, colloidal silicas. Some non-limiting
examples of silica
materials are available from Evonik Industries under the trade names Aerosil
2005P, Aerosil 3005P,
and Aerosil R972.
Some examples of clay materials that may be used at a low concentration
include, but are not
limited to, montmorillonite clays and hydrophobic ally treated montmorillonite
clays.
Montmorillonite clays are those which contain the mineral montmorillonite and
may be
characterized by a having a suspending lattice. Some examples of these clays
include but are not
limited to bentonites, hectorites, and colloidal magnesium aluminum silicates.
Clay materials may
be made hydrophobic by treatment with a cationic surfactant, such as a
quaternary ammonium
cationic surfactant. One example of a clay material is available from
Elementis Specialities, Plc. of
the UK under the trade name Bentone 38. A clay activator, such as propylene
carbonate or triethyl
citrate, may also be included in the antiperspirant composition.
II. EXAMPLES
Examples 1, 2 and 3 further describe and demonstrate some non-limiting
embodiments of
antiperspirant compositions suitable for use with the spray devices described
herein. The examples
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are given solely for the purpose of illustration and are not to be construed
as limitations of the
invention as many variations thereof are possible without departing from the
spirit and the scope of
the invention.
TABLE 1
Ingredient Example 1 Example 2 Example 3
28 28 19
Aluminum chlorohydratel
48.38 52.3 61.25
Dimethicone
Cyclopentasiloxane2
12
Hydrophobic tapicoa3
12 12
Hydrophilic tapioca4
2
Disodium Hectorite5
0.67
Triethyl citrate
Silicone gum6 1
Hydrophilic silica' 1 1
Hydrophobic silica' 0.25 0.25
Perfume 3.5 3.5 3.5
Betacyclodextrin fragrance 3 3 3
The values are shown on a by weight of the antiperspirant composition basis.
1 86% assay of anhydrous active, average particle size approximately 15
microns.
2 DC 200 Fluid (50 cst) available from Dow Corning
3 Dry Flo TS from Akzo Nobel
4 Tapioca Pure from Akzo Nobel
5 Bentone 38 available from Elementis
6 DC1503 (a mixture of dimethicone and dimethiconol) available from Dow
Corning
7 Aerosil A300 silica from Evonik
8 Aerosil A300 silica from Evonik
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The dimensions and values disclosed herein are not to be understood as being
strictly limited
to the exact numerical values recited. Instead, unless otherwise specified,
each such dimension is
intended to mean both the recited value and a functionally equivalent range
surrounding that value.
For example, a dimension disclosed as "40 mm" is intended to mean "about 40
mm."
Every document cited herein, including any cross referenced or related patent
or application,
is hereby incorporated herein by reference in its entirety unless expressly
excluded or otherwise
limited. The citation of any document is not an admission that it is prior art
with respect to any
invention disclosed or claimed herein or that it alone, or in any combination
with any other reference
or references, teaches, suggests or discloses any such invention. Further, to
the extent that any
meaning or definition of a term in this document conflicts with any meaning or
definition of the
same term in a document incorporated by reference, the meaning or definition
assigned to that term
in this document shall govern.
While particular embodiments of the present invention have been illustrated
and described, it
would be obvious to those skilled in the art that various other changes and
modifications can be
made without departing from the spirit and scope of the invention. It is
therefore intended to cover
in the appended claims all such changes and modifications that are within the
scope of this
invention.
