Dual component insert with uniform discharge orifice for fine mist spray

An aerosol actuator for dispensing a pressurized aerosol product, the actuator comprising both:

• a dual component insert comprising:
• a support insert comprising:
• a base wall having a support discharge orifice formed therein;
• a cylindrical wall being formed integral with and extending from the base wall so as to define an insert cavity;
• a single insert disk having a disk discharge orifice;
• a diameter of the disk discharge orifice being smaller than a diameter of the support discharge orifice and ranging between 0.002 of an inch to 0.010 of an inch;
• and
• the single insert disk being received and captively retained within the insert cavity solely by engagement with the base wall and an inwardly facing surface of the cylindrical wall of the support insert such that the disk discharge orifice is axially aligned with the support discharge orifice with a first surface of the single insert disk directly facing and sealing against the base wall of the support insert;
• a spray actuator comprising:
• a housing having an inlet communicating, via a passageway, with an actuator discharge cavity;
• the actuator discharge cavity being opened at one end and having a cylindrical post located therein supporting a mechanical break-up on an end face thereof;
• and
• the dual component insert being received and captively retained within the actuator discharge cavity of the spray actuator so as to seal the opened end of the actuator discharge cavity and facilitate dispensing of the aerosol product through the mechanical break-up and the axially aligned disk and support discharge orifices so that an opposed second surface of the single insert disk, following seating of the support insert in a discharge cavity of the actuator, is in constant direct abutting engagement with a mechanical break-up formed in a leading end of a cylindrical post of the actuator.

An aerosol actuator for dispensing a pressurized aerosol product, the actuator comprising both:

• a dual component insert comprising:
• a support insert comprising:
• a base wall having a support discharge orifice formed therein;
• a cylindrical wall being formed integral with and extending from the base wall so as to define an insert cavity;
• a single insert disk having a disk discharge orifice and the disk discharge orifice having a diameter ranging from 0.0045 of an inch to 0.0055 of an inch;
• the single insert disk having an insert disk diameter ranging from about 0.100 of an inch to about 0.160 of an inch, and the single insert disk having a thickness ranging from about 0.003 of an inch to about 0.007 of an inch;
• a diameter of the disk discharge orifice being smaller than a diameter of the support discharge orifice;
• the single insert disk being received and a peripheral edge of the single insert disk being captively retained within the insert cavity solely by engagement with the base wall and an inwardly facing surface of the cylindrical wall of the support insert such that the disk discharge orifice is axially aligned with the support discharge orifice with a first surface of the single insert disk directly facing and sealing against the base wall of the support insert;
• a spray actuator comprising:
• a housing having an inlet communicating, via a passageway, with an actuator discharge cavity;
• the actuator discharge cavity being opened at one end and the actuator discharge cavity having a cylindrical post located therein supporting a mechanical break-up on an end face thereof;
• the cylindrical post supporting a plurality of spaced apart fins, and each of the plurality of spaced apart fins extending radially from the cylindrical post;
• the dual component insert being received and captively retained within the actuator discharge cavity so as to seal the opened end of the actuator discharge cavity and facilitate dispensing of aerosol product through the mechanical break-up and the axially aligned disk discharge orifice and an opposed second surface of the single insert disk, following seating of the support insert in a discharge cavity of the actuator, directly facing the cylindrical post and directly, abutting against the mechanical break-up formed in the post;
• and
• the spray actuator being supported by a valve stem which is coupled to a valve assembly, an inlet of the valve assembly supporting a dip tube for conveying the aerosol product to be dispensed to the valve assembly, and the valve assembly being secured to a mounting cup.