Nozzle Insert Device and Methods for Dispensing Head Atomizer

A nozzle insert apparatus for insertion into an actuator on a dispenser head on a fluid product dispensing device, comprising:

• a pressure cap defining an interior pressure chamber, the pressure cap including an interior pressure chamber end wall disposed at an axial end of the pressure cap and including a pressure chamber exit orifice defined in the interior pressure chamber end wall, the pressure chamber exit orifice having a diameter D;
• a liquid conduit disposed in the pressure chamber, the liquid conduit including an axial liquid supply channel defined through the liquid conduit, the liquid supply channel terminating at a liquid supply channel exit opening;
• and
• an axial gap defined between the liquid supply channel exit opening and the interior pressure chamber end wall such that the liquid supply channel exit opening is axially offset from the interior pressure chamber end wall by an axial distance H.

A method of ejecting an atomized spray of a a liquid product and a gas propellant from a dispensing head on a dispensing device, comprising:

• (a) providing an actuator having a liquid duct, a gas duct and an actuator socket;
• (b) providing a pressure cap disposed in the actuator socket, the pressure cap forming a pressure chamber between the pressure cap and the actuator and including a pressure chamber exit orifice defined in the pressure cap, wherein the pressure chamber is in fluid communication with the gas duct;
• (c) providing a liquid conduit in the pressure chamber between the pressure cap and the actuator, the liquid conduit including a liquid supply channel defined therein, the liquid supply channel including a liquid supply channel axis and including a liquid supply channel exit opening substantially aligned with the pressure chamber exit orifice;
• (d) supplying a flow of liquid through the liquid supply channel toward the liquid supply channel exit opening;
• (e) supplying a flow of a gas from the gas duct through the pressure chamber toward the liquid supply channel axis between the liquid supply channel exit opening and the pressure chamber exit orifice, wherein the gas intercepts the flow of liquid, travels upstream toward the liquid supply channel exit opening and enters the liquid supply channel exit opening;
• (f) forming a reflux cell inside the liquid supply channel upstream of the liquid supply channel exit opening, wherein the liquid and the gas undergo turbulent mixing in the reflux cell;
• and
• (g) ejecting the liquid from the reflux cell through the pressure chamber exit orifice.