Insert with nozzle formed by micro stepped and conical surfaces

An actuator comprising:

• an actuator outlet being formed within the actuator;
• a post being centrally located within the actuator outlet of the actuator and extending normal to a base surface of the actuator outlet toward an open end of the actuator outlet, and the post comprising diametrically opposed first and second post shoulders;
• an insert being mounted and securely retained within the actuator outlet by an interference fit, and a base of the insert forming a rectangular-shaped discharge nozzle;
• the first and second post shoulders being sized and shaped to engage with an inwardly facing surface of the insert and space a remaining portion of the inwardly facing surface of the insert away from partially recessed outwardly facing surfaces of the post so as to define first and second separate and distinct product flow passages substantially within the post;
• and
• the nozzle being defined within the base of the insert by diametrically opposed first and second stepped shoulders and diametrically opposed first and second conical surfaces formed, and the first and the second stepped insert shoulders being arranged to receive, from a respective one of the first and second product flow passages, and redirect a major portion of the product to be dispensed toward the nozzle, while a pair of diametrically opposed first and second conical surfaces, formed within the base of the insert, being arranged to receive, from a respective one of the first and second product flow passages, and redirect only a minor portion of the product to be dispensed toward the nozzle.

A method of discharging a product to be dispensed from an actuator in a fan spray pattern, the method comprising:

• forming an actuator outlet within the actuator;
• centrally locating a post within the actuator outlet of the actuator and so as to extend normal to a base surface of the actuator outlet toward an open end of the actuator outlet;
• mounting and securely retaining an insert within the actuator outlet by an interference fit, and a base of the insert having a rectangular-shaped discharge nozzle formed therein;
• sizing and shaping first and second alignment protrusions so as to assist with spacing an inwardly facing cylindrical surface of the insert away from an exterior surface of the post and respectively define a first and second partially restricted flow passages between the inwardly facing cylindrical surface and the exterior surface of the post, with first and second unobstructed product flow passages being defined one either side of the first and the second alignment protrusions;
• and
• defining the nozzle within the base of the insert by diametrically opposed first and second stepped insert shoulders and diametrically opposed first and second conical surfaces, the first stepped shoulder being axially aligned with the first partially restricted flow passage and the first conical surface being axially aligned with the first unobstructed flow passage while the second stepped shoulder being axially aligned with the second partially restricted flow passage and the second conical surface being axially aligned with the second unobstructed flow passage so that the product to be dispensed, upon flowing through the actuator and being discharged from the nozzle, is sprayed by the nozzle in a desired fan spray pattern.