Conventional aerosol cans are disposable, gas-propelled, and pose significant environmental and safety concerns. They typically contain around 70% liquefied gas and only 30% active product. The gas is flammable, pressurized, and can be harmful to both users and the atmosphere. Our innovation introduces a refillable, propellant-free spray system that ensures users pay only for the actual product, significantly reducing waste, emissions, and hazards.

The system features two independent gas-free compression mechanisms, each optimized for specific applications depending on hygiene, safety, and production efficiency:

1. Mechanical air compression via flexible refill
   This variant uses a dual-chamber refill cartridge shaped like an accordion. The upper chamber holds the liquid, while the lower chamber contains air. A compact servomotor compresses the air chamber to store energy, which is released upon pressing the spray button to atomize the product. Since air never comes into contact with the liquid, this mechanism ensures high product purity, making it ideal for medical, cosmetic, or food-grade applications. The cartridge is removable, reusable, and available in multiple sizes.
2. Mini air compressor with sealed pressure chamber
   This version employs a built-in micro-compressor to pressurize a rigid chamber containing liquid. It includes check valves to prevent backflow, an electronically controlled relief valve for safe depressurization during refills or malfunction, and a mechanical safety valve for overpressure. It is suitable for general-use or industrial sprays that require precise control but not sterile-grade separation.

A fully functional prototype has been developed to validate performance, efficiency, and usability across both systems. The platform is modular and scalable.

Manufacturing process:

• The outer casing is made from aluminum or reinforced polymer, produced via high-pressure die casting or injection molding, depending on material.
• The refill cartridge is manufactured via blow molding or extrusion, using elastomers like silicone, TPE, or LDPE.
• Internal electronics (controller, valves, compressor, display) are designed for automated line assembly.

Target Markets and Applications:

• Medical / Food-grade: drug delivery, antiseptics, edible sprays (flexible refill system).
• Consumer & Cosmetics: moisturizers, perfumes, household cleaners.
• Industrial / Technical: paints, lubricants, solvents (sealed chamber system).

Key Advantages:

• No gas: non-flammable, safe for transport, environmentally friendly.
• Economic: users pay for 100% product, not 70% propellant.
• Modular and refillable: reduces waste and cost.
• Smart-ready: digital fill indicators, alerts, app connectivity.

This innovation offers a modern, safe, and sustainable alternative to traditional aerosols—preserving the practicality of spraying while eliminating the need for pressurized gas.