Note: Descriptions are shown in the official language in which they were submitted.
Background of Invention
This invention relates to the art of containers and,
more particularly, to hand collapsible dispensing containers
and methods of making the same.
Hand collapsible dispensing containers are pro~ided
for a multiplicity of purposes including, for example, the
dispensing of cosmetics, shampoos, foods, dentrlfices and the
like. Such
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~756~7
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containers include a tubular body of deformable material closed
at one end and provided with a closable dispensing head or nozzle
at the other end. Extruded metal tubes have been used for such
container bodies, but the brittleness of metal tubes upon repeated
use, expecially aluminum tubes, and the problems attendant to pro-
viding metal tubes with a satisfactory inner coating to protect
against corrosion and content contamination, have led to the use
of thermoplastics, such as polyethylene, for container body con-
structions. In connection with plastics such as polyethylene,
however, the permeability thereof causes deterioration o~ certain
; products. In this respect, for example, the flavor of den~ifrices
packaged therein deteriorates during storage due to such permeabili-ty.
Moreover, plastic containers absorb oxygen and, over a period of
time, such absorption can decompose the product in the container.
In an effort to avoid these problems, laminated constructions ha~e
been employed which, generally, include a barrier layer of metal
foil intermediate inner and outer layers of a thermoplastic such
as polyethylene.
While such metal, plastic and laminated collapsible
; 20 container constructions have enjoyed a certain degree of success
over the years there are problems attendant to each, including
those mentioned hereinabove, which render the construction thereof
undesirably expensive and/or which limit the materials ~rom which
the containers can be made ~nd the use of the containers with
respect to products packaged therein. In this respect, the tubular
body portion of containers having a laminated body construction
are produced by forming a flat laminate to tubular ~orm wîth over-
lapping edges and then heat sealing the edges to provide a tube
having a longitudinal seam. This, of ~ourse, necessitates com-
,
`- ~30 patability of th~ inner and outer layers of the laminate in order
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~756~7
to achieve a heat seal therebetween and, further, requires these
materials to be thermoplastic ~or the same reason. Thus, selection
of materials is limited as is the use of the container produced due
to such limited material selection. In this respect, even though
S a barrier layer is provided in the laminate, a thin inner ~ayer -~
of plas~ic material is necessary to protect the contents of the
package from the material o~ the barrier and/or to enable heat
sealing of the seam of the tube formed from the laminate. More-
over, as mentioned above, the inner layer must be a thermoplastic
material because of the heat sealing requirement. Accordingly,
while the inner film is made as thin as possible it remains that
a certai~ degree of permeability exists in the completed container.
Heretofore, the compatibili~y requirements for hea~ sealing to
produce a tubular container body have made it impossible to employ
materials in the laminate which would minimize the permeability
problem for the inner layer of the completed container.
With urther regard to a tubular container body including ;~
' a longitudin~l seam, the seam creates problems with respect to ~he
provision of indicia on the tubular body. In this respect, longi-
2~ tudinal seaming of the tubular body makes it necessary to pre-print
the plastic ilm defining the outer layer o~ the laminate by roto-
gravure printing methods, or to provide for one of ~he outer layers
o~ laminate to be a pre-printed paper or plastic, in which case the
. .
outermost laminate would be a transparent plastic material. Such
pre-printing ls expensive thus adding to the per ~mi~ cost o the
completed container and, further, pre-printing necessita~es precision
; in orming the tubular body to avoid misalignment or distor~ion o~
the printed indicia longitud.inally and laterally of the formed tube.
Tha inclusion of a longitudinal heat sealed seam in the tubular body
portion pro~ides an interruption in the otherwise circular outer
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surface contour of the tube and, thus, the tube cannot be printed
upon after formation thereof by less expensive techniques such
as roll printing.
Additionally, the head or nozzle portion of such dispensing
containers, having a body portion of either unitary plastic or
laminated construction, has heretofore been assembled on ~he
tubular body primarily by heat sealing. This again requires com~
patibility between the plastic material of the head and bod~ to
achieve a heat seal and the use of a thermoplastic material for
the head as well as the body of the container. Therefore~ the
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selection of materials for the head is also limited and can possibly
further limit use of the container. Still further, the manufacture
of such previous container structures is time consuming ancl expen-
sive, especially as a result of the heat sealing between the head
~15 and body components. In this respect, time is required to accurately
control heating of the plastic to the fusiQn temperature necessary
for the bond to be obtained, and then considerable time must be
allotted for cooling before the body and head can be removed from
the mandrel or jig on which the assembly takes place. This limits
production rate and, together with special heating, cooling and
pressure applying apparatus, results in an undesirably high per
unit cost for the container. 5uch cost renders the container un-
acceptable in certain product markets in which it would otherwise
be desirable and useful. Additionally, heat sealing can cause
' 25 a loss o structural integrity in the material of the body portion
adjacent the head, resulting in unacceptable containers or containers
subject to rupture during use.
A wide variety of two piece head assemblies have been de-
vised heretofore for mechanical attachment to a tubular body o
paper, metal, plastic or laminated construction. Gene:rally, such
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two piece assemblies receive an axial portion of the body tube end
between the two head pieces so as to clampingly engage the tube
end therebetween. While such a mechanical head and body construc-
tion avoids the heat sealing problems referred to above, the mechan-
ically joined head assemblies heretofQre provided have not been
commercially acceptable. Non-acceptance has resulted from such
problems as inability to obtain an air tight seal, inability ~o
prevent separation of the body and head assembly under the pressure
applied at the joint between the head assembly and the body during
use of the container, and low production rate and high production
costs caused by structural andlor assembly complexity... With regard
to achieving an air tight seal, it will be appreciated that any
leakage path ln the juncture between the.head assembly and body .
is undesirable both because the contents of the container may be
exuded therethrough and/or contaminated b~ contact wi-th air enter-
ing the interior of the container along such a leakage path. Separa~
~ion of the container body and head assembly during use of the
c~ntainer is obviously undesirable in that it renders the container .
useless for its intended dispensing and product storage ~unctions.
With regard to assembly time, million~ o collapsible dispensing .:
containers are produced each year for use in very competitive
markets, and the cost of production and the time required therefor
are extremely importan~ considerations i~ the industry. A number
of mechanically assembled dispensing head arrangements heretofore
provided have required thre.aded interengagement of the head members
or the application of an adhesive between the body tube and head
members, and these assembly steps are time consuming, limit pro-
duction rate and thus result in a higher production cost than is
desirable.
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Summary of Invention
The foregoing and other disadvantages of previous collapsible container
constructions are overcome or avoided by the present invention. In this
respect and in accordance with one aspect of the present invention ! a
hand collapsible container assembly is provided having a laminated body~
structure including an inner layer which is less permeable than those
of laminated body structures heretofore provided. More particularly,
the inner layer of the container body is defined by a thermosetting
plastic material. Preferably, the thermosetting plastic is an epoxy
resin bonded, for example9 to a barrier layer of metal foil. ~n such an
embodim~nt, the foi] and epoxy are formed into a tube ~ith overlapping
sides and the tube is then encased in a plastic sheath, such as by
extrusion. The tubular body thus ~ormed can be assembled with any
suitable head such as by bonding or heat sealing, or wi,th a two piece
head assembly as described hereinafter. The outer plastic sheath enables
the container body portion to be produced without a heat sealed seam,
and this advantageously provides for the tube to be roll printed after ~t
is produced, a much more economical procedure than the pre~printi,ng re~
quirements heretofore dictated by the heat sealed seam tube structure,
Additionally, the plastic sheath maintains the barrier laye~ and inner
layer of epoxy in tubular form and avoids the necessity for heat seal
bonding compatibility between the inner and outer layers. This advantageously
increases the materials which can be used for the laminate. Accordingly,
' it will be appreciated that the laminate may include additional layers o~
'~ paper, plastic and/or foil between the barrier layer and the plastic
sheath. Basically, the combination of materials used is limited only by
considerations concerning the proauct to be packaged and the ability to
achieve a desired structural integrity between the layers of the laminate.
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~7564'7 ~:
While the tubular body could, for example, be bonded to a dis~
pensing head by a heat seal between the head and outer layer of
the body, presuming the materials thereo~ to be compatible for
this purpose, the body preferably is mechanically Joined to a
two piece head assembly and preferably~ by an interference fit in
the manner and with a two piece head assembly according to the ::
present invention. This is preferred in th.at it minimizes cost
of production and further increases the materials available
for use iII constructing the container~
A container constructed in accordance with. anoth.er aspect
of the present invention has a two piece h.ead assembly mounted on
the body of the container in air tight sealed relation~hip there-
with. The body of the container includes at least a layer of
thermoplastic material, and the air tight seal is achieved by
an improved assembly method and through an improved interference
fit relationship between the body material and th.e components~ of
the head assembly. The head components: can be metal or plastic,
or a combination thereof, and the plastic materials can be either
thermosetting or thermoplastic t The tubular body can be plastic, .
or a laminate of plastic materials, plastic and foil, plastic and ~.
paper, or other combinations.
More particularly, in accordance w~th a preferred embodi-
ment, the head assembly is comprised of t~o components adapted to
be lockingly interengaged and having a cooperable recess and pro-
jection arrangement therebet~-een whieh enables an end o.~ the tubular
body portion of the container to be rece~ved and clampingly inter
engaged between the two components. The recess and pro~ection
arrangement lncludes a pair of opposed sealing surfaces spaced
apart a distance less than the wall thickne~s o~ the body, The
end Oe the body is heated to so~ten the th.ermoplastic l.ayer, and - ~:
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the spacing of the sealing surface causes the portion of the
body wall therebetween to be reduced in thickness and for the
plastic material to flow and fill voids between the head
members. This provides an air tight sealed relationship with
respect to the leakage of air or the procluct across the
juncture between the body and head assembly. Moreover, the
locking interrelationship between the head members assures
maintaining the sealed relationship and, together with the
orientation of the sealing surfaces, enhances retention of
the container body material between the head members under
pressure applied to the container body during use thereof.
Assembly of the head members is achieved without heat sealing,
adhesive bonding or complex mechanical manipulation of the parts
such as by screwing and, accordingly, a high production rate is
obtained. In this respect, for example, assembly by heat
sealing can be achieved at a rate of about 18 to 40 containers
per minute, whereas the assembly of body and head components
in accordance with the present invention can be achieved at a
; rate o~ about 60 to 100 per minute. Thus, production time
is considerably reduced as is the cost of equipment to achieve
assembly of the body and head, all of which leads to a lower
per unit cost with respect ~o a given container structure.
In accordance with one broad aspect, the invention
provides a collapsible dispensing container comprising a
tubular body having radially inner and outer surfaces and a
;~ radial thickness, at least the radial outer portion o~ said
body being thermoplastic, and a dispensing head assembly mounted
on one end of said body, said head assembly including axially
interengaging first and second head mem~ers~ one of said head
members including a dispensing nozzle, said first head member
being axially recei~ed in said one end of said body and having
~: B :~
~17~647
an outer wall facially engaging said inner surface of said
body, said first head member further including a ~irst wall
extending radially inwardly from said outer surface and a
circular second wall extending axially inwardly of said body
from said first wall, said one end of said tubular body
including first and secon~ portions respectively extending
radially and axially in overlying relationship with said
first and second walls o~ said first head member, said second
head member including first and second walls respectively
10 ~ parallel to and spaced from said first and second walls of said
first head member and cooperating therewith to engage said
first and second portions of said one end of said tubular body
therebetween, means lockingly interengaging said first and
second head members to retain said first and second head
members in assembled relationship and to maintain said first
and second walls of said second head member spaced from the
respective one of said first and second walls of said first
head member, said first and second walls of said second head
member having a corner therebetween facing the radially outer
surface of said first and second portions of said one end of
said tubular body, said second walls of said first and second
head members being radially spaced apart a distance less than
said radial thickness of said tubular body, said second portion
of said one end of said body being radially compressed between ~
said second walls to a thickness corresponding to the radial
space therebetween, and the material of said outer portion
of said body extending into said corner between said first and
second walls of said second head member.
~n accordance with another aspect~ the in~ention
provides a collapsible dispensing container comprising a
tubular body having radially inner and outer surfaces and a :
radial thickness, at least the radial outer portion o~ said .:
8a - ~
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~756~
body being thermoplastic, and a dispensing head assembly
mounted on one end of said body, said head assembly including
axially interengaging first and second head members, one of
said head members including a dispensing nozzle, said first
head member being axially received in said one end of said
body and having an outer wall facially engaging said inner
surface of said body~ said first head member further including
A a first wall extending radially inwardly from said outer
surface and a circular second wall which is axially planar
and extends axially inwardly of said body perpendicular to
said first wall, said one end of said tubular body including
first and second portions respectively extending radially and
axially in overlying relationship with said first and second
walls of said first head member, said second head member
including first and second walls respectively parallel to and
spaced from said first and second walls of said first head member
and cooperating therewith to engage said first and second
portions of said one end of said tubular body therebetween,
said first and second members including corresponding third
walls each spaced radially inwardly from and axially parallel ;
to the corresponding second wall, said third walls interengaging ~.
to maintain said second wall of said second head member radially
spaced from said second wall of said first head member a
distance less than said radial thickness of said tl~bular body,
said first and second walls of said second head member having ~.
a corner therebetween facing the radially outer surface of said
first and second portions of said one end of said tubular body,
said one end of said body being radially compressed between
said second walls of said first and second head members to a
thickness corresponding to the radial space therebetween, and :
the material of said outer portion of said body extending into
said corner between said first and second walls of said second
8b -
~6375647
head member.
In accordance with a ~urther aspect, the invention
provides a method of assembling a collapsible dispensing
container body tube comprising a wall including a thenmoplastic
material and having a radial thickness, and a dispensing head
including a first head member rec~ived in an end of said tube
and a coaxial second head member, said head members having
radially opposed wall means spaced apart a distance less than
said radial thickness and cooperably interengagable with an
axial end portion of said body tube to clampingly engage said
axial portion therebetween, said method comprising: s~pporting
said body tube and first head member for said axial portion of
said end of said body tube to extend axially beyond said wall
means on said first head member, heating said end portion of
said body tube to a temperature below the fusion temperature of
` said thermoplastic material and at which temperature said
3 thermoplastic material will flow under pressure, displacing
said end portion of said body tube to extend over said wall
means on said first head member, and axially joining said
second head member with said first head member for said end
portion to be clampingly engaged between said opposed wall
means for said spacing of said opposed wall means to apply
pressure on said end portion to flow said plastic material.
It is accordingly an outstanding ob~ect of the present ;
invention to provide improved collapsible dispensing container
constructions.
i A further object is ~he provision of a hand
- collapsible container construction including a laminated
tubular body portion having an inner layer of plastic material
less subject to product permeation than the inner layers of
~ such containers heretofore provided. `~
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S6~D~
Yet a further object is the provision of a collapsible
container construction including a laminated container body
portion
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~6~7S6~
constructed to form a tube having an outer s,urface uninterrupted
by a longitudinal seam.
Still a further object is the provision o;~ a collapsible
container construction including a tubular body portion providing
an inner sur~ace of an epoxy resin and a head co~prising an
assembly of component parts clampingly interengaging the material
of the container body therebetween.
Another object is the provision of a collaps~ble dis- "
,; pensing container construction which enables a broader selection
- of materials for the head and contai.ner body components than here-
` tofbre.possible. -
Yet another object of the pres.ent invention is the pro- .'.
,~ vision of a collapsible container construction which enables the "' :''
container body and head components to be assembled in an air ' '
, tight sealed relationship w-ithout heat sealing or adhesive bond- ,
ing therebetween. , ''
~, Still another object i5 the provision of a collapsible
container construction in wh.ich the head component is an improved
two piece assembly of component parts structurally i.nterrelated ',~
to enable achieving an air tight seal with. the body tube and im- .
proved structural integrity between the tube and head~ , ,
,' A further ob~ect i5 the provision of an improved meth.od
of assembling head and body components of a collapsible container ':
construction.
-: Brief Description Of The Drawing '
' The foregoing objects, and others~, ~ill i.n part be ob~ious :
and in par,t pointed out more fully hereinafter in conjunction with.
the written description of preferred embodiments of th.e invention
illustrated in the accompanying drawings in which.: ,~
FIGURE 1 is a perspective view of a collapsible dispensing
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~0756~7
container incorporating a head ass:embly i;n accordance ~ith the
present invention;
FIGURE 2 is an enlarged cro$s~sectlonal vie~ of the
head assembly of the container taken along line 2-2 in ~IGURE l;
FIGVRE 3 i5 an exploded cros~s-sectional Vie~ of the com~
ponent parts of the head assembly of the container ~tructu~e shown
in FIGURE 2.
FIGURE 4 is an enlarged cross-sect~.onal view~ of the area :,~:
of juncture between the body and head components~ shown in FIGURE , ,':
'; 10 . 2; ' '-`'~
FIGURES 5 and 6 are enlarged cro$,s~sectional view~s '~
similar to FIGURE 4 and illustrating s,tres$: relation6hips in th.e
', area of juncture avoided in accordance w~th.the present invention; ~,.
FIGURE 7 is a somewhat schemat~c illus~tra.tion sho~ing , `':
the manner in which the head components and container body are ''.
assembled;
, FIGURE 8 is a cross-sectional vie~ of anoth.er e~bodi,~ .. ,
` ment of a head assembly in accordance ~ith. the present i,nvention;
,, FIGURE 9 is a cross-sectional view i,llus~trating a lam~
inated tubular body construction for a colla.psible contai,ner in
: accordance with the present ~nventi,on;
,: : ,.
; FIGURE 10 is an elevation view, partially in section, ' '`.
sh~owing the tubular body portion of PIGURE 9 clampi,ngl~ interen~
gaged with a two piece head assembly; and, ,
FIGURE 11 is a cross-sectional view sh.owi:ng th:e' tubular
body port~ion of FIGURE 9 bonded to a head component~
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~75~;~7
Description of Preferred Embodiment~
Referring now in greater detail to the drawings ~here~
.- in the showings are for the purpose of illustrating preferred
embodiments of the invention only and not for the purpose of
limiting the invention, a collapsible dis,.pensing container 10 is
illustrated in FIGURE 1 which is comprised of a hody portion 12 .
of deformable material and a head assembly 1~ mounted on one end
of the body and comprised of first and second head members 16 and
18, respectively~ As. is well known, such collaps~ble containers
are assembled by mounting the head on one end of a tubular body
leaving the opposite end of the body open to receive the product
to be packaged therein. The dispensing end of the container thus
formed is provided with a cap, not sho~n, and, after the product ~. :
, has been introduced into the open end of the body, the latter
end is laterally crimped and suitablv sealed to provide a closed
end 20 for the container. In accordance ~ith th.e present in-
` vention, and for reasons which w-ill become apparent hereinafter, :.
tubular body portion 12 can be produced from any suitable material
including metal foils, thermoplastic or thermos:etting plastic
sheets or extruded tubes, and lami.nates of these ~aterials with
or without other suitable materials such as. paper~ By deformable ~.
. material, it will be understood that this term refers to the
ability to displace the tubular body in a Aqueezîng manner b~
hand to facilitate dispensing of the contents th.erefrom. Accord-
ingly, a plastic material or laminated body construction in
~hich the material has a tendency to return to an undistorted
;: .
,~ contour following such a squeezing action is considered to be
, deformable~ as is a metal foil or laminated body construction in
which the foil provides a stiffness allowing permanently deforma-
tion of the tubular body. In the embodiment shown in ~IGURES 1 :.
and 2, body portion 12 is illus~rated for simplicity of description
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~75~7
as a single layer of plastic material which may, Eor e~ample, be
polyethylene and the tubular construction of whic~ can be pro-
vided either by extrusion or by forming a sheet oE the plastic
material into a seamed tube.
First head member 16 is of circular contour transverse
to axis A of the dispensing container and, in the embodiment shown,
is made of plastic material, such as urea Eormaldehyde for example.
As best seen in FIGURES 2 and 3 of the draw-ing, head member 16 in-
cludes a dispensing nozzle portîon defined b~ a neck 22 centrally
bored to provide an outlet or dispensing passageway 24 opening
through the first head member. Neck 22 is provided w-ith external
threads 26 to receive an internally threaded cap, not shown, by
which the container is closed Eollowinguse thereof. First head
member 16 further includes a skirt portion 28 peripherally sur-
rounding the inner end oE neck 22 and pro~ecting radially out-
wardly thereErom and having a peripheral outer edge 30 which is
circular and dimensioned diametrically to be axially slidably
- received in the open end of tubular body portion 12 prior to
completion of the mounting of the head assembly on the body
portion, as set forth more fully hereinaEter. The axially outer
side of skirt portion 28 is provided with a circular recess 32
coaxial with neck 22 and having radially opposed inner and outer
recess walls 34 and 36~ respectively. The outer surface 28a oE
skirt portion 28 adjacent the inner end of neck 22 tapers out- -
-
wardly and axially inwarclly with respect to the outer end of
. ~
neck 22, whereby inner wall 34 of recess 32 has an axial length
greater than outer wall 36 of the recess. Recess 32 further in-
cludes a radially extending bottom wall 38, and a radially
extending planar wall 39 perpendicular to and intersecting outer
wall 36 of the recess and outer edge 30 of the skirt portion.
~all 34 is provided with a radially pro~ecting rib ~lO which is
peripherally continuous about the wall and which serves the
- 12 -
7564~7
purpose set forth hereinafter.
Second head member 18 is in the ~orm o~ a r~ng which, in
the embodiment shown is produced from plastic material, such as
polyethylene for example. Head member 18 has a circular inner
wall 42 of a diameter corresponding to the diameter o~ inner
wall 34 of recess 32 and having an axial height slightly less
than the height of recess wall 34. Additionally, the ring
member has a radially outer circular wall 44 the lower ledge
45 of which is rounded or tapered. Wall 44 is o~ a diameter
slightly less than the diameter of outer wall 36 of reces~s 32 for
the purpose set forth hereinaEter. The ring member further ;
includes a radially extending bottom wall 46 and a radially ex~
tending flange portion 48 including a radially extendîng planar
wall 50 perpendicular to outer wall 44 of the ring. Walls 44
and 50 intersect in a corner 51 extending peripherally of the
ring, and wall 44 provides a radial sealing surface radially
opposite wall or sealing surface 36 of member 16 ~or the purpose
set forth below. The axially outer or upper surface 52 o~ the
ring has a taper coinciding with that of skirt wall 28a. Cir-
' 20 cular inner wall 42 is provided w-ith a peripherally continuous
recess 54 positioned and dimensioned to receive rlb 40 of head `~
member 16 in the manner and for the purpose set forth hereinafter.
Walls 42, 44 and 46 of ring member 18 define- a pro-
~ection adapted to be axially received in recess 32 of head
;~ member 16. When the two head members are assembled, as set forth ~ .
hereinafter, the low-er part of ring wall 42 moves axially past
rîb 40 on wall 34 of member 16 until recess 54 is axially aligned ~ -
with the~r~b. ;At this time rib 40 is received in recess 54 and `
thus locks the ring in place against axial separation from head
30~ member 1~6. The relative axial positions of rib 40 and recess -
54 on walls 34 and 42 and the radial engagement between walls
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3 ~75G~ :
34 and 42 establish and maintain the desired spacing between
axially opposed walls 39 and 50 and between radially oppos.ed
walls 36 and 44 of the two head members. As an alternative to
such rib and recess interengagement, the diameter of walls 34
and 42 can be such as to provide an interference fit therebetween
to lockingly interengage the head members and maintain th.e
opposed walls thereof in the desired spaced relationsh.ip.
When the two head members are in assembled relationship,
radially opposed w-alls or sealing surfaces 36 and 44 of the two
members are radially spaced apart a distance slightly less than
the wall thickness of the material of tubular body portion 12.
Pre erably, axially opposed w-alls 3~ and 50 of the two head mem~ `
: bers are axially spaced apart a distance corresponding to the wall
thickness of the body material. These dimensional relationsh.ips
provide clearance spaces between the opposed walls which enable
:l the head assembly to be mounted on the end of tubular body 12 in .
a manner whereby an axial end portion of the body material i5 , .
~I clampingly interengaged between head members 16 and 18 in air ::~
~ tight sealing relationship therewith and against separation of
:' 20 the body tube from the head assembly during use of the container.
Moreparticularly in this respect, and as will be appreciated from : . :
FIGURE 2, an axial portion 12a of the end of tubular body portion
., 12 is folded inwardly to overlie radial ~all 39 of member 16 and .: :
thence axially inwardly as at 12b to overlie recess wall 36. Since
the thickness of the material of tubular.body portion 12 is greater
than the radial spacing between opposed walls 36 and 44, it will
be appreciated that portion 12b is radially compressed therebetween. ~ .
. In accordance with the present invention, portions 12a and 12b :.
:'. are heated to facilitate the bending thereof, to remove the plastic
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memory, and or the radial compression of portion 12b to caus~
the plastic material to flow into corner 51 between walls 44 and
50 of ring member 18, as best seen in FIGURE 4 of the drawing.
Such heating is to a temperature below the usion temperature
for the plas~ic material and sufficient to enable plastic flow
under pressure. The axial spacing between opposed walls 39 and
50 is such as to clampingly engage portion 12a of the body material
.. .,therebetwe,en, without any ,appreciable reduction in thickness of
portion 12a as is provided for by the spacing between radi.ally'
~opposed walls 36 and 44.- . - .- -
: ' The heating of body port;ons 12a and 12b, the raclial com- "
pression of portion 12b, and the resulting plastic flow enable
achieving the desired air tight.seal between the container body
and head assembly by tightly and sealingly interengaging wall
portion 12b between the radially opposed walls 36 and 44 and by
filling the void between the head members defined by corner 51.
Moreover, the heating removes the plastic memory and thus enhances
structural integrity in the areas of the bends between the outer
~' wall and portion 12a and between portions 12a.and 12b of the body .
, 20 mat.'erial,.thus to optimize the retention capability with respect
to separation of the body tube and head assembly during use of
the container and to optimize structural integrity o~ the container
, body against tearing of the body material ad~acent the head assembly.
'~, These attributes will be be~ter understood and appreciated from,the
.25 iLlustrations in ~IGUP~S 5 and 6.considered in conjunction with
~ FIG~RE 4. In FIGURES 5 and 6, tWQ piece head assemblies and bod~
', tubes are illustrated which, to f'acilit.ate the following description,
correspond.structurally with the component parts' shown in FIGURES
2-4. Accordingly, like numerals are employed to designate corres-
ponding component parts.
'
: ' ' . '
: - 15 - ,
.
:, ' .- ~. . :
~ 75647
Referring first to FIGURE 5, head members 16 and 18 are
dimensioned for radially opposed walls 36 and 44 and axially opposed
walls 39 and 50 to be spaced apart a distance corresponding to the
thickness of the body tube material. Thus, portio~s 12a and :~
12b of the body would be clampingly engaged between the corresponding . . .
opposed walls wi,thout any appreciable reduction in thickness of the.
,
- ' material. If portions 12a and 12b of the body material are not
. heate,d in accordance with the present invention1 the bending there-
of across walls 39 and 36 of body member 16 results in the,body
materiial being stretched in the areas of the bends and thus placed
~ under,tension in these areas as indicated in FIGURE 5 b~
', arrows 56. Such bending of the body material and stretc~ing thereof ',
around the corners between walls 30 and 39 and between walls 39
, and 36 of body member 16 creates a void in corner 5L. Moreover, '~ '.,
i 15 such bending and stretching creates an area of weakness across ' '... ' .
, each bend in the body material in the directions indicated by
, lines 58 and 60 respectively bisecting the angle between walls ,.
,~ 30 and 3 and the angle between walls 39 and 36 of body,member 16.......... ',~
, : , These structural characteristics and structural relationships ' .
,'20 enhance establishing a leakage path between the interior and ex~
terior of the container, enhance separation of the body and head , : ~
' assembly either by withdrawaL of body portions 12a and 12b due to ~-
I an i~adequate clamping relationship and/'or tearing of the body ;,,,~.'
'~ material ac~oss the bends thereof in the direction of lines 58
''25 and 60, both of which are undesirable and unacceptable character~
istics.
1 If, as shown in FIGUP~E 6, radially oppo.sed ~alls 36 and 44 ~ -'
are dimensioned to be spaced apar.~ a distance less than the thickness . .'~
o~the body tube material, the foregoing problems are not overcome. .- -
3Q In ~act, the stress problem is even more pronounced in the bend, . :~
16 -
~. ! ~, . . .
' . . . . . .
;'' ' . ' ' ' , ," ,. .
~756~7
between body tube portions 12a and 12b as a result of the com-
bined axial stretching and radial compression of portion 12b
during assembly of the head components. Moreover, such s~.retching
and compression results in thinnin~ of the ma~erial in the area of
the corner between walls 36 and 39 of head member 16 to a greater
extent than the thinning in the corresponding corner with the struc-
ture shown in FIGURE 5. Therefore, the tenslle stress in the body
-: . . material between portions 12a and 12b together with such thinness
... . . .. ..
increases the potential for the materiaL to tear across the bend
10 . in the direction of line 60 bisecting-the angle between.walls 36
: and 39. It will be~appreciated too that the tearing potential
exists in this construction at the bend between body tube 12 and
end portion 12a thereof in the direction of line 58 bisecting the
corner between walls 30 and 39 of head member ].6, and that a void
, 15 exists in corner 51 to enhance establishing a leakage path between :
I the interior and exterior of the container. While portion 12b .
may be radially compressed and somewhat thinned with~the structure ..
I ~ .. ..
shown in FIGU~E 6, there is no plastic ~low. Therefore~ the void.
created by corner 51 together with any other voids which may exist
' ~:20 as the result, for example, of scratches on the walls 44 and 50
~ or foreign particles adhering to these walls are not filled and~
'~ accordingly, enhance leakage across the body tube and head joint. : -
In light of the foregoing description of FIGURES 5 and 6,
, it will be appreciated fr.om FIGURE 4 that heating o~ the plastic
l~ 25 material,:radial compression thereof and plastic flow in accordance
'~ with the present invention enables applicant to achieve the desired
.
air tight seal and struc~ural integrity in the joint between the
.
body tube and head assembly. In this respect, heating of the plas~ic
to remove the plastic memory and to enable plastic flow avoids the
crPation of tensile stress in the bends between the body portions,
.
~ 17
'1': ~ ; ' ' ' ' '
: ' ,
. - : , . ~ ,
S~7S6~7
thus optimizing resistance to tearing of the body material in ~he
areas of the bends and along the lines 58 and 60. ~Ioreover, the
plastic flow which enables filling corner 51 also enables filling
other voids which may exist as the result of scratches or the like,
thus to optimize sealing of the joint between the body tube and
head assembly against leakage of alr or the contents of the container
thereacross. Moreover, plastic flow of material into corner 51 pro- ~
~ ~ides a maximum thickness of the material in the direction of line
60 and thus minimizes the pobsibility of tearing~or rupturlng of. ~
. 10 the material in this area. Still further, filling of the corner 51
.
increases the retention capability with respec~ to the body tube
material by eliminating an open area into which end portion 12b of
the body tube can move u~obstructed upon the application o~ suf~
cient radial force on portion 12a to cause withdrawal o portions
12a and.l2b from between the head members. For example! if a radial
force is applied to portion 12a in the structure shown in FIGURE 6,
assuming that the material would not tear along line 60, the void
in corner 51 defines a space into which portion 12b can move
unobstructed to enhance such withdrawal. It will be appreciated
that filling of the corner 51 as shown in FIGU~E 4 creates an ob-
struction which restrains such withdrawal of the body tube end :
: portions from the head assembly.
The thickness of the material o~ tubular body portion 12 .
will of course vary depending on a number of factors including the
use to which the dispensing cont.ainer is to be put, w~ether the
tabular body portion is of unitary or laminated sheet construc- .
~, tion, the type or types of material used to construct the body
. I . .
portion, and the like. Likewise, the clearance space between ..
radially.opposed walls 36 and 44.between which portion 12b of
the material of the tubular bod~ is radially compressed will vary
.
~, '
~ 18
.
.
~ - : . ;, . :' . .
11~3756~7
depending on the body material and construction of the tubular
body portion. A spacing between walls 36 and 44 which will provide
or compression of the body material between the walls to reduce the
thickness by about 25% is sufficient to achieve ~he desired cla~ping
interengagement and sealing reLationships between the head assembly
and tubular body. - -
The manner in which head members 16 and 18 are assembledwith tubular body portion 12 in the embodiment shown in FIGUR~S 1-
~is schematically shown in FI&URE 7 of the drawing. In this resp~ct,
~ . ............................... . . . ....... . . .
a mandrel 62 is provided which is suitably supported, by ~eans not
shown, for rotation about the axis of the mandrel. The mandrel
includes an abutment flan$e 64 at one end and a stub portion 66
of reduced diameter extending axially from the outçr end thereof
and providing an end face 68 with the body of the mandrel. Stub
portion 66 has a diameter corresponding to that of dispensing passage-
way 24 in head member 16, and the head member is first introduced
onto and supported by stub portion 66 with the inner end of the head
, member engaging face 68. Tubular body portion 12 of the container
; is then introduced onto the mandrel and against flange 64 and has a-
20 predetermined axial length which provides for the end thereof
l adjacent head member 16 to extend axially beyond wall 39 of the
I head member a distance corresponding to the axial length required
to provide material portions 12a and 12b. With these component
parts~so positioned on the mandrel~ the latter is rotated and a
~ .
~25 suitable heate~ ~orming tool 70 is displaccd radially inwardly
o the mandrel to heat and bend the overlappin~ portion o~ tubular
. , .
body 12 radially inwardly to the broken line position shown in
FIGURE 7. Forming tool 70 can be of Nylon, for example, and is
heated to removP the memory of the plastic material and ~o facilitate
bending and plastic flow thereof as described hereinabove. A~ter
' .
.
. ~' . ~ ' , ' . ' ,
.
~ ~ 7 ~ ~ ~7
the body ~aterial is so bent, rotation of the mandrel is stopped
and head member 18 is introduced axially onto head member 16 to
achieve mo~ement of the projection thereon into recess 32 in head
member 16. During advancement of head member 1~ onto head mem~er
16, walls 44 and 46 of the ring member and rounded or beveled edge
45 therebetween displace the ~adially inwardly overhanging portion
12b of the body material axially into recess 32 and radially out-
wardly against wall 36 thereof to achieve the plastic flow described
... . .......... . - - ................. .
above. Preferably, a suitable force applying member 72 is employed
to achieve seating of ring 18 with respect to recess 32 and the
assembly is completed when projection 40 and recess 54 lockingly
interengage. Thus, it will be appreciated that the assembly can
be achieved quickly and inexpensively. Once the assembly is c~mpleted
the container can be immediately removed from the mandrel. In this
respect, heating of the plastic is to a temperature below the fusion
temperature of the plastic, wherebg there is n~ heat sealing be-
tween the body and head assembly and thus there is no delay required
to enable cooling before removal of the assembly from the mandrel.
Generally, the cap component for the container assembly will be
applied prior to removal of the assembly rom the mandrel, whereby
the container is ready to be filled and closed upon removal thereof
from the mandrel.
FIGURE 8 illustrates another embodiment o~ a collapsible
.
container construction including a head assembly in accordance
with the present invention. The head assembly in this embodiment
includes a first head member 74 and a second head member 76 shown
as being of plas~ic materials which, for example, can be o poly-
ethylene and Nylon, respectively. Head member 74 includes a
neck portion 78 which is centrally bo~ed to provide a discharge
- 30 passageway 80 and which has external threads 82 to receive a
.
.. ., . - .,, - .. , .. . , - ,:
.
~)75691'7
closure cap, not illustrated. Head member 74 further includes a
skirt portion 84 extending radially outwardly of neck portion 78
from the inner end thereof and at an incline axially inwardly
with ~espect to the outer end of the neck portion. The inner
side of skirt portion 84 is provided with an annular projection
86 coaxial with passageway 80 and extending axially inwardly from
the skirt portion. More particularly~ projection 86 includes radially
inner and outer walls 88 and 90, respectively, and a bottom wall 92.
Further, the.skirt is provided with a radially extending wall 94
; 10 extending outwardly from wall 90 of projection 86 and intersecting
outer surface 96 of the skirt to define a circular outer edge 9~ :
. for the skirt.
; . Second head member 76 is a ring mem~er having a circular
. recess coaxial with passageway 80 and opening axially outwardly
lS with respect thereto.to receive projection 86. More particularly
the recess is defined by radially inner and outer wall.s 1.00 and 102,
: respectively, and a bottom wall 104 of mating contour with proiection
wall 92. Recess wall lO0 is of a diameter related to the diameter
of inner wall 88 of projection 86 to provide an intererence fit
therebetween, and recess wall 102 is of a diam~ter slightly greater
than the diameter of outer wall 90 o the proiection. As in the
embodiment sho~m in FIGURES 1-4, the diametrical relationship between
walls 90 and 102 provides a radial space or clearance therebetween
~ less than the thickness of the body material. Thus, axial por~ion
~5 12b of container body 12 is radi.ally compressed between walls 90
and 102 and, being heated as described hereinabove, plastic flow
is achieved to fill the corner between walls 90 and 34 of head
;: member 74. In this embodiment, the ring member has a circular
; outer edge 106 of a diameter corresponding to the inner diameter
:3~0 of the tubular body portion so as to be axially received in the
.
- : ~ . : . ;. . . : ., .
1~97~6~7
body portion. ~ radially extending wall 108 between recess wall
102 and outer edge 106 underlies skirt wall 94, and axial portion 12a
of tubular body 12 is clampingly engaged between these axially opposed
walls without appreciable reduction in the thickness of portion 12a.
The interference fit between recess wall 100 and projection wall 88
interengage the-head members against axial separation. If desired,
of course, recPss wall 100 and projection wall ~8 can be provided
with a suitable interengaging detent arrangement-to axially lock - -
head members 74 and 76 against separation.
It will be appreciated, from the foregoing description
of the embodiments of FIGU~ES 1~8, that the interengaging relation-
ship between the container body and head assembly achieved in accord-
ance with the present invention is independent of requirements for
compatibility of materials for purposes of achieving an adhesive
or heat seal bond between the tubular body portion and dispensing
head. Accordingly, while plastic materials are described in co~-
junction with the disclosed embodiments, and certain plastic
materials are identified as examples, the component parts of the
head assembly can be made from a wide variety of plastic materials
of either thermoplastic or thermosetting resins, rom metal such
as aluminum, or combinations of metal and plastic.
An improved laminated tubular body construction in accord-
ance with another aspect of the present invention and a preerred
combination o materials for such body portion is illustrated in
Z5 FIGUP~ 9 of the drawing. This body construction is parti~ularly
suited for use in connection with a dispensing container wherein
product permeation and oxygen absorption problems are encountered.
Referring now to FIGU~E 9, a tubular body portion 110 ~or a dis-
pensing container is comprised of a barrier layer 112 of a material
suitable for preventing oxygen absorption, such as a metal foil,
'.
- 22 -
,. ~ .... , . '', . . .
i7S~7
and an inner layer 114 of a thermosetting plastic, preferably an
epoxy resin, bonded to the barrier layer. The barrier layer a~d
the thermosetting plastic layer thereon are provided in sheet ~orm
and are formed into a tubular cross-sectional configuration with
the opposite side edges thereof circumferentially overlapped as
. shown in.FIGURE 9. This tubular con~iguration is then circumfer-
entially encapsulated in an outer layer 116 of suitable thermo-
. plastic.material., such as by extrusion.
. Barrier layer 112 optimizes protection against oxygen
absorption, and -inner layer 114 optimizes proteckion against pro-
duct permeation. In this respect it is known that t~ermosettingplastic materials are less permeable than the thermoplastic materials
heretoore employed in such collapsible container bodies. Accord-
in~ly, it will be appreciated that a tubular container body con-
struction including JUSt the barrier layer and thermo*etting plastic
.` inner layer would provide the desired end results with respect to
,
. these problems, and that the over~apping longitudinal edges of the
barrier layer and inner layer could be bonded for these two com-
ponents to alone provide the tubular bo~y portion ~or a container.
,20 In this respect, or example, the barrier layer and inner layer
could be formed to the tubular configuration prior to curing o~
the thermosetting resin, and the overlapping edges could be pressed
together and held during the application of heat to cure the resin.
However, it is preferred to encapsulate the barrier layer and inner
layer in an outer layer 116 in that the outer layer maintains the
barrier layer and inner layer in the tubular form thereof without
the necessity of forming a longi~udinal structural bond therebetween
and, thus, avoids problems encountered in conne~tion with ~orming
the tubular configuration prior to curing the thermosetting resin. ..30 Additionally, encapsulation of the barrier and inner.layers enables .:
: - 23 - ~
~ '
~ . ., . . ~
~7~7
obtaining a circular outer surface 118 for the tubular body of
the container which is free of circumferential interruptions in the
. circular contour such as are encountered in connection with a longi-
tudinal seam in the tubular body portion. Thls advantageously en-
ables indicia to be applied to the tubular body portion ater itis formed and such as by roll printing procedures which cannot be
satisfactorily employed with a longitudinally seamed tube. More- .
over, the uninterrupted circumferential contour adds to the ~esthetic
value of a dispensing container produced therewith.
In the preferred tubular body construction shown in FIGURE
9, barrier layer 112 is aluminum Eoil having a thickness of about ..
0.002 inch, epoxy layer 114 has a ~hickness of about 0.0005 inch,
: a suitable epoxy resin being that sold by Flanna Chemical Company
o ~olumbus, Ohio under product designation H-ll or H-23, and outer
lS layer 116 is a low density polyethylene having a thickness o-E about
0.003 inch. Wi~h regard to outer layer 116, it will ~e appreciated
, that the thickness thereof in the area of the overlap ~etween
,. barrier layer 112 and inner layer 114 ~ill ~ary frQm the latter
dimension. ~ . :
With urther regard to the tubular container body.struc~
ture shown in FIGURE 9, it will be appreciated that a preprinted
plastic or paper layer can be employed with the construction thereof
even though the circular outer surface facilitates printing of the
tube af~er formation thereof. If preprinting is desired, or if
. :25 an additional lamina is for some other reason.desired between
~! .
barrier layer 112 and outer layer 116, such a lamina can be bonded
.l, to barrier layer 112 prior to formation ther~of into the tubular .
. contour to be encapsulated in the outer layer of plastic material.
For example, a ~ilm of white pigmented po~yethylene preprinted
to bear desired indicia for the container body can be bonded to the
~' ~ ' , ' . '. ...
: ~ 2~
. . .
, . -, , . ,, . -, . . . . . . . . . .. . . . .
, . . . . ~ . . ~ , , ; ., : - -
.
~7564'7
outer surface of barrier layer 112, in which case the outer layer
116 of low density polyethylene could be transparent to rende~ the
indicia visible therethrough. Generally, such a preprinted layer
would have a thickness of about 0.002 inch.
FIGUP~E 10 illustrates laminated tubular body portion 110
in assembled relationship with respect to a head assembly corres-
ponding to that shown in FIGURES 2-4 of the drawing. In this
respect, an axial portion llOa of the tubular body is displaced
radîally inwardly of head member 16 to overlie radially extending
wall 39 thereof, and an-axial portion-llOb o~ the body material is
~, displaced axially inwardly of recess 32 in head member 16 tQ o~erlie
radially outer wall 36 of the recess.~ Portion llOb is radially
compressed between wall 36 of the recess and radialLy outer wall `-
~4 of the projection on ring member 18. Accordingly, as described
hereinabove, it will be appreciated that portion llOb is reduced
in thickness and that the material of outer layer 116 of the laminate
~, is plastic flowed into corner 51.
In connection with the assembly shown in FIGURE 10> it
will be appreciated that outer layer 116 of the laminate is o
suitable thermoplastic material such as polyethylene to enable
plastic flow into corner 51 upon radial compression o~ body portion
llOb. In connection with the assembly method, end portions llOa
"
, and llOb are heated to remove the memory of the thermoplastic, to
..
i facilitate bending of portions llOa and llOb, and to achieve plas~ic
flow ~or the purposes set orth hereinabove in connection with the
description of the embodiment shown in FIGU~ES 2-4. If the laminated
body construction includes a non-metallic barrier layer as opposed
to a~metal foil barrier layer, such heating is achieved prior to
interengaging the two head members and in the manner described here-
~30 inabo~e in conne tion with the description of FIGUP~E 7 of the
.. . .
.
.~ ' . - -',.
- 2S -
~. :
~L~75~47
drawing. .If, on the other hand, the laminate inclwdes a barrier :
layer of metal foil, heating for the foregoing purposes is achieved
in two separate steps. In this respect, portions llOa and llOb
,~: of the body material are heated as hereinbefore described while
supported on the assembly mandrel, and the body portions are dis-
placed radially inwardly across wall 39 of member 16 and thence
axialiy along wall 36 by assembly of ring member 18 on head'member
16. Thereafter, the assembled container is peripherally heated
in the area of the joint between the body and head members by a ''~ ' '
, 10 suitable induction heating device schematically represented in
FIGURE 10 by reference numeral 120 and which, in a well krlown
manner, inductively heats the metal ~oil and thus the thermoplastic
layer 116. Such a second heating step assures the desired plastic
; ' flow into.corner 51 to ach1eve an air tight s.eal and which plastic
` 15 flow might not be achieved to an optimum extent by the ~irst heat-
ing step alone. In this respect,the metal foil acts as a heat sink
~, during the preliminary heating operation and thus draws heat from
.~ the,thermoplastic layer. During the time required to bend the
. laminate and Join the two head members, such a heat sink effect
'li.20 can reduce the temperature of the plastic su~ficiently to reduce .,
; the plastic 10w necessary to obtain the desired sealing. The
second step is also to a temperakure below the fusion temperature
of the plastic and high enough ~or the plastic to flow under the
radial pressure applied to portion llOb of the laminate.
~25 While the tubular container body construc.tion shown in ~':
FIGURE 9 is preerably interengaged with a head assembly made ':
in accor~ance with the present inven~ion as described above to
~ avoid the ~ime consuming and expensive heat sealing,procedures, it .. :
" wi11 be appreciated that the tubular body portion can nonetheless `~~30 be heat sealed to'a dispensing head component. For example, as .:.
.. .
~, . .
2~ - ;
'. ' ' ' ' '~ ' ' ' ' . ' ' ' , ' "' , '
~ ~ 7 S ~ ~7
illustrated in FIGURE 11, a dispensing head component 122 includes
a skirt portion 124 provided on the underside thereof with a
peripherally continuous recess including an axially extending cir-
cular wall 126 and a radially extending-axially inclined wall 128.
An axial end portion llOc of tubular bod~ portion 110 is received
. in the recess with the outer end thereof in abutting relationship
with recess wall 126 and with the outer surface o-E outer layer
;~ 116 underlying recess wall.. l28.. Head component 122 would be pro-
duced from a material compatible with outer layer 116 for purposes
of establishing a heat seal bond therebetween. Accordingly,- the
head could be polyethylene in connection with the preerred con-
struction of tubular body portion 110 described herein. Thus, it
will be appreciated that the advantages provided by barrier layer 112
and epoxy layer 114 can be obtained with a variety of head struc- :
tures and mounting arrangements.
I While particular emphasis has been placed herein on the
I preferred embadiments of the invention lllustrated and described, .:.
it will be appreciated that many embodiments of the invention can
be made and that many changes can be made in the embodiments herein .
disclosed ~ithout deRarting from the principles of the present
invention. Therefore, it is to be distinctly understood that the . .
foregoing descriptive matter is.to be interpreted merely as illus- .-
trative of the present invention and not as a limitation.
.
: ~ .
', '
. . . .
.
'~
;, ~ : .
' . .. . .
27 - ~
: ~ :
