Note: Descriptions are shown in the official language in which they were submitted.
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ONE-PIECE DISPENSING SYSTEM
AND METHOD FOR MAKING SAIriE
TECHNICAL FIELD
This invention relates to a system for
dispensing a product from a container. The invention is
more particularly related to a system incorporating a
dispensing valve which is especially suitable for use
with a squeeze-type container wherein a product can be
discharged from the container through the valve when the
container is squeezed.
BACKGROUND OF THE INVENTION
AND
TECHNICAL PROBLEMS POSED BY THE PRIOR ART
A variety of packages, including dispensing
packages or containers, have been developed for personal
care products such as shampoo, lotions, etc., as well as
for other materials. Such containers typically have a
neck defining an open upper end on which is mounted a
dispensing closure. One type of dispensing closure for
these kinds of containers typically has a flexible,
pressure-openable, self-sealing, slit-type dispensing
valve mounted in the closure over the container opening.
When the container is squeezed, the valve slits open,
and the fluid contents of the container are discharged
through the open slits of the valve. The valve
automatically closes to shut off fluid flow therethrough
upon removal of the increased pressure.
Designs of closures using such valves are
illustrated in the U. S. Patent Nos. 5,271,531 and
x,033,655. Typically, the closure includes a body
mounted on the container neck to hold the valve over the
container opening.
A lid can be provided for covering the valve
during shipping and when the container is otherwise not
in use. See, for example, FIGS. 31-34 of U.S. Patent
SUBSTITUTE SHEET (RULE 26~
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No. 5,271,531. Such a lid can be designed to prevent
leakage from the valve under certain conditions. The
lid can also keep the valve clean and/or protect the
valve from damage.
A dispensing closure incorporating such a
pressure-openable valve provides advantages not found in
other types of dispensing closures. For example,
another common type of dispensing closure has a base
defining a dispensing orifice which is normally occluded
by a closed lid having a plug which enters into, and
seals, the orifice. The lid must be lifted open to
permit the product to be dispensed through the closure
orifice. The lid must be manually closed after
dispensing the product in order to permit the container
to be carried or moved in any position other than a non-
vertical position. Further, the lid must be closed in
order to minimize evaporation or drying out of the
product within the container. Also, the lid must be
closed in order to prevent contaminant ingress.
Other types of dispensing closures include
lift-up spouts or rotatable valve members. These
features must be manipulated by the user when it is
desired to open a dispensing passage and must be
manipulated by the user when it is desired to close the
dispensing passage.
With the above-discussed conventional types of
dispensing closures that do not incorporate a pressure-
openable valve, it may be possible to store the
container with the closure thereon in an inverted
position (with the dispensing closure at the bottom) so
as to maintain the container product near the dispensing
passage or orifice. This may be advantageous when the
product is a rather viscous liquid because, when the
inverted dispensing closure is opened, the product is
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already located at the dispensing passage or orifice and
the dispensing time is minimized.
However, while the inverted storage of such
dispensing closure and container may speed dispensing of
a viscous product, this can result in creating a rather
messy condition at or around the dispensing closure
passage or orifice. For example, with conventional
dispensing closures that have a lid plug sealingly
occluding a dispensing orifice in a closure base,
inverted storage causes the inner end of the lid plug to
be coated with the product. When the lid is opened, the
product on the end of the plug is carried with the plug
along the surface of the orifice. Some of the product
sticks to the surface of the orifice and/or adjacent
exterior edges of the closure base around the orifice.
Some of the product also sticks to the lid plug. When
the lid is subsequently closed after dispensing the
product, the product on the lid plug and around the
closure base orifice can create a messy condition around
the exterior edge of the dispensing orifice. With the
dispensing closure in the closed condition, the product
around the exterior of the dispensing orifice can dry
out and become somewhat hardened or encrusted during a
subsequent period of non-use. This is not only
aesthetically unpleasant, but it can inhibit the easy
opening of the lid during subsequent use.
A pressure-openable dispensing valve
advantageously eliminates or minimizes some of the
above-discussed problems. Because such a valve does not
have to be directly manipulated to effect its opening or
closing, the user merely needs to squeeze the container
to effect dispensing of the container product. Although
such a simple squeezing action is generally required for
dispensing a product, especially a viscous product,
through any type of dispensing closure, the use of a
SUBSTITUTE SHEET (RULE 26~
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pressure-openable valve in a dispensing closure
eliminates the need to also initially, manually
manipulate the valve, spout, or lid employed with other
types of conventional closures.
Because a closure with a pressure-openable
dispensing valve remains closed unless the container is
squeezed, the closure and container can be inverted for
storage (with the dispensing~closure and valve at the
bottom). Product does not leak through such a valve,
and there is little or no mess on the exterior of the
valve or surrounding closure surfaces.
Further, the use of a pressure-openable valve
permits more accurate control of the dispensing process.
Because the pressure-openable valve typically has a
relatively thin membrane in which the dispensing slots
are defined, there is no long orifice or passage through
which the product must pass prior to discharge from the
dispensing closure. Thus, the product discharges from
the dispensing closure through such a pressure-openable
valve relatively quickly and in substantially direct
response to squeezing forces applied to the container
which are readily sensed by the user as the user
squeezes the container. The user has a more accurate
"feel" of the relationship between the container
squeezing force and the discharging product as the user
squeezes the container.
Further, because the pressure-openable valve
membrane defining the dispensing aperture slits is
relatively thin, and because the valve can be positioned
in the dispensing closure at, or very near, the most
exterior surface of the closure, the user can readily
observe the valve and its dispensing slits. Thus, the
user can easily see the product being discharged, and
the user can more readily determine how hard to squeeze
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the container and when to terminate the squeezing of the
container.
While dispensing closures with pressure-
openable dispensing valves function generally
satisfactorily in applications for which they are
designed, it would be desirable to provide an improved
dispensing system incorporating such pressure-openable
valves. For example, in conventional dispensing
closures incorporating such pressure-openable valves,
special retention systems are required to hold the
valves within the closures. In particular, a pressure-
openable valve typically is retained in the closure base
by means of a separate retainer ring which is snap-fit
into the closure base over a flange of the valve. Thus,
at least three separate components are typically
required in such a conventional dispensing closure: the
closure base (which may or may not include an auxiliary,
hinged lid), the pressure-openable valve, and the
retainer ring.
Such snap-fit rings are small and somewhat
flexible. Because the pressure-openable valve and the
retainer ring are both relatively small, it is difficult
to provide a design which facilitates component assembly
and proper snap-fit retention. Careful control of
dimensional tolerances is required in order to insure
that the components can be properly assembled and in
order to insure proper engagement of the snap-tit
retention features.
During the manufacture of such a dispensing
closure, processes must be employed to handle (1) the
relatively small, and very flexible, pressure-openable
valve, (2) the small, snap-fit retainer ring, and (3)
the closure base. The processes include the following
the manufacture of the three components, the storage of
the three components, the processing of the three
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components (including quality control inspections and
material handling (including conveying)), and the
assembly of the components. These processes are all
susceptible to problems. For example, the components
can be inadvertently damaged during the manufacturing
operations. The components can also be inadvertently
misaligned during assembly (e.g., resulting in an
ineffective, or loose, snap-fit retention of the valve
within the closure base).
Thus, the manufacturing processes--involving
separate molding of the various components, inspection,
handling, and assembly--must be undertaken with great
care which is difficult and expensive to provide.
Notwithstanding the exercise of a high degree of care in
the manufacturing processes, such processes remain a
potential source of trouble and can occasionally result
in the manufacture of a defective assembly.
Further, the multi-component dispensing
closure employing a pressure-openable valve is prone to
failure after manufacture when subjected to
intentionally or inadvertently applied high impact
loads. For example, when a completed closure is shipped
to a packager for mounting on a filled container, the
packager typically handles the closure with automatic
equipment. A portion of the closure may be snagged by
such equipment, or the closure may be pushed with
excessive force~against another object. These actions
may lead to a loosening or separation of the closure
assembly components prior to, or during, the mounting of
the closure on the filled container. This can create
problems in the packager's automated filling line and
lead to spills and/or shutdowns of the line while the
problem is corrected.
In addition, when the completed package
(comprising the filled container and dispensing closure
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mounted thereon) is put into the distribution channels
by the packager, accidental or intentional loads imposed
on the closure may cause a failure of a part of the
closure. If the package is subjected to excessive
impact forces during shipping and/or while being stored
and/or displayed, then damage (e.g., loosening) of the
closure components may occur.
Also, the fact that the conventional closure
includes an assembly of the three components (closure
base, valve, and retention ring) makes it easier for
someone to tamper with the closure by partially or
completely separating the closure components.
Accordingly, it would be desirable to provide an
improved dispensing system which would eliminate, or at
least minimize, the problems associated with multi-
component dispensing closures.
In addition, in some applications, it would be
desirable to provide an even more secure dispensing
system which could altogether eliminate a separate
dispensing closure. Because a dispensing closure must
be mounted on a container, automatic processing systems
are typically employed to convey the container, fill the
container with product, convey the closure, and apply
the closure to the filled container. Costs are
necessarily associated with the manufacture, handling,
and assembly of the closure. Further, the use of a
separate closure provides the opportunity for accidental
misapplication of the closure to the container by the
packager during the container filling and capping
operation. This can result in an improperly assembled
package which may cause problems in the filling line and
which may leak in the filling line or subsequently
during shipping and storage. A misapplied closure may
become loose and fall away from the container during
shipping and storage. If the closure remains on the
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container, but does not properly seal the container, the
product within the container may become contaminated or
spoiled.
Even when a package comprises a properly
assembled and sealed container and closure, such a
package still presents a potential problem.
Specifically, consider the situation when the consumer
has used up all of the product from the container.
Instead of disposing of the empty container, the
consumer may remove the closure and then refill the
container with another product which may be the same as
the original product or which may be different.
Refilling of the container with the same product
potentially diminishes sales of the original packager.
On the other hand, when the container is
refilled with a different product, there is a danger
that the user, or subsequent user, may not realize that
the re-filled product is different from the product
described on the container label. Use of the re-filled
product by someone thinking that it is the original
product described on the container label could result in
property damage or personal injury.
Additionally, the relative ease of the
removability of some types of closures from containers
accommodates "black market" operations. In such
operations, a black marketer salvages used, empty
packages (comprising a container and dispensing closure)
and.re-fills the container with a product that may be
similar to, but not the same as, the original product
3~ described on the container label. The re-filled package
is then returned to the retail distribution chain. This
can result in consumer dissatisfaction wherein the next
consumer purchases the package assuming that it contains
the original product described on the container label,
but the different, re-filled product does not perform to
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the consumer's satisfaction. Use of the refilled
product under such circumstances may also result in
property damage, personal injury, and/or the tarnishment
of the reputation of the original packager or marketer.
Accordingly, it would be desirable to provide an
improved dispensing system in which access to the
container interior cannot be readily obtained.
It would also be desirable to provide an
improved dispensing system for a package which would
reduce the number of separate components needed to
produce a completed package. Providing an improved
dispensing system for a container that eliminates the
need for a separate closure would discourage product
refilling by an individual consumer as well as by
organized black marketers. This would provide increased
product security as well as minimize the potential for
property damage or personal injury compared to packages
which employ separate closures.
It would also be beneficial if such an
improved dispensing system could accommodate the use of
a variety of different materials. Further, it would be
desirable if such an improved dispensing system could be
provided with a design that would accommodate efficient,
high quality, large volume manufacturing techniques with
a reduced product reject rate.
The present invention provides an improved
dispensing system which can accommodate designs having
the above-discussed benefits and features.
SUMMARY OF THE INVENTION
According to one aspect of the present
invention, a dispensing system is provided for a
container. The dispensing system includes a dispensing
end structure molded from a first material to define a
dispensing orifice and a surrounding attachment region.
An optional lid may be provided. The system also
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includes a dispensing valve which is subsequently from a
second material. The valve includes (1) a peripheral
portion molded against, and bonded to, the end structure
attachment region, and (2) a central portion extending
from the peripheral portion across the dispensing
orifice. The dispensing system functions as a one-piece
component and may be incorporated directly as a unitary
part of a container body or may be provided as a closure
per se for a container.
In one preferred form, the dispensing end
structure is an injection-molded closure body~to which
the valve can be molded and which has an annular skirt
that can be releasably or permanently attached to a
container neck that defines an opening to the interior
of a container.
In another preferred form of the invention,
the dispensing end structure, into which the valve is
molded, is incorporated as a unitary part of a preform
which can be subsequently formed into an open-ended body
of a container that can be subsequently filled with
product and sealed closed. Alternatively, the end
structure can be injection-molded so as to initially
include a unitary open-ended container body to which the
valve is molded and which is subsequently filled and
sealed at the bottom end. The end structure can also be
a small tube to which the valve is molded and which can
be subsequently molded to a larger size.
According to another aspect of the invention,
a novel method is provided for making the dispensing
system. The method includes providing a first material
in the form of a dispensing structure that defines a
dispensing orifice and a surrounding attachment region.
The method includes the step of subsequently molding a
dispensing valve from a second material to include (1) a
peripheral portion molded against, and bonded to, the
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end structure attachment region, and (2) a central
portion that extends from the peripheral portion across
the dispensing orifice.
The method preferably also includes the
molding of a secondary sealing lid for covering the
valve in a closed position and for being moved away from
the closed position to permit the dispensing of the
container-stored contents out of the valve. In a
preferred embodiment, the dispensing end structure and a
lid are molded together as a unitary structure with a
hinge connecting the lid to the body to accommodate
movement between the closed position and the open
position.
In one preferred form of the method, the
dispensing end structure is injection-molded in the form
of a closure having an annular skirt that can be
attached to a container neck that defines an opening to
the interior of the container.
In another preferred form of the invention,
the dispensing end structure is injection-molded as a
unitary part of the open-ended body of a container to
which the valve can be molded and which can be
subsequently filled with product and sealed closed.
Alternatively, the dispensing end structure can include
a molded, small tube to which the valve is molded and
which can then,be subsequently blow-molded through the
valve to form a larger size container body having a
closed bottom end. The larger container can then be
filled through the valve. Alternatively, the closed
bottom end could be cut off, the container filled
through the open bottom end, and the bottom end resealed
closed.
The dispensing end structure can also be
molded in the form of a preform having an annular mass
of first material connected with the attachment region
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to which the valve is to be bonded. The annular mass is
then formed into an open-ended body of a container which can
be subsequently filled with product and sealed closed. This
forming step can include axially stretching the annular mass
to form a hollow, cylindrical wall defining the container
body.
Alternatively, a first material can be formed into
the open-ended body of the container by blow molding or
vacuum forming. In one such process, the dispensing end
structure can be provided in the form of a plastic sheet
defining the dispensing orifice and valve attachment region.
The valve is then molded onto the sheet attachment region.
Then the sheet is formed into the open-ended body of the
container or into a formed, filled, and sealed container.
According to another aspect of the present
invention, there is provided a dispensing system for a
container, said system comprising: a dispensing end
structure molded from a first material to form a unitary
dispensing body which is adapted to extend from a container
and which defines a dispensing orifice and which has an
exterior surface that in part defines an attachment region
surrounding said orifice; and a dispensing valve molded from
a second material to define (a) a flexible central portion
having a dispensing orifice which opens to permit flow
therethrough in response to increased pressure on one side
of said valve and which closes to shut off flow through said
valve upon removal of the increased pressure, (b) a skirt
extending outwardly from said flexible central portion, and
(c) a peripheral portion extending peripherally from said
skirt, said peripheral portion having been molded against
said body attachmentregion in surface-to-surface contact to
create a bond between said peripheral portion and said body
attachment region wherein said bond includes a weld defined
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by the interface solidification of melted portions of said
first and second materials so as to locate said valve
central portion inwardly of said body dispensing orifice
with said valve skirt extending outwardly through said body
dispensing orifice, said bond preventing damage-free removal
of said valve from said body attachment region.
According to another aspect of the present
invention, there is provided a dispensing system for a
container, said system comprising: a dispensing end
structure molded from a first material to define a
dispensing orifice and a surrounding outwardly facing
attachment surface which is recessed relative to an adjacent
exterior surface portion of said first material of said
dispensing end structure; and a dispensing valve molded from
a second material and including (a) a flexible central
portion having a normally closed dispensing aperture which
opens to permit flow therethrough in response to increased
pressure on one side of said valve, (b) a skirt extending
from said flexible central portion, and (c) a peripheral
portion which (1) has an increased thickness relative to
said skirt, (2) is joined to said skirt in a unitary manner,
and (3) has a configuration wherein at least part of said
peripheral portion has a generally diverging shape
transverse cross section, at least part of said peripheral
portion having been molded against said body attachment
surface in surface-to-surface contact to create a bond
between said peripheral portion and said body attachment
surface securing said valve on said dispensing end structure
so that both said valve flexible central portion and at
least a major portion of said valve skirt are located
inwardly of said exterior surface portion of said dispensing
end structure and so that said valve peripheral portion has
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an exposed exterior surface free of an overlying clamping
attachment structure when a lid, if any, is open.
Numerous other advantages and features of the
present invention will become readily apparent from the
following detailed description of the invention, from the
claims, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings forming part of the
specification, in which like numerals are employed to
designate like parts throughout the same,
FIG. 1 is a perspective view of a first embodiment
of a dispensing system of the present invention shown
incorporated in a closure with an open lid;
FIG. 2 is a perspective view of a pressure-
openable, slit-type valve prior to installation in the
closure illustrated in FIG. l;
FIG. 3 is a top plan view of the valve shown in
FIG. 2;
FIG. 4 is a side elevational view of the valve
shown in FIG. 2;
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FIG. 5 is an enlarged, fragmentary, cross-
sectional view of the closure shown in FIG. 1 with the
lid closed and with the closure installed in an inverted
orientation on a container;
FIG. 6 is a view similar to FIG. 5, but FIG. 6
is fragmentary view of FIG. 5 showing the closure with
the lid open and with the container being squeezed to
open the valve for discharging product from the
container;
FIG. 7 is a fragmentary, cross-sectional view
of the body of the closure illustrated in FIG. 1;
FIG. 8 is a fragmentary, cross-sectional view
similar to FIG. 7, but FIG. 8 shows the valve molded
onto the closure body;
FIG. 9 is a fragmentary, cross-sectional view
of an alternate embodiment of the dispensing system of
the present invention;
FIG. 10 is a fragmentary, cross-sectional view
of a precursor structure or preform employed in the
manufacture of another alternate embodiment of the
dispensing system of the present invention; and
FIG. 11 is a view similar to FIG. 9, but FIG.
I1 shows the bottom sealed closed across the container
bottom, the valve molded in place, and product within
the container.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
While this invention is susceptible of
embodiment in many different forms, this specification
and the accompanying drawings disclose only some
specific forms as examples of the invention. The
invention is not intended to be limited to the
embodiments so described, and the scope of the invention
will be pointed out in the appended claims.
For ease of description, the dispensing system
components of this invention are described in various
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positions, and terms such as upper, lower, horizontal,
etc., are used with reference to these positions. It
will be understood, however, that the components may be
manufactured and stored in orientations other than the
ones described.
With reference to the figures, a first
embodiment of a dispensing system of the present
invention is illustrated in FIGS. 1-8 and is represented
generally in those figures by reference numeral 40. The
first embodiment of the dispensing system is provided in
the form of a closure 40 which is adapted to be mounted
on a container 41 (FIG. 5). The container 41 has a
conventional mouth or opening 42 formed by a neck 43 or
other suitable structure. The neck 43 typically has
(but need not have) a circular cross-sectional
configuration, and the body of the container may have
another cross-sectional configuration, such as an oval
cross-sectional shape, for example.
The container 41 may typically be a squeezable
container having a flexible wall or walls which can be
grasped by the user and compressed to increase the
internal pressure within the container so as to squeeze
the product out of the container through the closure
when opened. The container wall typically has
sufficient, inherent resiliency so that when the
squeezing forces are removed, the container wall returns
to its normal,~unstressed shape. Such a structure is
preferred in many applications, but may not be necessary
or preferred in other applications.
The closure 40 includes a base 46 and
preferably includes a lid 48 connected to the base 46
with a hinge 47. Preferably, the hinge 47 is a snap-
action hinge formed integrally with the lid 48 and base
46 in a unitary structure. The illustrated snap-action
hinge 47 is a conventional type described in U.S. Patent
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No. 4,403,712. Other hinge structures may be employed,
including a "floppy" living film hinge. However, it is
preferable to employ a snap-action hinge so as to be
able to readily maintain the hinge 48 in the open
position during an application of the container contents
at the application site.
The base 46 is preferably injection-molded
from two different materials, such as thermoplastic or
thermosetting materials compatible with the container
contents. The base 46 is an integral structure which
includes a body or end structure 50 molded from a first
material and a pressure-openable dispensing valve 54
molded from a second material. The valve 54 is bonded
to the closure body or end structure 50 to form a one-
piece dispensing system. No separate snap-fit retaining
ring is required.
In the first embodiment illustrated in FIGS.
1-8, the body 50 includes an annular skirt or wall 56
which may have suitable connecting means (e.g., a
conventional thread 55 (FIG. 5) or conventional snap-fit
bead (not illustrated)) for engaging a suitable
container cooperating means, such as a thread 56 on the
container neck 43 (or bead, not shown) to secure the
closure base 46 to the container 41. The closure base
body 50 and container 41 could also be fixed together by
induction melting, ultrasonic melting, gluing, or the
like.
Near the top of the annular wall 56, the
closure body 50 has a deck comprising a first, most
outwardly, annular shoulder 57a and a second, somewhat
higher annular shoulder 57b. A spout 57c projects from
the shoulder 57b. The inner radius of the spout 57c
terminates in an annular attachment surface or seating
surface 58 around a discharge aperture or orifice 60
over the container neck opening 42. The annular surface
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58 is preferably inclined at an oblique angle relative
to the longitudinal axis of the orifice 60.
Preferably, an annular, flexible "crab's claw's
shape seal 62 (FIGS. 5 and 7) projects from the deck
shoulder 57b and is received against the upper edge of
the container neck 43 adjacent the container neck
opening 42 so as to provide a leak-tight seal between
the closure base 46 and the container neck 43. Of
course, other types of closure base/container seals may
ZO be employed. Also, if air-tightness is not required, no
closure base/container seal 62 need be employed.
The container 41 and closure 40 may be
normally stored in the upright orientation wherein the
closure 40 is at the top of the container. The closure
lid may be either closed or open. The container 41 and
closure 40 may also be stored in an inverted position
while the lid is either open or closed. When stored in
the inverted position, the closure 40 (with the lid 48
closed or open) functions as a support base.
The preferred form of the valve 54 is
illustrated FIGS. 2-4. The valve 54 is of a known
design employing a flexible, resilient material which
can open to dispense product. The valve 54 may be
molded from thermosetting elastomeric materials, such as
natural rubber and the like. Preferably, however, the
valve 54 is molded from thermoplastic elastomers based
upon materials~such as thermoplastic propylene,
ethylene, urethane, and styrene, including their
halogenated counterparts.
A valve which is similar to, and functionally
analogous to, valve 54 is disclosed in the U.S. Patent
No. 5,439,143. However, the preferred form of the valve
54 employed in the present invention has a peripheral
flange structure (described in detail hereinafter) which
differs from the flange structure of the valve shown in
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the U.S. Patent No. 5,439,143.
As illustrated in FIGS. 3-4, the valve 54 includes
a flexible, central portion, wall, or face 64 which has a
concave configuration (when viewed from the exterior) and
which defines at least one, and preferably two, dispensing
slits 66 extending through the central wall or face 64. A
preferred form of the valve 54 has two, mutually
perpendicular, intersecting slits 66 of equal length. The
intersecting slits 66 define four, generally sector-shaped,
flaps or petals in the concave, central wall 64. The flaps
open outwardly from the intersection point of the slits 66
in response to increasing container pressure of sufficient
magnitude in the well-known manner described in the U.S.
Patent No. 5,439,143.
The valve 54 includes a skirt 68 (FIG. 4) which
extends outwardly from the valve central wall or face 64.
At the outer (upper) end of the skirt 68 there is a thin,
annular flange 70 which extends peripherally from the skirt
68 in an angled orientation. The thin flange 70 terminates
in an enlarged, much thicker, peripheral flange 72 which has
a generally dovetail shaped transverse cross section.
To accommodate the seating of the valve 54 in the
closure 40, the attachment region or surface 58 of the
closure body 50 has the same mating angle as the angle of
the valve flange dovetail configuration. The bottom surface
of the valve flange 72 is disposed on, and bonded to, the
closure body attachment region or surface 58.
When the valve 54 is properly mounted within the
closure 40 as illustrated in FIGS. 1 and 5, the
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central wall or face 64 of the valve 54 lies recessed
within the closure body dispensing orifice 60. However,
when the lid 48 is open (FIGS. 1 and 6) and the
container 41 is squeezed to dispense the contents
through the valve 54 (as described in detail in the U.S.
Patent No. 5,439,143), then the valve central wall or
face 64 is forced outwardly from its recessed position
toward the upper end of the dispensing passage or
orifice 60 (FIG. 6) .
In use, the container lid 48 is opened, and
the container 41 is typically inverted and squeezed to
increase the pressure within the container above
ambient. This forces the product within the container
toward the valve 54 and forces the valve 54 from the
recessed or retracted position (illustrated in FIGS. 1
and 5) toward the outwardly extending position. The
outward displacement of the concave, central wall or
face 64 is accommodated by the relatively, thin,
flexible, skirt 68. The skirt 68 moves from an inwardly
projecting, rest position to the pressurized position
wherein the skirt 68 rolls outwardly toward the outside
of the closure body 50. However, the valve 54 does not
open (i.e., the slits 66 do not open) until the valve
central wall or face 64 has moved substantially all the
way to a fully extended position adjacent or beyond the
dispensing passage 60. Indeed, as the valve central
wall 64 moves outwardly, the valve central wall 64 is
subjected to radially inwardly directed compression
forces which tend to further resist opening of the slits
66. Further, the valve central wall 64 generally
retains its outwardly concave configuration as it moves
outwardly and even after it reaches the fully extended
position. However, when the internal pressure becomes
sufficiently high, then the slits 66 of the valve 54
begin to open to dispense product (FIG. 6). The product
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is then expelled or discharged through the open slits
66. For illustrative purposes, FIG. 6 shows drops 80 of
liquid product being discharged.
The lid 48 includes a concave, top wall 85
(FIG. 5) and an outer skirt or wall 87. As illustrated
in FIG. 5, the lid outer wall 87 is adapted to seat on
the annular shoulder 57a defined at the top of the
closure base body sidewall 56.
The lid 48 includes a novel structure for
preventing discharge of the container product through
the valve 54 when the lid is closed and the container is
inadvertently squeezed or subjected impact forces which
would increase the pressure within the container. In
particular, a spud or seal post 90 (FIG. 5) projects
inwardly from the lid central panel 85. The post 90
includes a generally cylindrical portion having an
external, cylindrical surface 94. In the embodiment
illustrated, the seal post 90 is formed as a solid
structure, but it could be formed as a hollow recess in
the lid central panel 85.
The post 90 terminates in an outwardly convex
distal end surface 96 that substantially conforms to the
concave configuration of the outer surface of the valve
central wall 64. However, when the lid 48 is closed,
the post distal end surface 96 is spaced outwardly from
the valve central wall 64 (FIG. 5) by an amount which
accommodates an initial, small outward displacement of
the valve central wall 64 into engagement with the post
distal end surface 96 before the valve slits 66 open.
Thus, when the closed container is subjected to external
forces which increase the container internal pressure,
the valve central wall 64 is forced outwardly against
the conforming surface 96 of the seal post 90. This
occurs inwardly of the outermost position at which the
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valve slits 66 would open. Thus, the valve 54 remains
sealed closed in such over-pressure situations.
Further, it will be appreciated that as the
valve central wall 64 moves outwardly, the valve skirt
68 is carried upwardly around the seal post 90.
Preferably, the external diameter of the seal post 90 is
less than the internal diameter of the valve skirt 68,
but the seal post external diameter is sufficiently
large so that the valve skirt 68 can seal against an
annular portion of the seal post cylindrical surface 94
during overpressure conditions when the valve is forced
outwardly.
In a contemplated embodiment, as the valve 54
articulates or moves outwardly from the fully recessed
position illustrated in FIG. 5 to a more outwardly
position (intermediate the positions shown in FIGS. 5
and 6), the periphery of the valve central wall 64 and
portion of the skirt 68 may tend to be compressed
slightly in the radially inwardly direction to
accommodate the movement of the valve. The slight
reduction in the diameters of portions of the valve may
be characterized as somewhat of a "collapsing" motion
which occurs around the seal post 90 and which
facilitates the sealing of the valve 54 by the seal post
90. The sealing engagement between the seal post distal
end surface 96 and the valve central wall 64, as well as
between the seal post cylindrical surface 94 and the
adjacent valve skirt 68, serves to provide a highly
effective seal which prevents unwanted dispensing of
product into the lid region of the closure.
Preferably, the lid seal post 90 is smooth and
free of indentations or other structure which could
collect unwanted product, and the smooth surface of the
seal post 90 provides a highly effective sealing surface
for engagement with the valve 54. In other contemplated
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embodiments, there need not be sealing around the seal
post cylindrical surface 94 so long as the valve wall 64
engages the post end surface 96 before the slits start
to open.
The outward movement of the valve central wall
64 from the recessed position (FIG. 5) to the more
outwardly position against the seal post 90 temporarily
increases the internal volume of the system. This
volume increase can reduce the rate of pressure increase
or peak pressure, and this can help accommodate the
over-pressure condition resulting from external impact
forces during shipping or handling.
Another, somewhat similar valve sealing
structure incorporated in a lid is disclosed in U.S.
Patent No. 5,213,236. This may be preferable in some
applications.
In a preferred embodiment, the closure base
body 50, lid 48, and hinge 47 are molded from a first
material, such as polypropylene, and the valve 54 is
molded from a second material, such as a thermoplastic
elastomer.
According to one technique, a multi-shot
injection molding process is used to first mold the
closure base body or end structure 50 as a "preform" in
a first injection phase in a mold. This includes the
optional lid 48 and hinge 47 in the preferred embodiment
illustrated. T'he preform is then transferred to a
second, differently shaped cavity generally within the
same mold wherein the second material (e. g.,
thermoplastic elastomer) is injection-molded (over-
molded) in a second phase onto and against the annular
attachment surface 58 of the closure preform to form the
valve 54. The valve 54 is preferably attached or bonded
to the closure base body 50 by the creation of a weld
defined by the interface solidification of melted
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portions of the first and/or second materials. The valve 54
may be molded with the slits 66. However, in a presently
preferred method, the valve slits 66 are cut into the wall
or face 64 by suitable conventional or special techniques.
Descriptions of mufti-shot, mufti-material
injection molding techniques are set forth in "Multi-
Material Injection Saves Time, While Cutting Costs", MODERN
PLASTICS, March 19, 1994 (author: Peter Mapleston), in
"Molding Many Parts Into One", Product Design and
Development, December 19, 1995, page 16 (author: Jay
Rosenberg), and in U.S. Patent No. 5,439,124.
The above-described molding technique need not be
employed. Other techniques may be used. For example,
according to a preferred method for making the closure, the
body, lid, and hinge can be initially molded from a first
material in a mold assembly pursuant to the process for
molding a body, lid, and hinge disclosed in the European
Patent No. 0 570 276. Subsequently, the valve 54 can be
molded from a second material against the closure body
surface 58 in the same mold assembly after repositioning an
internal mold element. The European Patent No. 0 570 276
discloses how an internal mold element 12 can be
repositioned to accommodate the molding of a second material
into a ring 8 against the closure body. This technique can
be employed according to the present invention for molding
the valve 54 in a mold assembly against the previously
molded closure body.
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The use of a thermoplastic elastomer for
injection molding the valve 54 is in many applications
because a thermoplastic elastomer provides suitable
characteristics which accommodate the desired opening
and closing of the valve 54 in response to the container
interior pressure changes.
A closure lid, such as the lid 48, need not be
provided. If provided, the closure lid 48 may be an
entirely separate piece unconnected to the closure base
46. Preferably, however, the hinge 47 is provided for
connecting the lid 48 to the body base 46 to form a
unitary structure. The hinge may be a floppy hinge or a
snap-action hinge, but a snap-action hinge 47 is
preferred.
When the user desires to dispense product from
the container through the closure 40, the user lifts the
lid 48 away from the valve 54. When the lid 48 is moved
far enough away from the valve 54, the product may be
discharged from the container through the valve 54 by
squeezing the container as previously described in
detail. When it is again desired to seal the container
closed, the lid 48 is moved back onto the base body 50.
In some packages, the lid 48 can be designed to be left
open.
Because the valve 54 is bonded to the closure
body 50, the closure may be characterized as a one-piece
system or integral system. Because the valve 54 is
molded directly into the closure body 50, separate
manufacture, storage, and handling of the valve 54 is
not required. Costly manufacturing processes for
assembling a small valve into a closure body are
eliminated. The one-piece system eliminates or
minimizes potential defects arising from improper
assembly. The one-piece dispensing system is less
likely to leak or become loose.
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Alternate embodiments of the dispensing system
of the present invention are illustrated in FIGS. 9, 10,
and 11. In these other embodiments, the dispensing
system is provided directly in a container body rather
than in a separate closure mounted to a container body.
Elimination of the separate dispensing closure reduces
the number of components of the package and provides a
more secure package. Because there is no separate
dispensing closure mounted to the container, easy access
to the container interior is eliminated. Further,
elimination of a separate closure per se avoids
manufacturing problems associated with storing,
handling, and assembling a separate closure on a
separate container. Further, potential loose fit or
leakage problems associated with separate closures are
eliminated.
The alternate embodiments of the dispensing
system may be characterized as including, among others,
any of the following: (1) a dispensing end structure in
the form of an open-ended container body 100 (FIG. 9)
with a dispensing valve bonded to the container body,
(2) a dispensing end structure in the form of a preform
100A (FIG. 10) which has a dispensing valve bonded
thereto and which can be subsequently formed into an
open-ended container body, or (3) a dispensing end
structure in the form of a small preform tube or body
with a dispensing valve bonded to it and with can be
subsequently blow-molded to form a larger, bottom-sealed
container (FIG. 11). The dispensing valve may be any
suitable dispensing valve, such as the dispensing valve
54 described above with reference to the first
embodiment illustrated in FIGS. 1-6.
In the alternate embodiments, the dispensing
end structure 100 may be directly injection-molded as an
open-ended container body illustrated in FIG. 9. The
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dispensing end structure may also be created by first
molding a preform 100A (shown in solid lines in FIG. 10)
to which the valve can be molded and which is
subsequently stretched or formed into the open-ended
container body (shown in dashed lines in FIG. 10). The
dispensing end structure may also be created by first
molding a small tube preform to which the valve can be
molded and which is subsequently blow-molded to form a
larger size container. In any case, the dispensing end
structure (e. g., 100 or 100A) has a valve attachment
surface 158 surrounding a dispensing orifice 160.
Preferably, the dispensing end structure has a
peripheral shoulder 157a, a deck 157b, and an annular
spout 157c projecting upwardly from the deck 157b. The
spout 157c defines the valve attachment region or
surface 158 and the dispensing orifice 160.
Preferably, the attachment region surface 158
is defined on an annular shoulder and is oriented at an
oblique angle to the longitudinal axis of the dispensing
orifice 160. The attachment region surface 158 is
preferably oriented at an angle to match the angle of
the surf ace of the valve flange (e . g . , flange 72 of the
valve 54 which is fully illustrated FIGS. 2-4). Other
suitable types of valves and flange arrangements may be
employed. For example, the bottom seating surface of
the valve flange 72 may be generally planar instead of
angled, and the attachment surface 158 may be planar,
rather than angled.
According to one form of the invention, the
dispensing end structure 100 is injection-molded from a
first material (e. g., polypropylene) to initially
include (1) the above-described valve mounting
configuration (e. g., shoulder 157a, deck 157b, spout
157c, attachment surface 158, and dispensing orifice
160), and (2) an open-ended container body portion
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having a hollow, cylindrical wall 110 (FIG. 9).
Subsequently, the valve (such as the valve 54 which is
fully illustrated in FIGS. 2-4) can be injection-molded
onto the attachment region surface 158 (in the same
manner as previously described with respect to molding
the valve 54 onto the first embodiment closure body
attachment surface 58 illustrated in FIGS. 7 and 8).
Preferably, a multi-shot injection molding
process is used to make the system which includes the
dispensing end structure 100 shown in FIG. 9. In a
first phase, the dispensing end structure 100 (which
contains the container body wall 110) is injection-
molded in a mold from a first material (e. g.,
polypropylene). The structure 100 may be transferred to
a second, differently shaped cavity generally within the
same mold wherein a second material (e.g., a
thermoplastic elastomer) is injection-molded (over
molded) in a second phase onto and against the
attachment surface 158 of the dispensing end structure
so as to form the valve (e. g., valve 54 shown in FIGS.
2-4). Preferably, the structure 100 and valve 54 are
molded from two different materials pursuant to the
technique taught in the European Patent No. 0 570 276
wherein a movable internal mold element is employed.
The mold element is repositioned after the body is
molded to accommodate molding of the valve. The valve
is preferably bonded to the dispensing end structure
surface 158 by the creation of a weld defined by the
interface solidification of melted portions of the first
and/or second materials.
The open-ended structure 100 can then be
provided to the product packager for filling and
sealing. That is, the packager can fill the interior of
the container body wall 110 with product through the
open end (opposite the end at which the valve is
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located). The open end of the container body wall 110
can then be sealed closed by a suitable conventional or
special process. FIG. 11 shows the completed package
with sealed closed bottom end 124, closed on the top
with 54, and filled with a liquid product 128.
In another form of the invention, a dispensing
end structure may be initially molded as a preform 100A
in the first injection phase as shown in solid lines in
FIG. 10 so as to have a thicker, short wall or annular
mass 120 of the first material extending from the deck
157b. Owing to the unitary, injection-molded nature of
the preform 100A, the annular mass or wall 120 may be
characterized as being connected to the attachment
region 158 (through the deck 157b and spout 157c).
After the dispensing end structure or preform 100A is
injection-molded, the valve (such as valve 54) is molded
onto the dispensing end structure attachment surface 158
to form the dispensing system.
Subsequently, the dispensing system (i.e., end
structure preform 100A with the valve bonded thereto) is
transferred to a secondary processing system wherein the
annular mass or wall 120 is subsequently stretched
axially along its length to create the open-ended
container body having an annular wall 310 as shown in
dashed lines in FIG. 10. The valve is not shown in FIG.
10 for ease of illustration, but it is to be understood
that the valve'would have been molded in place to form
the dispensing system prior to the wall 120 being
stretched. This stretching process is illustrated in
FIG. 10 by the arrow 130 which represents the
application of a tensile stretching force to the
structure to form the wall 110. Any suitable stretching
process or body-forming process may be employed. One
process for making a unitary, open-ended container body
having a dispensing end is disclosed in the
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international patent application PCT/EP95/01395
(Publication WO 95/28274).
According to yet another contemplated aspect
of the present invention, the dispensing end structure
can be made by initially injection-molding a preform
that includes a small diameter tube or container body
with an open bottom end. Then, the valve (e. g., valve
54) is molded into the dispensing orifice (pursuant to
the techniques discussed above in describing the first
embodiment) to create the dispensing system. The open-
ended dispensing system (i.e., the small diameter tube
or container body preform with the slit valve in place)
can then be blow molded to a larger, final
configuration. To do this, the open, bottom end of the
smaller preform would be clamped and sealed off by the
closed, blow mold halves during the blow-molding
process. The tube or body can be pressurized and blown
by inserting and sealing off the blow pin through the
valve slits (or alternatively by sealing the end of the
blow pin against the valve flange 70. The tube or body
is blow-molded toga larger size and final configuration
so that the first material creates a closed bottom end
opposite the top valve end. Following trimming of the
flash on the sealed closed bottom end, the resulting
molded product is then provided to the packager for
filling through the valve. Alternatively, the closed
bottom end could cut off, and the body could then be
filled through the open bottom end which could be
subsequently sealed closed.
In yet another form of the present invention,
the dispensing end structure may be initially provided
in the form of a sheet of thermoplastic material
defining a dispensing orifice and valve attachment
region. The valve is then molded directly onto the
sheet of thermoplastic material against the attachment
SUBSTITUTE SHEET (RULE 26)
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region. The sheet is subsequently subjected to a
secondary forming operation, such as vacuum forming, so
as to form the open-ended container body which can then
be filled with product and sealed closed by the
packager. Alternatively, the sheet could be formed,
filled, and bottom-sealed in a pouch sealing type of
operation prior to molding the valve to the container.
The above-described injection-molding process,
wall stretching process, blow-molding process, vacuum-
forming process, and pouch-sealing process may employ
conventional or special techniques. The details of such
techniques form no part of the present invention.
Although FIGS. 9 and 10 do not show a lid, it
will be appreciated that the dispensing end structure
may be molded with or without a lid.
It will be readily observed from the foregoing
detailed description of the invention and from the
illustrations thereof that numerous other variations and
modifications may be effected without departing from the
true spirit and scope of the novel concepts or
principles of this invention.
