Note: Descriptions are shown in the official language in which they were submitted.
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-1-
IMPROVED NECK-FINISH FOR AN AEROSOL CONTAINER
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
MICROFICHE/COPYRIGHT REFERENCE
[0003] Not Applicable.
TECHNICAL FIELD
[0004] This invention relates generally to a dispensing system for a
fluent product, which can include liquids, gases, foams, dispersions, paste,
creams, etc. The invention more particularly relates to dispensing systems
that include a pressure capable container, such as for example, an aerosol
container.
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-2-
BACKGROUND OF THE INVENTION
AND
TECHNICAL PROBLEMS POSED BY THE PRIOR ART
[0005] Aerosol packages are used for storing and dispensing fluent
products, such as, for example, paint, hairspray, whip cream, etc. and are
typically made up of a pressure capable container, an aerosol valve
assembly, a dispensing actuator, and a propellant. In the aerosol spray
industry, the pressure capable containers have historically been provided in
the form of molded glass bottles, formed or fabricated metallic cans or
bottles, and molded plastic bottles, with molded glass bottles initially being
the norm, metallic cans and bottles growing in popularity over time with
advancements in materials and manufacturing, and plastic bottles currently
growing in popularity due to further advancements in materials and
manufacturing. The aerosol valve assembly typically includes an aerosol
valve and a metallic mounting cup that forms a crimped fitment between the
valve assembly and the pressure capable container to mount the aerosol
valve to the container and create a hermetically-sealed pressurized vessel.
This crimped fitment typically creates a leak-free, secure seal that can
withstand the possible 15 bar plus pressure inside the pressure. capable
container and historically has required that a different mounting cup be used
for a molded glass or plastic bottle than the mounting cups that are used for
metallic cans or bottles.
[0006] Figs. 1-6 illustrate examples of pressure capable containers
10A and 10B and valve assemblies 12A and 12B that are currently used for
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-3-
aerosol packages, with Figs. 1-3 showing a metallic, pressure capable
container 10A and corresponding aerosol valve assembly 12A and Figs. 4-6
showing a molded, pressure capable container 10B and corresponding
aerosol valve assembly 12B. The pressure capable container 10A of Figs. 1-
3 is shown in the form of a formed, aluminum can/bottle 14 and the pressure
capable container 10B of Figs. 4 and 6 is shown in the form of a plastic
container 15 that is formed via injection molding followed with a blow molding
operation.
[0007] Each of the pressure capable containers 10A and 10B has a
chamber 16 to contain a fluent product, a dispensing opening 18 extending
from the chamber 16 to an exterior of the container 10, and a neck finish
area 19 in the form of an annular neck 20 surrounding the opening 18 and an
annular neck flange 22 on a distal end of the neck 20 to mount the
corresponding aerosol valve assembly 12A or 12B. As best seen in Figs. 2
and 5, the neck finish areas 19 of the conventional metallic pressure capable
container 10A and the conventional molded pressure capable container 10B
differ significantly. Specifically, the neck finish area 19 of the molded
pressure capable container 10B is thicker and bulkier in comparison to the
neck finish area for the metallic pressure capable container 10A. The thicker
and bulkier neck finish area 19 of the molded pressure capable container
1 OB is, in part, a carryover from the functionally and manufacturing needs of
the glass aerosol bottle industry. Specifically, because of the brittleness of
glass, excessive stresses from the crimped fitment with the mounting cup of
the aerosol valve assembly could cause a leak or vulnerable spot for failure
if
dropped or if put under excessive environmental conditions. In contrast, the
strength, durability and robustness of the metal materials used to form
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-4-
metallic pressure capable containers, such as the container 10A, allow the
neck finish area 19 to be smaller. These differences in the neck finish areas
19 require that the valve assemblies 12A and 12B use different metallic
mount cups 23A and 23B that are compatible with the corresponding
container 10A and 10B, as will be discussed in further detail below.
[0008] Each of the aerosol valve assemblies 12A and 12B includes an
aerosol valve 24 (not shown sectioned in Figs. 1, 3, 4, and 6), a gasket 26,
and the metallic mounting cup 23A or 23B that is crimped to the flange 22
and neck 20 of the corresponding container 10A or 10B. Although not
shown, it will be understood by those skilled in the art that each of the
aerosol valve assemblies 12A and 12B will also typically include a dip tube,
and in some cases may include a fluent product containing pouch or bag
mounted on a fitment of the aerosol valve 24 in a so-called "bag-on-valve"
type construction. It will also be understood by those skilled in the art that
the construction of the aerosol valve 24 and the gasket 26 are not dependent
upon the type of container 10A or 10B with which they are used and that
there are many known constructions for the aerosol valve 24 and gasket 26.
It will further be understood by those skilled in the art that the aerosol
valve
24 is typically retained in the corresponding mounting cup 23A and 23B by a
crimped fitment, such as shown at 29 in Fig. 2.
[0009] Figs. 3 and 6 show the mounting cups 23A and 23B,
respectively, prior to assembly with the aerosol valve 24 and corresponding
container 10A and 10B. The mounting cups 23A and 23B are typically
stamped from a suitable sheet metal having a material thickness Tm that is
commonly in the range of 0.010 inch to 0.016 inch, depending upon the
particular metal material used, with 0.010 inch to 0.011 inch being a
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-5-
preferred range for tin plate steel and 0.015 inch to 0.016 inch being a
preferred range for aluminum. As can be seen, the mounting cups 23A and
23B are identical in their essential features with the exception of the
respective cylindrical skirts 30A and 30B that help to define an annular
channel 32 for receiving the neck flange 22 of the respective container 10A
and 10B. The skirt 30B is longer than the skirt 30A to accommodate the
bulkier neck finish area 19 of the container 10B and to allow an outside crimp
of the mounting cup 23B to the neck finish area 19, as shown at 34 in Fig. 5.
It should be noted that the neck finish area 19 of the container 10B isn't
suitable for an inside crimp. While the neck finish area 19 of the container
10A can accommodate an outside crimp, an inside crimp is generally the
preferred form of crimped fitment in the aerosol industry and is illustrated
in
Fig. 2 at 36.
[0010] The pressure capable container's 10A and 10B and
corresponding aerosol valve assemblies 12A and 12B have proven to be
very suitable for their intended purpose. However, in an ever competitive
market, there is always room for improvements.
SUMMARY OF THE INVENTION
[0011] In accordance with one feature of the invention, a molded,
pressure capable container is provided for use with an aerosol valve
assembly to dispense a fluent product stored in,the container. The aerosol
valve assembly includes an aerosol valve and a mounting cup that is crimped
onto the container to mount the aerosol valve to the container. The container
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-6-
includes a molded body having a chamber to contain a fluent product, a
dispensing . opening extending from the chamber to an exterior of the
container, an annular neck surrounding the opening, and an annular neck
flange on a distal end of the neck to mount the aerosol valve assembly. The
annular neck flange is configured for crimping of the mounting cup thereto
and is defined by a radially outermost, annular edge; an annular end surface
extending from the annular edge to the opening; and a frustoconical-shaped
surface extending from the annular edge to an outer surface of the annular
neck, with the annular edge and the frustoconical-shaped surface being
engageable with the mounting cup upon crimping of the mounting cup to the
annular neck flange.
[0012] As one feature, the annular neck flange has a radial thickness
Tr from the edge to the opening, and the annular edge has axial thickness Ta
transverse to the radial thickness Tr, and the ratio of radial thickness Tr to
the axial thickness Ta is no less than 3.0/1Ø In a further feature, the
ratio of
radial thickness Tr to the axial thickness Ta is no less than 3.5/1Ø In yet
a
further feature, the ratio of radial thickness Tr to the axial thickness Ta is
in
the range of 4.1/1.0 to 3.0/1Ø
[0013] In one feature, the frustoconical-shaped surface is centered on
a central, longitudinal axis, with the frustoconical-shaped surface being
defined by a linear projection rotated about the axis. The frustoconical-
shaped surface forms an angle a with the axis in the range of 45 to 70 . In a
further feature, the angle a is in the range of 55 to 65 . In yet a further
feature, the angle a is 60 .
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-7-
[0014] According to one feature, the annular edge is centered on a
central, longitudinal axis, has an axial thickness Ta parallel to the axis and
is
blended to the end surface with a blend radius that is no greater than 60% of
the thickness Ta. In a further feature, the blend radius in no greater than
50% of the thickness Ta.
[0015] As one feature, the annular edge is blended to the
frustoconical-shaped surface with a blend radius that is no greater than 60%
of the thickness Ta. In a further feature, the blend radius is no greater than
50% of the thickness Ta.
[0016] In accordance with another feature of the invention, the
container is combined with an aerosol valve assembly, the aerosol valve
assembly including an aerosol valve and a metallic mounting cup. The
metallic mounting cup is formed from a material having a thickness Tm, and
is crimped to the neck flange.
[0017] As one feature, the annular edge defines a central, longitudinal
axis and has an axial thickness Ta parallel to the axis that is no greater
than
4.0 x Tm. In a further feature, Ta is no greater than 3.5 x Tm. In yet a
further feature, Ta is no greater than 2.5 x Tm.
[0018] According to one feature, the annular edge is blended to the
end surface and the frustoconical-shaped surface with blend radiuses R that
are no greater than 2.1333 x Tm. In a further feature, the blend radiuses R
are no greater than 1.333 x Tm.
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-8-
[0019] Other objects, features, and advantages of the invention will
become apparent from a review of the entire specification, including the
appended claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Fig. 1 is a longitudinal, partial section view illustrating a prior art
pressure capable container and aerosol valve assembly;
[0021] Fig. 2 is an enlarged, fragmentary view of the area indicated in
Fig. 1 by the dashed line labeled "FIG. 2";
[0022] Fig. 3 is an enlarged view of a mounting cup component of the
aerosol valve assembly of Fig. 1 prior to installation;
[0023] Fig. 4 is a longitudinal, partial section view of another prior art
pressure capable container and aerosol valve assembly;
[0024] Fig. 5 is an enlarged, fragmentary view of the area indicated in
Fig. 4 by the dashed line labeled "FIG. 5";
[0025] Fig. 6 is an enlarged view of a mounting cup component of the
aerosol valve assembly of Fig. 4 prior to installation;
[0026] Fig. 7 is a longitudinal, partial section view of a pressure
capable container and aerosol valve assembly embodying the present
invention;
[0027] Fig. 8 is an enlarged, fragmentary view of the area indicated in
Fig. 7 by the dashed line labeled "FIG. 8"; and
[0028] Fig. 9 is an enlarged view of the area indicated in Fig. 7 by the
dashed line labeled "FIG. 9", but in FIG. 9 the mounting cup and gasket have
been omitted.
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-9-
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] 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, however. The
scope of the invention is pointed out in the appended claims.
[0030] For ease of description, the features of this invention and the
container employed with the features of this invention are described in the
normal (upright) operating position. Terms such as upper, lower, horizontal,
etc., are used with reference to this position. It will be understood,
however,
that the components embodying this invention may be manufactured, stored,
transported, used, and sold in an orientation other than the position
described.
[0031] Figures illustrating the features of this invention and the
container and aerosol valve assembly show some conventional mechanical
elements that are known and that will be recognized by one skilled in the art.
The detailed description of such elements is not necessary to an
understanding of the invention, and accordingly, is herein presented only to
the degree necessary to facilitate an understanding of the novel features of
the present invention.
[0032] Figs. 7-9 illustrate a molded, pressure capable container 50
embodying the present invention and intended for use with an aerosol valve
assembly 12A such as is conventionally used for metallic pressure capable
containers like the container 10A as previously described in connection with
Figs. 1-3. As best seen in Fig. 7, the container 50 includes a molded body
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-10-
52 having a chamber 54 to contain a fluent product, a dispensing opening 56
extending from the chamber 54 to an exterior of the container 50, and a neck
finish area 57 in the form of an annular neck 58 surrounding the opening 56,
and an annular neck flange 60 on a distal end of the annular neck 58 to
mount the aerosol valve assembly 12A. As best seen in Figs. 8 and 9, the
neck flange 60 is configured for crimping of the mount cup 23A thereto and is
defined by a radially outermost, annular edge 62; an annular end surface 64
extending from the annular edge 62 to the opening 56; and a frustoconical-
shaped surface 66 extending from the annular edge 62 to an outer surface
68 of the annular neck 58. The annular edge 62 and frustoconical-shaped
surface 66 are engageable with the cup 23A upon crimping of the cup 23A to
the flange 60 with an outside crimp, as shown at 69. The annular neck 58 is
cylindrical in the illustrated embodiment, and the neck 58 and the annular
neck flange 60, including the annular edge 62, annular end surface 64, and
frustoconical-shaped surface 66, are centered on a central, longitudinal axis
70.
[0033] Preferably, as best seen in Figs. 8 and 9, the annular end
surface 64 is generally planar transverse to the axis 70, but includes a pair
of
seal beads 72 and 74 for sealing engagement with the gasket 26 with the
gasket 26 compressed between the end surface 64 and the mounting cup
23A by the crimped fitment. However, in some applications, it may be
desirable for the seal beads 72 and 74 to be eliminated and/or for the end
surface 64 to have a general shape that is non-planar.
[0034] With reference to Fig. 9, the annular neck flange 60 has a radial
thickness Tr extending from the annular edge 62 to the opening 56, and the
annular edge 62 has an axial thickness Ta transverse to the radial thickness
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-11-
and parallel to the axis 70. Preferably, the ratio of the radial thickness Tr
to
the axial thickness Ta is in the range 4.1/1.0 to 3.0/1.0, and even more
preferably the ratio of radial thickness Tr to the axial thickness Ta is no
less
than 3.5/1Ø However, in some applications it may be desirable for the ratio
of Tr to Ta to be outside of the preferred values.
[0035] As shown in Figs. 8 and 9, the frustoconical-shaped surface 66
preferably is a frustoconical surface 66 defined by a linear projection
rotated
about the axis 70. The surface 66 forms an angle a with the axis 70 that is
preferably in the range of 45 to 70 , and more preferably in the range of 55
to 65 . While it is believed that these ranges for the angle a are important
to
achieving a desired crimped fitment with the mounting cup 23A, in some
applications it may be desirable for the angle a to be outside of the
preferred
ranges.
[0036] The annular edge 62 is preferably blended to the annular end
surface 64 with a blend radius R1 and to the frustoconical-shaped surface 66
with a blend radius R2. Preferably, the blend radiuses R1 and R2 are no
greater than 60% of the axial thickness Ta, and even more preferably the
blend radiuses are no greater than 50% of the axial thickness Ta. As with
the angle a, in some applications it may be desirable for one or both of the
blend radiuses R1 and R2 to be outside of the preferred range.
[0037] The frustoconical-shaped surface 66 is also preferably blended
to the outer surface 68 of the neck 58 with a blend radius R3, and preferably
the blend radius R3 is in the range of 50% to 25% of the radial thickness Tr.
In this regard, it should be noted, that in some cases the blend radius R3
may be so large that it defines the frustoconical-shaped surface 66 so that
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-12-
the surface 66 is defined by a nonlinear projection (the blend radius R3)
rotated about the axis 70, however this is not preferred.
[0038] The annular neck 58 has a radial wall thickness Tw and the
ratio of the thickness Tr to the thickness Tw is preferably in the range of
1.60/1.0 to 2.0/1Ø However, in some applications it may be desirable for
the ratio to be outside of the preferred range.
[0039] With reference to the mounting cup 23A, it is also preferred that
the axial thickness Ta be no greater than 4.0 x the thickness Tm of the
material forming the mounting cup 23A. In a preferred form, Ta is no greater
than 3.5 x Tm. It is preferred that Ta be no greater than 2.5 x Tm for
mounting cups 23A that have a material thickness Tm in the range of 0.015
inch to 0.016 inch, such as for aluminum mounting cups. It is also preferred
that the blend radiuses R1 and R2 be no greater than 2.1333 x Tm. For
mounting cups 23A that have a material thickness Tm in the range of 0.015
inch to 0.016 inch, such as for aluminum mounting cups, it is preferred that
the blend radiuses R1 and R2 be no greater than 1.333 x Tm.
[0040] It should be appreciated that while the mounting cup 23A has
been described herein as a metallic mounting cup 23A, it is possible that a
non-metallic mounting cup 23A could be desirable in some applications.
[0041] In one highly preferred embodiment for use with mounting cups
23A having a material thickness Tm of 0.015 inch or 0.016 inch, the opening
has a diameter D = 1 inch, Tr = 0.123 inch, Ta = 0.35 inch, R1 and R2 =
0.015 inch, R3 = 0.040 inch, a = 60 , and Tw = 0.066 inch, with each of the
dimensions being a nominal dimension that can vary within tolerances that
are standard in the aerosol package industry.
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-13-
[0042] The container 50 can be formed of any suitable plastic using
any suitable molding process or combination of molding processes. For
example, in one preferred form, the material is Polyethylene Naphthalate
(PEN), and a preform for the container 50 is injection molded to define the
neck finish area 57, with the remainder of the container 50 being finished in
a
blow molding process to form the chamber 54.
[0043] It has been discovered that by providing the neck finish area 57
with the frustoconical-shaped surface 66, the molded pressure capable
container 50 can be used with mounting cups, such as mounting cup 23A,
that are conventionally used with metallic pressure capable containers, such
as container 10A, and that a preferred crimped fitment can be achieved with
careful selection of the angle a and/or the blend radiuses R1 and R2. This
allows for molded pressure capable containers to use the same mounting
cup as metallic pressure capable containers, thereby reducing the need for a
mounting cup that is specific to molded pressure capable containers, and
further, allows for the less expensive mounting cup 23A to be utilized with a
molded pressure capable container. In this regard, it will be understood that
the mounting cup 23A requires less material than the mounting cup 23B and
is easier to form. Further, the neck finish area 57 requires less material
than
the neck finish area 19 of the molded container 10B shown in Figs. 4-6.
[0044] Moreover, in comparison to the crimped fitment between the
mounting cup 23B and the molded container 10B shown in Figs. 4-6, it is
believed that the crimped fitment between the neck finish area 57 and the
mounting cup 23A provides improved retention of the mounting cup 23A to
the container 50, greater stability of the container 50 and mounting of the
aerosol valve assembly 12A at elevated temperatures, and greater
CA 02786822 2012-07-11
WO 2011/090457 PCT/US2010/000162
-14-
robustness of the seal created by the gasket 26, neck finish area 57, and
mounting cup 23A.
