NECK-FINISH FOR AN AEROSOL CONTAINER

Abstract

A molded, pressure capable container (50) is provided for use with an aerosol valve assembly (12A) to dispense a fluent product stored in the container (50). The aerosol valve assembly (12A) includes an aerosol valve (24) and a mounting cup (23A) that is crimped onto the container (50) to mount the aerosol valve (24) to the container (50). The container (50) includes a molded body (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). The neck flange (60) 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).

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable.

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

MICROFICHE/COPYRIGHT REFERENCE

Not Applicable.

TECHNICAL FIELD

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.

BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE PRIOR ART

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.

FIGS. 1-6 illustrate examples of pressure capable containers 10A and 10B and valve assemblies 12A and 12B that are currently used for 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.

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 10B 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 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.

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.

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 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.

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

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 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.

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 3.0/1.0. In a further feature, the ratio of radial thickness Tr to the axial thickness Ta is no less than 3.5/1.0. 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 3.0/1.0.

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 α with the axis in the range of 45° to 70°. In a further feature, the angle α is in the range of 55° to 65°. In yet a further feature, the angle α is 60°.

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.

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.

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.

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·Tm. In a further feature, Ta is no greater than 3.5·Tm. In yet a further feature, Ta is no greater than 2.5·Tm.

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×Tm. In a further feature, the blend radiuses R are no greater than 1.333×Tm.

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

FIG. 1 is a longitudinal, partial section view illustrating a prior art pressure capable container and aerosol valve assembly;

FIG. 2 is an enlarged, fragmentary view of the area indicated in FIG. 1 by the dashed line labeled “FIG. 2”;

FIG. 3 is an enlarged view of a mounting cup component of the aerosol valve assembly of FIG. 1 prior to installation;

FIG. 4 is a longitudinal, partial section view of another prior art pressure capable container and aerosol valve assembly;

FIG. 5 is an enlarged, fragmentary view of the area indicated in FIG. 4 by the dashed line labeled “FIG. 5”;

FIG. 6 is an enlarged view of a mounting cup component of the aerosol valve assembly of FIG. 4 prior to installation;

FIG. 7 is a longitudinal, partial section view of a pressure capable container and aerosol valve assembly embodying the present invention;

FIG. 8 is an enlarged, fragmentary view of the area indicated in FIG. 7 by the dashed line labeled “FIG. 8”; and

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.

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, however. The scope of the invention is pointed out in the appended claims.

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.

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.

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 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.

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.

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 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 3.5/1.0. However, in some applications it may be desirable for the ratio of Tr to Ta to be outside of the preferred values.

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 α 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 α are important to achieving a desired crimped fitment with the mounting cup 23A, in some applications it may be desirable for the angle α to be outside of the preferred ranges.

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 α, 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.

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 the surface 66 is defined by a nonlinear projection (the blend radius R3) rotated about the axis 70, however this is not preferred.

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 2.0/1.0. However, in some applications it may be desirable for the ratio to be outside of the preferred range.

With reference to the mounting cup 23A, it is also preferred that the axial thickness Ta be no greater than 4.0×the thickness Tm of the material forming the mounting cup 23A. In a preferred form, Ta is no greater than 3.5×Tm. It is preferred that Ta be no greater than 2.5×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×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×Tm.

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.

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, α=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.

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.

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 α 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.

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 robustness of the seal created by the gasket 26, neck finish area 57, and mounting cup 23A.

Claims

1. A molded, pressure capable container (50) for use with an aerosol valve assembly (12A) to dispense a fluent product stored in the container (50), the aerosol valve assembly (12A) including an aerosol valve (24) and a mounting cup (23A) that is crimped onto the container (50) to mount the aerosol valve (24) to the container (50), the container (50) comprising:

a molded body (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), 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),

the neck flange (60) being configured for crimping of the mounting cup (23A) thereto and being 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), wherein the annular edge (62) and the frustoconical-shaped surface (66) are engageable with the mounting cup (23A) upon crimping of the mounting cup (23A) to the annular neck flange (60).

2. The container (50) of claim 1 wherein the annular neck flange (60) has a radial thickness Tr from the annular edge (62) to the opening (56), and the annular edge (62) 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 3.0/1.0.

3. The container (50) of claim 2 wherein the ratio of radial thickness Tr to the axial thickness Ta is no less than 3.5/1.0.

4. The container (50) of claim 2 wherein the ratio of radial thickness Tr to the axial thickness Ta is in the range of 4.1/1.0 to 3.0/1.0.

5. The container (50) of claim 1 wherein the frustoconical-shaped surface (66) is centered on a central, longitudinal axis (70), with the frustoconical-shaped surface (66) being a frustoconical surface (66) defined by a linear projection rotated about the axis (70) forming an angle α with the axis (70) in the range of 45° to 70°.

6. The container (50) of claim 5 wherein the angle α is in the range of 55° to 65°.

7. The container (50) of claim 5 wherein the angle α is 60°.

8. The container (50) of claim 1 wherein the annular edge (62) is centered on a central, longitudinal axis (70), has an axial thickness Ta parallel to the axis (70), and is blended to the end surface with a blend radius R that is no greater than 60% of the thickness Ta.

9. The container (50) of claim 8 wherein the blend radius R is no greater than 50% of the thickness Ta.

10. The container (50) of claim 1 wherein the annular edge (62) is centered on a central, longitudinal axis (70), has an axial thickness Ta parallel to the axis (70), and is blended to the frustoconical-shaped surface (66) with a blend radius R that is no greater than 60% of the thickness Ta.

11. The container (50) of claim 10 wherein the blend radius R in no greater than 50% of the thickness Ta.

12. The container (50) of claim 1 in combination with an aerosol valve assembly (12A), the aerosol valve assembly comprising an aerosol valve (24) and a mounting cup (23A), the mounting cup (23A) formed from a material having a thickness Tm, the mounting cup (23A) being crimped to the annular neck flange (60).

13. The container (50) of claim 12 wherein the annular edge (62) is centered on a central, longitudinal axis (70) and has an axial thickness Ta parallel to the axis (70) that is no greater than 4.0×Tm.

14. The container (50) of claim 13 wherein Ta is no greater than 3.5×Tm.

15. The container (50) of claim 12 wherein the annular edge (62) is blended to the annular end surface (64) and the frustoconical-shaped surface (66) with blend radiuses R that are no greater than 2.1333×Tm.