U.S. patent application number 14/971925 was filed with the patent office on 2016-06-23 for package for consumer care products.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Justin Alan ELLSWORTH.
Application Number | 20160174686 14/971925 |
Document ID | / |
Family ID | 55182552 |
Filed Date | 2016-06-23 |
United States Patent
Application |
20160174686 |
Kind Code |
A1 |
ELLSWORTH; Justin Alan |
June 23, 2016 |
Package For Consumer Care Products
Abstract
A movable elevator platform for use in a dispensing package is
provided, the movable elevator platform having a coupling sleeve
capable of engaging a screw assembly and a rim surrounding the
coupling sleeve, said rim being non-removably attached to the
coupling sleeve and including a flange. The movable elevator
platform has a vertical contact surface area and a horizontal
contact surface area. About 20% to about 90% of the horizontal
contact surface area is located on the flange, and the flange has a
width that does not exceed about 8.5 mm.
Inventors: |
ELLSWORTH; Justin Alan;
(Sharonville, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
55182552 |
Appl. No.: |
14/971925 |
Filed: |
December 16, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62095101 |
Dec 22, 2014 |
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62114930 |
Feb 11, 2015 |
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Current U.S.
Class: |
401/68 ;
401/55 |
Current CPC
Class: |
B65D 83/0011 20130101;
A45D 40/04 20130101 |
International
Class: |
A45D 40/04 20060101
A45D040/04; B65D 83/00 20060101 B65D083/00 |
Claims
1. A movable elevator platform for use in a dispensing package, the
movable elevator platform comprising: a coupling sleeve capable of
engaging a screw assembly; and a rim surrounding the coupling
sleeve, said rim being non-removably attached to the coupling
sleeve and comprising a flange; wherein said movable elevator
platform has a vertical contact surface area and a horizontal
contact surface area; wherein about 20% to about 90% of the
horizontal contact surface area is located on the flange; wherein
the flange has a width D1 that does not exceed about 8.5 mm.
2. The movable elevator platform of claim 1, wherein about 45% to
about 70% of the horizontal contact surface area is located on the
flange.
3. The movable elevator platform of claim 1, further comprising a
plurality of partitions attached to the rim.
4. The movable elevator platform of claim 3, wherein the plurality
of partitions comprise from about 10% to about 60% of the
horizontal contact surface area.
5. The movable elevator platform of claim 3, wherein the plurality
of partitions comprise from about 20% to about 40% of the
horizontal contact surface area.
6. The movable elevator platform of claim 1, further comprising a
tab.
7. The movable elevator platform of claim 1, further comprising a
convex top face.
8. The movable elevator platform of claim 1, wherein the coupling
sleeve is coupled to the rim by at least one tapered partition.
9. The movable elevator platform of claim 1, further comprising
more than four apertures.
10. The movable elevator platform of claim 1, wherein the flange is
tapered.
11. The movable elevator platform of claim 1, further comprising at
least one partition having a width D2, wherein the at least one
partition is attached to the rim, and wherein D1 is greater than
the width D2.
12. The movable elevator platform of claim 1, further comprising a
plurality of partitions, each of the plurality of partitions having
a width D2, wherein the plurality of partitions are attached to the
rim, and wherein the width D1 is greater than the width D2 of each
of the plurality of partitions.
13. The movable elevator platform of claim 12, wherein the rim has
a height D4 and each of the plurality of partitions has a height
D5, wherein the height D5 is greater than or equal to the height
D4.
14. The movable elevator platform of claim 12, wherein the width D2
of each of the plurality of partitions is less than or equal to
about 5 mm.
15. The movable elevator platform of claim 12, wherein the width D2
of each of the plurality of partitions is less than or equal to
about 2 mm.
16. The movable elevator platform of claim 12, wherein the width D2
of each of the plurality of partitions is less than or equal to
about 1.2 mm.
17. The movable elevator platform of claim 1, wherein the coupling
sleeve comprises a non-threaded section and a threaded section.
18. A movable elevator platform for use in a dispensing package,
the movable elevator platform comprising: a coupling sleeve capable
of engaging a screw assembly; and a rim surrounding the coupling
sleeve, said rim being non-removably attached to the coupling
sleeve and comprising a flange; wherein said movable elevator
platform has a vertical contact surface area and a horizontal
contact surface area; wherein the flange has a width D1 that does
not exceed about 8.5 mm; wherein the ratio of the vertical contact
surface area to the horizontal contact surface area is from about
1:10 to about 10:1.
19. The movable elevator platform of claim 18, wherein the ratio of
the vertical contact surface area to the horizontal contact surface
area is from about 1:5 to about 8:1.
20. The movable elevator platform of claim 1, wherein the ratio of
the vertical contact surface area to the horizontal contact surface
area is from about 1:2 to about 7:1.
Description
FIELD
[0001] This disclosure relates to packages for consumer care
products and methods of manufacturing the same. The packages are
particularly suited for antiperspirant and/or deodorant products,
but can equally be employed for other types of consumer care
products.
BACKGROUND
[0002] Traditionally, consumer care products such as
antiperspirants and/or deodorant products are packaged in an oval
or round plastic barrel component. The top of the barrel is open to
allow the product to be exposed and dispensed for use, while the
opposite, i.e. bottom, end of the barrel contains a mechanism
(e.g., a product support elevator coupled with a hand-rotatable
screw) to assist in the dispensing of the product.
[0003] Antiperspirant and deodorant compositions are offered by
manufacturers in a variety of sizes and product forms such as
liquids, creams, gels, semi-solids, and solid sticks. These
products have different ingredients, active levels, solvents,
viscosities, shapes, sizes, and fill volumes to address a variety
of consumer preferences and needs. In this regard, manufacturers
desire a more efficient way of producing these numerous product
offerings, especially under a single brand.
[0004] Currently, manufacturers may use different size barrels to
accommodate different fill volumes. Alternatively, manufacturers
may accommodate different fill volumes by changing the spindle
and/or the elevator designs. A change in one molded component of
the packaging requires adaptations of the other components. Each
packaging design must be adapted to avoid manufacturing, shipping,
storage, and dispensing problems that are associated with these
different product offerings. For example, different fill volumes
for compositions may exhibit different stability profiles, may
apply different internal pressures on the package, may require
air-tight seals, may cause different degrees of solvent syneresis
or weeping, and may require different package designs for ease of
and consistent dosing of the composition.
[0005] In addition, manufactures have historically used a large
number of injection molding parts to make different packaging
components for the various product offerings. As a result,
sometimes as many as 50-75 or more different molds must be
developed, used, and maintained in the injection molding process.
Thus, multiple product offerings to consumers present a major
challenge to manufacturers.
[0006] Thus, a need exists for interchangeable package components
to accommodate different fill volumes within a single package
and/or product chamber configuration. The use of the same mold
parts to manufacture packages that accommodate different fill
volumes reduces manufacturing cost and complexity since fewer
injection molds are needed. Also, manufacturing may be consolidated
to fewer manufacturing lines. These advantages are provided while
still providing a dispensing packaging demonstrating adequate
strength, flexibility, aesthetic appearance, stability, and
dispensing consistency for a variety of product offerings.
SUMMARY
[0007] The present disclosure is directed to consumer care products
and/or packages. In accordance with one of the embodiments, a
package for consumer care products and methods of manufacturing the
same are provided. The packages are particularly suited for
antiperspirant and/or deodorant products, but can equally be
employed for other types of consumer care products.
[0008] In one embodiment, a movable elevator platform for use in a
dispensing package includes a coupling sleeve capable of engaging a
screw assembly and a rim surrounding the coupling sleeve. The rim
is non-removably attached to the coupling sleeve and includes a
flange. The movable elevator platform has a vertical contact
surface area and a horizontal contact surface area. About 20% to
about 90% of the horizontal contact surface area is located on the
flange. The flange has a width that does not exceed about 8.5
mm.
[0009] In another embodiment, a movable elevator platform for use
in a dispensing package includes a coupling sleeve capable of
engaging a screw assembly and a rim surrounding the coupling
sleeve. The rim is non-removably attached to the coupling sleeve
and includes a flange. The movable elevator platform has a vertical
contact surface area and a horizontal contact surface area. The
flange has a width that does not exceed 8.5 mm. The ratio of the
vertical contact surface area to the horizontal contact surface
area is from 1:10 to 10:1.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] While the specification concludes with claims that
particularly point out and distinctly claim the invention, it is
believed that the present invention will be better understood from
the following description of embodiments, taken in conjunction with
the accompanying drawings in which:
[0011] FIG. 1 is a front view of an illustrative consumer care
product and dispensing package according to one or more embodiments
shown and described herein.
[0012] FIG. 2 is an exploded perspective view of an illustrative
dispensing package for consumer care product, illustrating some of
the individual components and having a form suitable for bottom
filling according to one or more embodiments shown and described
herein;
[0013] FIG. 3 is cross-sectional front view taken along a major
axis of an illustrative dispensing packaging with a movable
elevator platform at a first fill volume position according to one
or more embodiments shown and described herein;
[0014] FIG. 4 is cross-sectional front view taken along a major
axis of an illustrative dispensing packaging with a movable
elevator platform at a second fill volume position according to one
or more embodiments shown and described herein;
[0015] FIG. 5 is an example of a front view of an illustrative
movable elevator platform according to one or more embodiments
shown and described herein;
[0016] FIG. 6 is a side view of the movable elevator platform of
FIG. 5;
[0017] FIG. 7 is a top view of the movable elevator platform of
FIG. 5;
[0018] FIG. 8 is a perspective, bottom view of the movable elevator
platform of FIG. 5;
[0019] FIG. 9 is a bottom view of the movable elevator platform of
FIG. 5;
[0020] FIG. 10 is a perspective, bottom view of the movable
elevator platform of FIG. 5;
[0021] FIG. 11 is a cross-sectional view of the front view of the
movable elevator platform of FIG. 5;
[0022] FIG. 12A is a perspective, bottom view of the movable
elevator platform of FIG. 5 and illustrating a plane for the
horizontal cross section according to one or more embodiments shown
and described herein;
[0023] FIG. 12B is a perspective, bottom view of the movable
elevator platform of FIG. 5 after horizontal cross sectional cut
according to one or more embodiments shown and described
herein;
[0024] FIG. 12C is a perspective, bottom view of the movable
elevator platform of FIG. 5 filled with a composition according to
one or more embodiments shown and described herein;
[0025] FIG. 13A is a perspective, top view of a prior art
elevator;
[0026] FIG. 13B is a perspective, bottom view the elevator of FIG.
13A; and
[0027] FIG. 13C is a perspective, bottom view of the elevator of
FIG. 13A after a horizontal cross sectional cut.
DETAILED DESCRIPTION
[0028] While the specification concludes with the claims
particularly pointing out and distinctly claiming the invention, it
is believed that the present invention will be better understood
from the following description.
[0029] As used herein, "consumer care product", which may also be
referred to as the "product", refers to any consumer care product,
including, but not limited to, beauty care products, household care
products, health care products, pet care products, and the
like.
[0030] "Antiperspirants", as used herein, includes antiperspirants,
deodorants, deodorant/antiperspirants and body sprays, and may also
be considered as beauty care products.
[0031] The term "translucent", as used herein may include
"frosted", "glittered", "pearlescence" and the like and is defined
herein as the practice of inducing a low level of light scattering
into an otherwise "clear" material causing the material to become
matted in appearance.
[0032] As used herein, "substantially opaque" refers to the ability
to sufficiently block the transmission of light so that bodies
lying behind are not easily perceivable. Substantially opaque
includes "tinted" and is defined herein as the practice of adding a
low level of pigment or dye into a material for the purpose of
imparting a color into the material.
[0033] As used herein, "identifier" relates to a means for
communicating between the consumer and the consumer care product
such that the consumer may readily identify the consumer care
product and its associated traits, including, but not limited to
product form, product performance, scents and the like. Identifiers
of the present invention may include, but are not limited to,
pressure sensitive labels; shrink wrap labels; indicia; colors or
other visually detectable or discernable aspects (e.g., "sparkles"
or "glitter" via incorporation of interference pigments) that are
part of the material from which the packaging components are made
or that is subsequently added to the manufactured components;
defined relief, indentation, windows and/or gaps formed in the
components during or after their manufacture; cast designs,
including but not limited to novelty casting to identify
characters, paraphernalia, animals, and the like; particular shapes
or other means of decoration and/or information sharing used to
identify and distinguish the product. The identifiers may be formed
concurrently with the manufacture of the components with which they
are associated, may be introduced during the manufacture of the
components, and/or may be formed or applied to the components after
the components are manufactured. The identifiers of the present
invention may be the same or different from one another.
[0034] As used herein, "novelty cast" may include, but is not
limited to, casts/shapes that replicate cars, sport balls, animals
or people figures, characters, logos, sport paraphernalia (e.g.,
helmets, bats, jerseys, shoes and the like), fashion accessories
and the like.
[0035] By "brand sub line" it is meant a line of products that are
targeted to a particular consumer sub-group, provides a real or
perceived distinctive benefit, and/or manifests a real or perceived
distinctive attribute. By way of example, a consumer care product
may be an antiperspirant/deodorant product with the sub lines
including, a sensitive skin line, a botanical line, a high
performance/high efficacy line, and a no fragrance line. Another
example of sub lines may include a "treatment" line that comprises
treatments to address extreme personal care conditions (e.g.,
malodor, excessive perspiration (hyperhidrosis), excessive
dandruff, excessive dryness, or oiliness), a "high performance"
line that targets superior performance as compared to other offered
products, an "essentials" line that provides value-added, trusted
or reliable performance, and an "expressives" line that provides
sensorial experiences with reliable performance. There may be a
single product form or multiple product forms within a given sub
line. For example, antiperspirant and deodorant products can come
in a variety of forms, including solids, soft solids, gels, and
roll-ons. Various sub lines may include the same or different
product forms and may include the same number or a different number
of product forms. The consumer care product may include a single
source identifier (e.g. single brand name) for the multiple sub
lines.
[0036] FIG. 1 is a front elevation of one embodiment of a
dispensing package 100 of a consumer care product as fully
assembled. The dispensing package 100 comprises an outer cap 300,
an outer jacket 200, a source identifier 192, and an identifier
191.
[0037] FIG. 2 is an exploded perspective view of FIG. 1 of a
dispensing package 100 for a consumer care product shown and
described herein, illustrating some of the individual components.
FIG. 2 shows generally one embodiment where the dispensing package
100 may comprise at least one product chamber 110 and an outer
jacket 200 for dispensing a consumer care composition. The
dispensing package 100 further comprises an outer cap 300,
optionally a seal component 310, a movable elevator platform 320,
and a screw assembly 330.
[0038] As shown in FIG. 2 an illustrative dispensing package 100
has a product chamber 110 that at least partially surrounds and
supports a consumer care composition, and an outer surface 130, an
upper dispensing end 140, a lower end 150, top opening 160 that
allows the consumer care composition to move up and outward, and a
top ridged opening 161.
[0039] The consumer care composition may be in the form of a solid,
semi-solid, liquid, gel, mousse or the like. Held within the
surrounding walls, particularly an inner surface (not shown) of the
product chamber 110, the composition may be dispensed from the top
opening 160 of the product chamber 110 and from the top ridged
opening 161, both located at the upper dispensing end 140 of the
product chamber 110.
[0040] The sidewall of the product chamber 110 may terminate in an
upper dispensing end 140. With respect to the product chamber 110
and outer surface 130, the distance from the upper dispensing end
140 to the lower end 150 of the sidewall may optionally vary,
moving around the circumference of such component (not shown),
giving rise to an upper end or top opening that is higher in some
spots than others, for example, the product chamber 110 may be
higher along the sides of the dispenser than at the back or front
of the dispensing package 100. This allows for flexibility in body
design and can allow the upper dispensing end of the product
chamber 110 to be configured such that, toward the end of the
dispenser life, it is less likely to come into contact with the
surface to which the product is applied. Optionally, the upper
dispensing end of the product chamber 110 may be beveled or
chamfered.
[0041] FIGS. 3 and 4 are cross-sectional front views taken along
the major axis of one embodiment of the dispensing packaging. FIG.
3 shows the movable elevator platform 320 at a first fill volume
position 560. FIG. 4 shows the movable elevator platform 320 at a
second fill volume position 570.
[0042] As shown in FIGS. 3 and 4, a movable elevator platform 320
comprises a coupling sleeve 325 having a non-threaded section 530
and a threaded section 540 along an inner surface 550 of the
coupling sleeve 325. The dispensing packaging further comprises a
screw assembly 330 comprising a spindle 332 that supports threads
333, a seal 334 extending around the circumference of the spindle
332, a threaded first portion 335 coupled to the threaded section
540 along the inner surface of the coupling sleeve 325 of the
movable elevator platform 320. The screw assembly 330 further
comprises a non-threaded second portion 336. In this embodiment,
the seal 334 frictionally engages with the non-threaded section 530
of the coupling sleeve 325, providing a seal that otherwise is
maintained during the advancement of the movable elevator platform
320 along an axis from a first fill volume position 560 to a second
fill volume position 570. In one embodiment the seal 334 that
frictionally engages with the non-threaded section 530 of the
coupling sleeve 325 provides a seal that substantially prevents air
and/or liquid from passing between the seal 334 and the
non-threaded section 530 of the coupling sleeve 325. In another
embodiment, the frictional engagement of the seal 334 (or the seal
334) is maintained for a distance corresponding to the distance
that the movable elevator platform 320 moves along an axis from a
first fill volume position 560 to a second fill volume position
570, the distance being from about 0.1 inch to about 1.0 inch,
and/or from about 0.2 inch to about 0.6 inch.
[0043] Also as shown in FIGS. 3 and 4, the non-threaded section 530
of the movable elevator platform 320 is at the lower end of the
inner surface 550 of the coupling sleeve 325 and the threaded
section 540 is at the upper end of the inner surface 550 of the
coupling sleeve 325. The movable elevator platform 320 further
comprises a rim 400 that is in frictional contact with the inner
surface 120 of the product chamber 110 along the product chamber
major axis 180 and minor axis 190. In an embodiment, the seal 334
extends beyond the outer surface 361 of the spindle 332. The seal
334 may have a first diameter and the inner surface 550 of the
non-threaded section 530 of the coupling sleeve 325 has a second
diameter, wherein the first diameter is greater than the second
diameter.
[0044] In some embodiments, the seal 334 may comprise a continuous
bead around the circumference of the outer surface of the spindle
332, as shown in FIGS. 3 and 4. Alternatively, the seal 334 may be
a thread that is dimensioned to frictionally engage with the inner
surface 550 of the non-threaded section 530 of the coupling sleeve
325, thereby providing a seal and allowing the movable elevator
platform 320 to advance along an axis from a first fill volume
position 560 to a second fill volume position 570.
[0045] In some embodiments the dispensing packaging 100 further
comprises a ratchet platform 380 where the non-threaded second
portion 336 of the spindle 332 extends from the ratchet platform
380 to the seal 334 for a distance of about 5 mm to about 45 mm or
from about 8 mm to about 35 mm or from about 10 mm to about 30
mm.
[0046] The spindle 332 may be separately molded and attached to the
screw base or the spindle 332 may be molded integrally with the
screw base.
[0047] In one embodiment, the fill volume provides a composition
volume of from about 5 ml to about 200 ml and/or from about 25 ml
to about 150 ml and/or from about 40 ml to about 100 ml and/or from
about 50 ml to about 80 ml. In one embodiment, the second fill
volume position 570 is about 1% to about 30% greater and/or about
5% to about 25% greater, and/or about 10% to about 20% greater,
than the first fill volume position 560 of the same size package.
In one embodiment, the first fill volume position 560 provides a
composition volume from about 15 ml to about 60 ml, or from about
25 ml to about 50 and the second fill volume position 570 provides
a composition volume from about 70 ml to about 200 ml or from about
75 ml to about 100 ml.
[0048] The size of the package depends, in part, upon the
composition to be dispensed, the dose at which it is applied, the
dispenser's intended life, and the intended use (e.g., value size,
samples, travel size, and the like). The volume of the product
chamber 110 will typically be larger than the volume of consumer
care composition to accommodate component features and production
requirements.
[0049] In one embodiment, the consumer care product is a top fill
product, e.g. wherein the composition is filled into the product
chamber 110 from the top of the package, comprising an
antiperspirant or deodorant composition.
[0050] In addition, minimizing the amount of plastic used in the
dispensing package 100 is also advantageous in terms of cost.
However, thin plastic walls are difficult to make in the injection
molding processes. In order to house compositions with different
rheologies, in the same or similar packaging, manufacturers using
interchangeable molds must make sure that the package has enough
strength to work for all product sizes, shapes, and composition
rheologies. For example, more torque is usually required to move a
solid deodorant composition through the dispensing opening of the
package compared to liquid compositions. For liquid compositions,
more frictional engagement may be needed to ensure that the liquid
composition does not leak around the circumference of the platform
and/or the screw assembly 330. Thus, it may be necessary to provide
the packaging with more frictional contact between the outside
surface of the movable elevator platform 320 and the inner surface
of the product chamber 110. This may result in more force placed on
the walls of the product chamber 110 and consequently the outer
jacket 200.
[0051] In certain embodiments, the product chamber 110 can be
molded of a more rigid, more expensive plastic to hold the consumer
care composition with adequate strength while the outer jacket 200
may be molded of a less expensive material. The opposite may also
be employed. Also, the same or similar materials of equal thickness
may be utilized for both the product chamber 110 and the outer
jacket 200 of the dispensing package 100. Product sold under the
same branding may be manufactured where the outer jacket 200 varies
as to size, color, shape, etc. to identify the composition while
the product chamber 110 is kept constant regardless of the product
features. Likewise, the design of the outer jacket 200 could be
kept constant, while the outer surface 130 of the product chamber
110 may vary in terms of color, surface features, etc.
[0052] In some embodiments, the dispensing package 100 is made of
less material, with adequate versatility and strength, whereby the
product chamber 110 is in frictional contact with the inside
surface of the outer jacket 200, where the product chamber 110 may
remain constant as the shape, color, size, etc. of outer jacket 200
is varied.
[0053] In some embodiments, the design of the movable elevator
platforms 320 described herein may reduce the amount of plastic
required, as compared to conventional movable elevator platforms.
The movable elevator platforms 320 described herein also reduce the
amount of unusable composition required within the dispensing
package 100, as compared to conventional elevator platforms. Often
because of the inherent design of the movable elevator platforms,
the manufacturers of such dispensing packages will have to overfill
the dispensing package. The overfilled amount may be unusable to
the user of the dispensing package 100, as it is required to bind
the composition to the movable elevator platform so that the
composition may be capable of being moved within the dispensing
package.
[0054] In some embodiments, the movable elevator platforms 320
described herein also allow for the dispensing package 100 to be
bottom-filled. Bottom-filling is a well-known method of
manufacturing antiperspirants and is typically characterized by
filling a dispensing package 100 with a composition in its molten
state from the bottom of the dispensing package 100 and allowing
the composition to cool. It is not uncommon to bottom-fill a
dispensing package 100 while the movable elevator platform 320 and
screw assembly 330 are present within the dispensing package 100.
When the dispensing package 100 is bottom-filled while the movable
elevator platform 320 and screw assembly 330 are present, the
design of the movable elevator platform 320 should be one that does
not significantly restrict the flow of the composition through the
movable elevator platform 320. If too much flow is restricted
because of the design of the movable elevator platform 320, then
the dispensing package 100 may not be suitable for bottom-filling.
Suitable movable elevator platforms for use in bottom-filled
dispensing packages typically have a number of apertures to permit
the flow of the composition through the movable elevator platform
320 while the composition is in a molten state. If the movable
elevator does not have enough apertures and/or too many components
that restrict flow, the movable elevator platform 320 may be
unsuitable for use in a bottom-filled dispensing package 100 or may
retard the filling of each dispensing package 100, resulting in
inefficiencies during the manufacturing process.
[0055] The movable elevator platforms described herein have a
horizontal contact surface area on the bottom face located on plane
X and a vertical contact surface area located on plane Y (as
illustrated in FIG. 5). The vertical and horizontal contact surface
areas are determined as follows. A three-dimensional (3D)
computer-aided design (CAD) software program, such as, for example,
SolidWorks.RTM. (Dassault Systemes SOLIDWORKS Corp., Waltham,
Mass.), may be used to calculate the vertical and horizontal
contact surface areas. First, a horizontal cross section 580 is
made at the highest point of the shortest partition inside the rim
(as shown in FIGS. 12A & 12B), which typically represents the
lowest fill point of the composition within the elevator (as shown
in FIG. 12C). All horizontal areas such as those located on a
flange and a partition that are below the horizontal cross section
580 (as shown in FIG. 12B) and inside the rim of the elevator when
viewed from the bottom of the elevator are counted. All horizontal
areas visible from the top view are not included in the
calculation. The vertical contact surface area includes any
vertical partition area, vertical flange area, vertical tab area,
and any other vertical area which is below the horizontal cross
section 580, including the inside and outside of the rim. However,
the vertical area located within the port 520 for a screw is not
included in the vertical contact surface area, while the vertical
area of the perimeter of the exterior wall 600 of the port 520 for
a screw is included.
[0056] The ratio of the vertical contact surface area (VCSA) to the
horizontal contact surface area (HCSA) may be from about 1:10 to
about 10:1, alternatively from about 1:5 to about 8:1, or
alternatively from about 1:2 to about 7:1. In some embodiments, the
VSCA to HCSA ratio may be about 6:1. As a non-limiting example, the
vertical contact surface area may be about 20.53 cm.sup.2 and the
horizontal surface area is about 3.51 cm.sup.2. The movable
elevator platforms 320 described herein may have about 20% to about
90%, or alternatively from about 45% to about 70%, of the
horizontal contact surface area located on the flange. In some
examples, about 50% to about 60% of the HCSA is located on the
flange. In some examples, less than about 58% of the HCSA is
located on the flange.
[0057] The movable elevator platforms 320 described herein may also
include one or more partitions. In some embodiments, about 10% to
about 60% of the HCSA is located on the one or more partitions. In
some embodiments, about 20% to 40%, or alternatively from about 25%
to about 35%, of the horizontal contact surface area is located on
the one or more partitions. In some embodiments, greater than about
26% of the horizontal contact surface area is located on the
partitions.
[0058] The movable elevator platforms 320 described herein
preferentially locate a significant percentage of the contact
surface area to the horizontal contact surfaces in part by locating
a significant portion of the contact surface to the outer portions
of the movable elevator platforms 320 while still having a flange
470 and other components that do not significantly impact the flow
of the compositions during bottom-filling. Such a design reduces
the amount of VSCA required to adhere to and move the composition
within the dispensing package 100. In this regard, reducing the
amount of vertical contact surface area required may also reduce
the amount of overfill required. Thus, the movable elevator
platforms 320 described herein may decrease the amount of
overfilling necessary and the amount of plastic required to
manufacture the movable elevator platform 320, while allowing the
dispensing package to be bottom-filled through the movable elevator
platform 320.
[0059] The movable elevator platforms 320 described herein include
a rim, a coupling sleeve, and partitions that form apertures. The
movable elevator platforms 320 described herein also have a top
face and a bottom face. The top face in some examples may be flat,
concave, or convex. In some examples, the movable elevator platform
320 may have a flange 470 located on or about the rim.
[0060] As shown in FIG. 5, the movable elevator platform 320 may
include a rim 400, a coupling sleeve 325 attached to the rim 400,
and one or more partitions 410 that are attached to the rim 400 and
form apertures 420. In some embodiments, the coupling sleeve 325
may be attached to the rim 400 via one or more partitions 410, and
in some cases, may be further supported using one or more tapered
partitions 440. The movable elevator platform 320 may have a top
face 450 and a bottom face 460. In some embodiments, the top face
450 may be concave, convex, or flat. In some embodiments, the rim
400 may include a flange 470 located on or about the top end 480 of
the rim 400.
[0061] As shown in FIG. 6, the coupling sleeve 325 may include a
port 520 for engaging the screw assembly 330. Also as shown in FIG.
6, the tapered partitions 440 may be located on opposites sides of
the coupling sleeve 325. As shown in FIG. 7, the movable elevator
platform 320 may include numerous partitions 410 that altogether
form numerous apertures 420. In some embodiments, the movable
elevator platform 320 includes more than 4 apertures, and in some
embodiments, has at least 12 apertures. In some embodiments, the
movable elevator platform 320 may include a tab 495 for removing
the movable elevator platform 320 from the mold during
manufacture.
[0062] As shown in FIG. 8, the flange 470 of the movable elevator
platform 320 may have a width D1 from the proximal end 474 of the
flange 470 to the distal end 476 of the flange 470, when viewed
from the bottom view as shown, of about 1 mm to about 5 mm,
alternatively from about 1.5 mm to about 4 mm, or alternatively
from about 1.8 mm to about 3.6 mm. The width of D1 may vary around
the flange 470 when the flange 470 is tapered. In some examples,
when the width of D1 varies around the movable elevator platform
320 so as to be a tapered flange 470, the width of D1, while
varying, never exceeds about 8.5 mm, about 8 mm, about 7 mm, about
6 mm, about 5 mm, about 4 mm, or even about 3 mm.
[0063] In some embodiments, the partition 410 may have a width D2
from the proximal end 414 of the partition 410 to the distal end
416 of the partition 410. In some embodiments, all of the
partitions 410 have a similar or the same D2. In some embodiments,
D2 is about 0.69 mm. In some examples, the length of D2 varies
among the partitions 410. In some embodiments, the width D1 (at any
point around the flange 470) is greater than the width of D2 (at
any one point along the partition) for at least one partition. In
some embodiments, D1 is greater than D2 for more than one
partition. In some embodiments, at least one D2 is about 0.69 mm,
alternatively less than about 1 mm, alternatively less than about 2
mm, or alternatively less than about 5 mm. In some embodiments,
none of the partitions have a D2 that exceeds about 5 mm, about 2
mm, or about 1.2 mm. In some embodiments, the ratio of D1 to D2 is
always at least greater than about 2, in some embodiments, even
greater than about 3, and in some embodiments, greater than about
5, even though the width of D1 may vary around the flange 470 and
the width of D2 may also vary.
[0064] As shown in FIG. 9, the flange 470 may overhang from the rim
400 when viewed from the bottom of the movable elevator platform
320. In some embodiments, the coupling sleeve 325 has a width of D3
as measured at the bottom face 460 of the movable elevator platform
320 from the outer most ends, as illustrated in FIG. 10. As shown
in FIG. 10, the rim 400 may have a height of D4 as measured from
the junction 485 (of the flange 470 and the rim 400) to the bottom
end 490 of the rim 400. In some embodiments, the partition 410 may
include a top end 500 and bottom end 510 and may have a height of
D5 as measured from the top end 500 to the bottom end 510. In some
embodiments, the height D5 is always greater than the height D4. In
some embodiments, D5 is more than about 10% greater than D4,
alternatively about 20% greater than D4, or alternatively about 30%
greater than D4. In some embodiments, D4 is about 3.53 mm and D5 is
about 5.18 mm. As illustrated in FIGS. 8 and 10, the line formed to
calculate the width of D1, D2, D3, D4, and D5 always has an angle
A1 that is 90 degrees with respect to the midpoint of the line and
the start and end of the line.
[0065] As shown in FIG. 11, the coupling sleeve 325 may include a
non-threaded section 530 located in closer proximity to the top
face 450 and a threaded section 540 for engaging the screw assembly
330 located at the entrance of the port 520 (FIG. 10).
[0066] As illustrated in Table A below, the movable elevator
platform 320 is a significant improvement over the prior art
elevator 620 shown in FIGS. 13A-13C, as the movable elevator
platform 320 is still capable of being bottom filled. While the
prior art elevator 620 contains a flange, the flange's dimensions
may impact the bottom-filling process such that the elevator is
incapable of being bottom-filled. In this regard, the prior art
elevator 620 has a D1 that is too long in certain areas of the
flange which may impede the fill of the composition through the
elevator. In contrast, the movable elevator 320, while having a
relatively low VCSA: HSCA ratio, is capable of being bottom
filled.
TABLE-US-00001 TABLE A Movable Elevator Prior Art Platform 320
Elevator 620 Horizontal Area of Flange 1.78 cm.sup.2 2.66 cm.sup.2
Longest D1 of Flange 3.0 mm 8.99 mm Vertical Contact Surface Area
20.53 cm.sup.2 16.12 cm.sup.2 (VCSA) Horizontal Contact Surface
Area 3.51 cm.sup.2 4.52 cm.sup.2 (HCSA) VCSA:HSCA Ratio 5.85:1
3.56:1 % of HCSA Located on Flange 50.7 58.8 % of HCSA Located on
Partitions 26.15 16.72 % of HCSA Located on Bottom End 21.36 24.49
of Rim % of HCSA Located on Tab 1.79 NA Bottom-Fill Capable Yes
No
Illustrative Packaging Materials and Manufacturing
[0067] A variety of thermoplastic materials or rigid and semi-rigid
materials can be used for the product chamber, outer jacket, and
other components of the package described herein, such as, for
example, the movable elevator platform 320 (FIG. 5). For example,
rigid and semi-rigid materials may include, but are not limited to,
metals, including, but not limited to, aluminum, magnesium alloy,
steel; glass, including, but not limited to, laminates; and
polymeric materials such as polypropylene (PP), polyethylene (PE),
polystyrene (PS), polyethylene-terepthalate (PET),
styrene-acrylonitrile copolymer (SAN), polyethylene-terepthalate
copolymers, polycarbonate (PC), polyamides,
acrylonitrile-butadiene-styrene (ABS), thermoplastic elastomers,
polyoxymethylene copolymer and mixtures thereof.
[0068] In one embodiment, the molten thermoplastic material has a
viscosity, as defined by the melt flow index (MFI) of about 0.1
g/10 min to about 500 g/10 min, as measured by ASTM D1238 performed
at temperature of about 23.degree. C. with about a 2.16 kg weight.
For example, for polypropylene, the melt flow index can be in a
range of about 0.5 g/10 min to about 200 g/10 min. Other suitable
melt flow indexes include about 1 g/10 min to about 400 g/10 min,
about 10 g/10 min to about 300 g/10 min, about 20 to about 200 g/10
min, about 30 g/10 min to about 100 g/10 min, and about 50 g/10 min
to about 75 g/10 min. The MFI of the material is selected based on
the application and use of the molded package. For example,
thermoplastic materials with an MFI of about 5 g/10 min to about 50
g/10 min may be suitable for use as caps and closures for
dispensing packaging.
[0069] In one embodiment, the thermoplastic material can be, for
example, a polyolefin. Illustrative polyolefins include, but are
not limited to, polypropylene, polyethylene, polymethylpentene, and
polybutene-1. Any of the aforementioned polyolefins could be
sourced from bio-based feedstocks, such as sugarcane or other
agricultural products, to produce a bio-polypropylene or
bio-polyethylene.
[0070] Polyolefins advantageously demonstrate shear thinning when
in a molten state. Shear thinning is a reduction in viscosity when
the fluid is placed under compressive stress. Shear thinning can
beneficially allow for the flow of the thermoplastic material to be
maintained throughout the injection molding process. Without
intending to be bound by theory, it is believed that the shear
thinning properties of a thermoplastic material, and in particular
polyolefins, results in less variation of the materials viscosity
when the material is processed at lower pressures.
[0071] Other suitable thermoplastic materials include renewable
polymers such as, for example, polymers produced directly from
organisms, such as polyhydroxyalkanoates (e.g.,
poly(beta-hydroxyalkanoate),
poly(3-hydroxybutyrate-co-3-hydroxyvalerate, NODAX.RTM., and
bacterial cellulose; polymers extracted from plants, agricultural
and forest, and biomass, such as polysaccharides and derivatives
thereof (e.g., gums, cellulose, cellulose esters, chitin, chitosan,
starch, chemically modified starch, and particles of cellulose
acetate), proteins (e.g., zein, whey, gluten, and collagen),
lipids, lignins, and natural rubber; thermoplastic starch produced
from starch or chemically modified starch and polymers derived from
naturally sourced monomers and derivatives, such as
bio-polyethylene, bio-polypropylene, polytrimethylene
terephthalate, polylactic acid, NYLON 11, alkyd resins, succinic
acid-based polyesters, and bio-polyethylene terephthalate.
[0072] The suitable thermoplastic materials may include a blend or
blends of different thermoplastic materials. For example, the blend
may be a combination of materials derived from virgin bio-derived
or petroleum-derived materials, or recycled materials of
bio-derived or petroleum-derived materials. One or more of the
thermoplastic materials in a blend may be biodegradable.
Thermoplastic materials may be biodegradable.
[0073] The thermoplastic material can also be, for example, a
polyester. Illustrative polyesters include, but are not limited to,
polyethylene terphthalate (PET). The PET polymer could be sourced
from bio-based feedstocks, such as sugarcane or other agricultural
products, to produce a partially or fully bio-PET polymer. Other
suitable thermoplastic materials include copolymers of
polypropylene and polyethylene, and polymers and copolymers of
thermoplastic elastomers, polyester, polystyrene, polycarbonate,
poly(acrylonitrile-butadiene-styrene), poly(lactic acid), bio-based
polyesters such as poly(ethylene furanate) polyhydroxyalkanoate,
poly(ethylene furanoate), (considered to be an alternative to, or
drop-in replacement for, PET), polyhydroxyalkanoate, polyamides,
polyacetals, ethylene-alpha olefin rubbers, and
styrene-butadiene-styrene block copolymers. The thermoplastic
material can also be a blend of multiple polymeric and
non-polymeric materials. The thermoplastic material can be, for
example, a blend of high, medium, and low molecular polymers
yielding a multi-modal or bi-modal blend. The multi-modal material
can be designed in a way that results in a thermoplastic material
that has superior flow properties yet has satisfactory
chemo/physical properties. The thermoplastic material can also be a
blend of a polymer with one or more small molecule additives. The
small molecule could be, for example, a siloxane or other
lubricating molecule that, when added to the thermoplastic
material, improves the flowability of the polymeric material.
[0074] Polymeric materials may also include various fillers known
to the skilled artisan, such as, for example, mica, interference
pigments, wood flour; or materials that are capable of "blooming"
to the surface of a molded component. Other additives may include
inorganic fillers such calcium carbonate, calcium sulfate, talcs,
clays (e.g., nanoclays), aluminum hydroxide, calcium silicate
(CaSiO3), glass formed into fibers or microspheres, crystalline
silicas (e.g., quartz, novacite, crystallobite), magnesium
hydroxide, mica, sodium sulfate, lithopone, magnesium carbonate,
iron oxide; organic fillers such as rice husks, straw, hemp fiber,
wood flour; or wood, bamboo, or sugarcane fiber.
[0075] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0076] Every document cited herein, including any cross referenced
or related patent or application and any patent application or
patent to which this application claims priority or benefit
thereof, is hereby incorporated herein by reference in its entirety
unless expressly excluded or otherwise limited. The citation of any
document is not an admission that it is prior art with respect to
any invention disclosed or claimed herein or that it alone, or in
any combination with any other reference or references, teaches,
suggests or discloses any such invention. Further, to the extent
that any meaning or definition of a term in this document conflicts
with any meaning or definition of the same term in a document
incorporated by reference, the meaning or definition assigned to
that term in this document shall govern.
[0077] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *