U.S. patent application number 17/006938 was filed with the patent office on 2021-03-18 for apparatus and method of making an aerosol dispenser.
The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Robert Paul Cassoni, Matthew Aaron Neumann.
Application Number | 20210078791 17/006938 |
Document ID | / |
Family ID | 1000005206313 |
Filed Date | 2021-03-18 |
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United States Patent
Application |
20210078791 |
Kind Code |
A1 |
Cassoni; Robert Paul ; et
al. |
March 18, 2021 |
Apparatus and Method of Making an Aerosol Dispenser
Abstract
A method and apparatus of making an aerosol container. A
polymeric container may be provided. The container may have a
closed end bottom and a neck longitudinally opposed to the closed
end bottom. The container has an internal container volume. A valve
and a bag may be provided and a portion of the valve and the bag
may be disposed within the container. The bag has a first bag
volume. A portion of the at least one of the neck and the bag may
contact a portion of the valve to form a temporary seal. Propellant
may be introduced into the container. The bag may be collapsed from
the first bag volume to a second bag volume. The pressure of the
propellant and the pressure within the bag equilibrate. The valve
may be joined to the container and the propellant may be sealed
within the container.
Inventors: |
Cassoni; Robert Paul;
(Waynesville, OH) ; Neumann; Matthew Aaron;
(Montgomery, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Family ID: |
1000005206313 |
Appl. No.: |
17/006938 |
Filed: |
August 31, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62899768 |
Sep 13, 2019 |
|
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|
62991779 |
Mar 19, 2020 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 83/384 20130101;
B65D 83/62 20130101; B65D 83/48 20130101; B65D 83/0061
20130101 |
International
Class: |
B65D 83/62 20060101
B65D083/62; B65D 83/38 20060101 B65D083/38; B65D 83/48 20060101
B65D083/48; B65D 83/00 20060101 B65D083/00 |
Claims
1. A method of making an aerosol container comprising: providing a
polymeric container having a closed end bottom and a neck
longitudinally opposed to the closed end bottom, wherein the neck
defines an opening, and wherein the container has an internal
container volume; providing a valve and a bag, wherein at least a
portion of the valve and the bag are disposed in the opening of the
neck, wherein the bag has a first bag volume; contacting a portion
of at least one of the neck and the bag to a portion of the valve
to form a temporary seal; introducing a propellant into the
container; collapsing the bag from the first bag volume to a second
bag volume, and wherein the second bag volume is less than the
first bag volume; and joining the valve to the container to seal
the valve to the container, wherein the propellant is sealed within
the container.
2. The method of claim 1, wherein the valve is welded to the
container.
3. The method of claim 1, wherein joining the valve to the
container comprises spinning the valve relative to at least one of
the bag and the container to weld the valve to the bag.
4. The method of claim 1, wherein the bag and the valve are
separate.
5. The method of claim 1, comprising concentrically blow molding
the container and the bag.
6. The method of claim 1, wherein a portion of the bag contacts a
portion of the valve to form the temporary seal.
7. The method of claim 1, wherein the propellant flows between a
portion of the neck and the bag.
8. The method of claim 1, wherein the propellant flows between a
portion of the neck and the valve.
9. The method of claim 1, wherein joining comprises spinning at
least one of the valve and the container to spin weld the valve to
the container.
10. The method of claim 1, wherein the bag has a first bag pressure
prior to introducing propellant into the container and a second bag
pressure after propellant has been introduced into the container,
and wherein the first bag pressure is less than the second bag
pressure.
11. The method of claim 1, wherein the propellant is a multi-phase
propellant.
12. The method of claim 1, wherein the second bag volume is from
about 0.1% to about 5% of the internal container volume.
13. The method of claim 1, wherein the second bag volume is from
about 5% to about 50% of the internal container volume.
14. The method of claim 1, wherein the first bag volume is greater
than about 20% of the internal container volume and the second bag
volume is less than about 15% of the internal container volume.
15. The method of claim 1, wherein the bag is joined to a portion
of the valve prior to the bag and the valve being disposed in the
container.
16. A method of making an aerosol container comprising: providing a
polymeric container having a closed end bottom and a neck
longitudinally opposed to the closed end bottom, wherein the neck
defines an opening; providing a valve and a bag, wherein at least a
portion of the valve and the bag are disposed in the opening of the
neck; contacting a portion of at least one of the neck and the bag
to a portion of the valve to form a temporary seal; introducing a
propellant into the container; positioning the valve in an open
configuration; collapsing the bag, wherein at least a portion of a
fluid contained within the bag is released through the valve; and
joining a portion of the valve to a portion of the container to
seal the propellant within the container.
17. The method of claim 16, wherein the propellant is introduced
between the bag and the neck or the valve and the neck.
18. The method of claim 16, wherein the valve is positioned in the
open configuration while the propellant is introduced into the
container.
19. The method of claim 16, wherein the valve is positioned in the
open configuration prior to introducing the propellant into the
container.
20. The method of claim 16, comprising positioning the valve in a
closed configuration.
21. The method of claim 20, wherein the valve is positioned in an
open configuration and a closed configuration while the propellant
is being introduced into the container.
22. The method of claim 16, wherein joining comprises spinning at
least one of the valve and the container to seal the valve to the
container.
23. A method of making an aerosol container comprising: providing a
polymeric container having a closed end bottom and a neck
longitudinally opposed to the closed end bottom, wherein the neck
defines an opening, wherein the container has an internal container
volume; providing a valve and a bag, wherein at least a portion of
the valve and the bag are disposed in the opening of the neck;
contacting a portion of at least one of the neck and the bag to a
portion of the valve to form a temporary seal; providing a fluid
chamber having a fluid chamber volume; engaging at least a portion
of at least one of the valve and the container with the fluid
chamber; positioning the valve in an open configuration;
introducing a propellant into the container; releasing a fluid from
the bag through the valve and into the fluid chamber; and joining
the valve to the container to seal the valve to the container,
wherein the propellant is sealed within the container.
24. The method of claim 23, wherein the valve is positioned in the
open configuration prior to introducing propellant into the
container.
25. The method of claim 23, wherein the fluid chamber volume is
variable.
26. The method of claim 23, wherein the fluid chamber comprises a
piston.
27. The method of claim 26, comprising moving the piston from a
first position to a second position.
28. The method of claim 23, wherein the fluid chamber volume is
less than the internal container volume.
29. The method of claim 23, wherein the fluid chamber volume is
from about 10% to about 60% of the internal container volume.
30. A method of making an aerosol container comprising: providing a
polymeric container having a closed end bottom and a neck
longitudinally opposed to the closed end bottom, wherein the neck
defines an opening; providing a valve and a bag, wherein at least a
portion of the valve and the bag are disposed in the opening of the
neck; contacting a portion of at least one of the neck and the bag
to a portion of the valve to form a temporary seal; positioning the
valve in an open configuration; decreasing the pressure within the
bag; introducing a propellant into the container; and joining the
valve to the container to seal the valve to the container, wherein
the propellant is sealed within the container.
31. The method of claim 30, wherein the bag has a first bag volume
prior to decreasing the pressure within the bag and a second bag
volume after decreasing the pressure within the bag.
32. The method of claim 31, wherein the second bag volume is
greater than about 95% of the first bag volume.
33. The method of claim 31, wherein the bag has a third bag volume
after introducing the propellant into the container, wherein the
third bag volume is less than the first bag volume.
34. The method of claim 30, wherein the pressure of the container
is decreased prior to introducing the propellant into the
container.
35. The method of claim 30, comprising positioning the valve in a
closed configuration.
36. The method of claim 35, wherein the valve is positioned in the
closed configuration prior to introducing the propellant into the
container.
Description
FIELD
[0001] The present disclosure is directed to a method of making an
aerosol dispenser, and, in particular, to a method of making an
aerosol dispenser including a container, a valve, and a product
delivery device such that the product delivery device does not
interfere with joining the valve to the container.
BACKGROUND
[0002] Aerosol dispensers typically comprise a container which acts
as a pressure vessel for propellant and product contained therein.
A valve assembly may be joined to a container to seal product
and/or propellant within the container and to allow for selective
dispensing of the product and/or propellant from the container. A
product delivery device may be used to dispense the product and/or
propellant from the container. The product delivery device may
include a bag. The bag may be configured to hold product and/or
propellant. The bag may be collapsible such that the bag changes
volume during the manufacture of the aerosol dispenser.
[0003] During the manufacture of the aerosol dispenser, product and
propellant are introduced into the container. However, the sequence
of introducing these materials and the collapsible nature of the
bag may result in the bag interfering with the joining of the valve
assembly to the container. Interference of the bag with the joining
of the valve assembly to the container may result in improper
joining of the valve assembly and the container, which may result
in a defective seal between the valve assembly and the container
such that propellant and/or product unintentionally leaks from the
dispenser. Further, the bag may become damaged upon interference
with the joining of the valve assembly and the container. For
example, the bag may tear upon interfering with the joining of the
valve assembly and the container.
[0004] Thus, it would be beneficial to provide an apparatus and a
method for controlling the collapse of the bag during manufacture
of the aerosol dispenser.
SUMMARY
[0005] In some embodiments, a method of making an aerosol container
may include: providing a polymeric container having a closed end
bottom and a neck longitudinally opposed to the closed end bottom,
wherein the neck defines an opening, and wherein the container has
an internal container volume; providing a valve and a bag, wherein
at least a portion of the valve and the bag are disposed in the
opening of the neck, wherein the bag has a first bag volume;
contacting a portion of at least one of the neck and the bag to a
portion of the valve to form a temporary seal; introducing a
propellant into the container; collapsing the bag from the first
bag volume to a second bag volume, and wherein the second bag
volume is less than the first bag volume; and joining the valve to
the container to seal the valve to the container, wherein the
propellant is sealed within the container.
[0006] In some embodiments, a method of making an aerosol container
may include: providing a polymeric container having a closed end
bottom and a neck longitudinally opposed to the closed end bottom,
wherein the neck defines an opening; providing a valve and a bag,
wherein at least a portion of the valve and the bag are disposed in
the opening of the neck; contacting a portion of at least one of
the neck and the bag to a portion of the valve to form a temporary
seal; introducing a propellant into the container; positioning the
valve in an open configuration; collapsing the bag, wherein at
least a portion of a fluid contained within the bag is released
through the valve; and joining a portion of the valve to a portion
of the container to seal the propellant within the container.
[0007] In some embodiments, a method of making an aerosol container
may include: providing a polymeric container having a closed end
bottom and a neck longitudinally opposed to the closed end bottom,
wherein the neck defines an opening, wherein the container has an
internal container volume; providing a valve and a bag, wherein at
least a portion of the valve and the bag are disposed in the
opening of the neck; contacting a portion of at least one of the
neck and the bag to a portion of the valve to form a temporary
seal; providing a fluid chamber having a fluid chamber volume;
engaging at least a portion of at least one of the valve and the
container with the fluid chamber; positioning the valve in an open
configuration; introducing a propellant into the container;
releasing a fluid from the bag through the valve and into the fluid
chamber; and joining the valve to the container to seal the valve
to the container, wherein the propellant is sealed within the
container.
[0008] In some embodiments, a method of making an aerosol container
may include: providing a polymeric container having a closed end
bottom and a neck longitudinally opposed to the closed end bottom,
wherein the neck defines an opening; providing a valve and a bag,
wherein at least a portion of the valve and the bag are disposed in
the opening of the neck; contacting a portion of at least one of
the neck and the bag to a portion of the valve to form a temporary
seal; positioning the valve in an open configuration; decreasing
the pressure within the bag; introducing a propellant into the
container; and joining the valve to the container to seal the valve
to the container, wherein the propellant is sealed within the
container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1A is a side view of an aerosol dispenser.
[0010] FIG. 1B is a side view of an aerosol dispenser.
[0011] FIG. 2 is a sectional view of an aerosol dispenser including
a bag.
[0012] FIG. 3 is a sectional view of an aerosol dispenser including
a dip tube.
[0013] FIG. 4 is a partial, sectional view of a neck of a
container.
[0014] FIG. 5A is a sectional view of a valve assembly.
[0015] FIG. 5B is a perspective, sectional view of a valve assembly
disposed in a container.
[0016] FIG. 6A is a partial sectional view of a manifold
operatively engaged with at least a portion of at least one of the
valve assembly and the container.
[0017] FIG. 6B is a sectional, side view of a manifold operatively
engaged with at least a portion of at least one of the valve
assembly and the container.
[0018] FIG. 7A is a partial, side view of a manifold operatively
engaged with at least a portion of at least one of the valve
assembly and the container and a fluid chamber operatively engaged
with the valve assembly.
[0019] FIG. 7B is a sectional view of a manifold operatively
engaged with at least a portion of at least one of the valve
assembly and the container and a fluid chamber operatively engaged
with the valve assembly.
DETAILED DESCRIPTION
[0020] The present disclosure is directed to an aerosol dispenser
and, more specifically, an apparatus and method for manufacturing
an aerosol dispenser. An aerosol dispenser may include a container
for containing a product and a propellant and a valve assembly for
dispensing the product or the product and the propellant from the
container. Other components may be included in the aerosol
dispenser such as a nozzle for controlling the spray
characteristics of a product as it discharged from the aerosol
dispenser and an actuator for selectively dispensing product from
the aerosol dispenser. Products may include, but are not limited
to: shave cream, shave foam, body sprays, body washes, perfumes,
hair cleaners, hair conditions, hair styling products,
antiperspirants, deodorants, personal and household cleaning or
disinfecting compositions, air freshening products, fabric
freshening products, hard-surface products, astringents, foods,
paint, pharmaceuticals, and insecticides. The relatively large
number of products that may be dispensed using aerosols has made
aerosols a popular choice among manufacturing companies. The
relative popularity of aerosol dispensers has resulted in companies
considering cost cutting measures with respect to aerosol
dispensers and to consider materials, at least in part, for aerosol
dispensers to minimize the environmental impact. For example, an
aerosol dispenser made from polymeric components may aid in the
recyclability of the dispensers and help with reducing cost, such
as by reducing the cost of manufacturing, eliminating expensive
metal components, and reducing the cost of shipping, through weight
reduction of each dispenser. The use of different materials also
allows for greater flexibly in the size and shape of the
dispenser.
[0021] One way to relatively reduce cost is to optimize the
manufacturing process and/or equipment for aerosol dispensers. The
present disclosure is directed to a method and apparatus that
reduces the time need to pressurize and seal the container of the
aerosol. More specifically, the pressurizing of the container and
the joining of the valve assembly to the container may be completed
substantially simultaneously or, stated another way, at a single
station within the manufacturing process. Further, the process may
be used to control the components of the aerosol container such
that the integrity of the seal and the bag are not adversely
affected. The process and equipment controls the volume and/or
pressure within the bag to prevent the bag from being adversely
affected during the sealing process while allowing for sufficient
pressurization of the container with a propellant.
[0022] With reference to FIGS. 1A, 1B, 2, and 3, an aerosol
dispenser 30 may include a container 32, a valve assembly 52 (also
referred to herein as a valve), a product delivery device 56, an
actuator 46, and a nozzle 60. The container 32 may include a base
cup 48 joined thereto and indicia 50 disposed on, for example, the
sidewalls, 36 of the container 32. The container 32 may define an
internal container volume and be configured to hold a fluid, which
includes liquids and gases or another other freely flowing
material. The valve assembly 52 may be joined to a portion of the
container 32. The term joined includes directly or indirectly
joined. Joined includes removably joined and fixedly joined. Joined
includes both mechanical attachment, such as by screws, bolts,
interference fit, friction fit, welding, and integrally molding,
and chemical attachment, such as by adhesive or the adhesive
properties inherent in the materials being attached. The valve
assembly 52 may be joined to the container 32 such that a portion
of the valve assembly 52 is disposed within the container 32. The
product delivery device 56 may be joined to at least one of a
portion of the container 32 and a portion of the valve assembly 52,
and the product delivery device may be in fluid communication with
the actuator 46 and the nozzle 60.
[0023] A base cup 48 may be joined to the bottom portion, which is
opposite the valve assembly 52, of the container 32 and may be
used, for example, to aid in positioning the dispenser on flat
surfaces and to reinforce the bottom 34 of the aerosol dispenser.
The container 32 may be configured to hold product and/or
propellant. The product delivery device may be disposed at least
partially within the container and the valve may be joined to the
container 32 and may be in operative communication with the product
delivery device. The product and/or the propellant may be stored in
the container 32. Upon being dispensed, the product and/or
propellant may travel from and/or through the product delivery
device 56 and through the valve assembly 52.
[0024] The valve assembly 52 may be in fluid communication with a
nozzle 60. The nozzle 60 directs product out of the aerosol
dispenser and into the environment or onto a target surface. The
nozzle may be configured in various different ways depending upon
the desired dispensing and spray characteristics. The actuator 46
may be engaged by a user and is configured to initiate and
terminate dispensing of the product and/or propellant. Stated
another way, the actuator provides selective dispensing of the
product and/or propellant. The actuator 46 may be depressible,
operable as a trigger, push-button, and the like, to cause release
of a product from the aerosol dispenser 30. The actuator 46 may
include a connector such as a male or female connector, snap-fit
connector, or the like to secure the actuator to the container 32.
It is to be appreciated that to dispense product, the aerosol
dispenser does not need to include an actuator and a nozzle. The
product and/or propellant may be dispensed from the stem.
[0025] The container 32 may be used to hold product and/or
propellant. The container 32 may be any shape that allows product
and/or propellant to be held within the interior of the container
32. For example, the container 32 may have a cross-sectional
circular-shape, peanut-shape, oval-shape, or rectangular-shape. It
is to be appreciated that the container 32 may be molded, which
allows for any number of shapes to be used. The container 32 may be
longitudinally elongate such that the container has an aspect ratio
of a longitudinal dimension to a transverse dimension, such as
diameter. The aspect ratio may be greater than 1, equal to 1, such
as in a sphere or shorter cylinder, or an aspect ratio less than 1.
The containers 32 may be cylindrical.
[0026] The container 32 may include a closed bottom 34, one or more
sidewalls 36, and a neck 40.
[0027] The one or more sidewalls 36 may extend between the closed
bottom 34 and the neck 40. The sidewalls 36 define the shape of the
container 32. A shoulder 42 may be included between the neck 40 and
the one or more sidewalls 36. The neck 40 of the container 32 may
define an opening 38. The opening 38 may be opposite the bottom 34
of the container 32. The neck 40 and/or shoulder 42 may have a
uniform or varying thickness in order to achieve a desired strength
in these regions of the container 32.
[0028] The bottom 34 of the container 32 may be configured for
resting on horizontal surfaces such as shelves, countertops, tables
etc. The bottom 34 of the container 32 may include a re-entrant
portion or base cup 48. The base cup 48 may be joined to the bottom
34 of the container 32 and may aid in reinforcement of the bottom
34 and/or may allow the container to rest on horizontal surfaces.
The container 32 may not include a base cup and may be configured
to sit on at least a portion of the bottom 34. Suitable shapes of
the bottom 34 include petaloid, champagne, hemispherical, or other
generally convex shapes. Each of these shapes of the bottom 34 may
be used with or without a base cup 48. The container 32 may have a
generally flat base with an optional push-up.
[0029] The container 32 may be polymeric. The container 32 may
include polyethylene terephthalate (PET), polyethylene furanoate
(PEF), polyester, nylon, polyolefin, EVOH, polypropylene,
polyethylene, or mixtures thereof. The container 32 may be a single
layer or multi-layered. The container 32 may be injection molded or
further blow molded, such as in an injection-stretch blow molding
process or an extrusion blow molding process.
[0030] The container 32 may be axisymmetric as shown, or, may be
eccentric. The cross-section may be square, elliptical, irregular,
etc. Furthermore, the cross section may be generally constant as
shown, or may be variable. For a variable cross-section, the
container 32 may be, for example, barrel shaped, hourglass shaped,
or monotonically tapered.
[0031] The container 32 may range from about 6 cm to about 60 cm,
or from about 10 cm to about 40 cm in height, taken in the axial
direction. The container 32 may have a cross-section perimeter from
about 3 cm to about 60 cm, or from about 4 cm to about 10 cm. The
container 32 may have a volume ranging from about 40 cubic
centimeters to about 2000 cubic centimeters exclusive of any
components therein, such as a product delivery device 56.
[0032] At 21.degree. C., the container 32 may be pressurized to an
internal gage pressure of about 100 kPa to about 1500 kPa, or from
about 110 kPa to about 1300 kPa, or from about 115 kPa to about 490
kPa, or about 270 kPa to about 420 kPa using a propellant. An
aerosol dispenser 30 may have an initial propellant pressure of
about 1500 kPa and a final propellant pressure of about 120 kPa, an
initial propellant pressure of about 900 kPa and a final propellant
pressure of about 300 kPa, or an initial propellant pressure of
about 500 kPa and a final propellant pressure of 0 kPa, including
any values between the recited ranges.
[0033] The propellant may include hydrocarbons, compressed gas,
such as nitrogen and air, hydro-fluorinated olefins (HFO), such as
trans-1,3,3,3-tetrafluoroprop-1-ene, and mixtures thereof.
Propellants listed in the US Federal Register 49 CFR 1.73.115,
Class 2, Division 2.2 may be acceptable. The propellant may be
condensable, which is a propellant that exists at multiple phases
at standard operating pressures and temperatures of an aerosol
dispenser. The propellant may be condensable at pressures less than
1500 kPa at 21.degree. C. A condensable propellant, when condensed,
may provide the benefit of a flatter depressurization curve at the
vapor pressure, as product is depleted during usage. A condensable
propellant may provide the benefit that a greater volume of fluid
may be placed into the container at a given pressure. Generally,
the highest pressure occurs after the aerosol dispenser is charged
with product but before the first dispensing of that product by the
user.
[0034] The product delivery device 56 may be used to contain and/or
provide for delivery of product and/or propellant from the aerosol
dispenser 30 upon demand. Suitable product delivery devices 56
comprise a piston, a bag 24, or a dip tube 26, such as illustrated
in FIGS. 2 and 3. It is to be appreciated that either the bag 24 or
the dip tube 26 may be attached to an adaptor 64. The bag 24 or the
dip tube 26 may be directly joined to the valve assembly 52 or the
bag 24 and the dip tube 26 may be indirectly joined to the valve
assembly 52. The bag 24 or the dip tube 26 may be attached to an
adaptor 64 and the adaptor 64 may be joined to the valve assembly
52. The product delivery device 56 may include polyethylene
terephthalate (PET), polypropylene (PP), polypropylene (PP),
polyethylene furanoate (PEF), polyester, nylon, polyolefin, EVOH,
or mixtures thereof. The container 32 may be a single layer or
multi-layered.
[0035] As illustrated in FIG. 2, the product delivery device may be
a bag 24. The bag 24 may be disposed within the container 32 and be
configured to hold a product therein. Propellant may be disposed
within the container 32 and between the container and the bag 24. A
portion of the bag 24 may be joined to at least one of the
container 32 and a portion of the valve assembly 52, such as the
valve body 54. The bag 24 may be positioned between the container
32 and the valve body 54. The bag 24 may be inserted into the
container 32 and subsequently joined thereto. The bag 24 may be
joined to the valve body 54, and the valve body 54 joined to the
bag 24 may be subsequently inserted into the container 32.
[0036] As illustrated in FIG. 3, the dispenser may include an
adaptor 64 and a dip tube 26. The adaptor 64 may be disposed within
the container 32. The adaptor 64 may engage a portion of the neck
40. The dip tube 26 may be joined to the adaptor 64 and extend from
the adaptor 64 toward the bottom 34 of the container 32. It is to
be appreciated that the dip tube 26 may be attached directly to a
portion of the valve assembly, such as the valve body 54. The dip
tube 26 and/or the adaptor 64 may be attached to the valve body 54
prior to being disposed within the container. The dip tube 26
and/or the adaptor 64 may be disposed within the container and then
subsequently joined to a portion of the container 32 and/or the
valve body 54.
[0037] The product delivery device 56 may include a metering device
for dispensing a pre-determined, metered quantity of product. The
product delivery device 56 may include an inverting valve such as a
valve including a ball therein to alter the path of product flow.
The product delivery device 56 may include a dip tube disposed in a
bag. The product delivery device 56 may be polymeric.
[0038] The container 32, and/optionally the product delivery device
56 may be transparent or substantially transparent. This
arrangement provides the benefit that the consumer knows when
product is nearing depletion and allows improved communication of
product attributes, such as color, viscosity, etc. Also, indicia
disposed on the container 32, such as labeling or other decoration
of the container 32, may be more apparent if the background to
which such decoration is applied is clear. Labels may be shrink
wrapped, printed, etc., as are known in the art.
[0039] The container 32 may include a neck 40. The neck 40 may
define an opening 38 and be configured to receive a valve assembly
52. The valve assembly 52 may be inserted, at least partially, into
the opening 38 of the neck 40 of the container 32, such as
illustrated in FIGS. 2 and 3. The valve assembly 52 may include a
valve body 54, a valve stem 62, and a resilient member 58. At least
a portion of the valve assembly 52 may be movable in relationship
to the balance of the aerosol dispenser in order to open and close
the aerosol dispenser for dispensing product. The valve assembly 52
may be opened due to movement of the valve stem 62 which may be
through use of an actuator 46 or through manual or other mechanical
depression of the valve stem 62. When the valve 52 is opened, for
example, by way of the actuator 46, a flow path is created for the
product to be dispensed through a nozzle 60 to ambient or a target
surface. The valve assembly 52 may be opened, for example, by
selective actuation of the actuator 46 by a user.
[0040] A portion of the valve body 54 may be sealed to the neck of
the container 32, such as illustrated in FIGS. 2 and 3, to prevent
the escape of propellant, product, and the loss of pressurization.
The valve body 54 may be sealed to the container 32 utilizing a
press fit, interference fit, solvent welding, laser welding, sonic
welding, ultrasonic welding, spin welding, adhesive or any
combination thereof, so long as a seal adequate to maintain the
pressure results. The valve body 54 may be joined to the container
32 such that at least a portion of the valve body 54 is disposed
within the container 32. The valve body 54 may be joined to the
container 32 such that the valve body 54 is joined to the opening
of the neck and at least a portion of the valve body 54 is disposed
on top of the neck.
[0041] As illustrated in FIG. 4, the container 32 may include a
first support surface 124 that extends about the longitudinal axis
70. The first support surface 124 may be positioned between the
opening 38 of the container 32 and the bottom 34 of the container
32. The first support surface 124 may be positioned within the
opening 38 such that the opening diameter OD is greater than the
first support surface diameter FSD. The container 32 may include a
second support surface 126 that extends about the longitudinal axis
70. The second support surface 126 may be positioned between the
first support surface 124 and the bottom 34 of the container 32.
The second support surface may be positioned within the opening 38
such that the opening diameter OD is greater than the second
support surface diameter SSD. The first support surface diameter
FSD may be greater than the second support surface diameter SSD.
The first support surface 124 may be configured to support a
portion of the valve assembly 52. The second support surface 126
may be configured to support a portion of the valve assembly 52
and/or the product delivery device 56. The first support surface
124 may be joined to a portion of the valve assembly 52, such as
the valve body 54. The second support surface 126 may be joined to
at least one of a portion of the valve assembly 52, such as the
valve body 54, and the product delivery device 56. It is to be
appreciated that the first support surface 124 may be joined to a
portion of the valve assembly 52, such as the valve body, and the
second support surface 126 may be used to support at least one of
the valve assembly 52 and the product delivery device 56. The
second support surface 126 may not be joined to the valve assembly
52 or the product delivery device 56 and, rather, may support the
valve assembly 52 and/or the product delivery device 56.
[0042] The first support surface 124 may circumscribe the second
support surface 126. The first support surface 124 may be in the
same plane as the second support surface 126 or may be in a
different plane. The first support surface 124 may be above the
second support surface 126. The first support surface 124 may be
disposed radially outward of the second support surface 126.
[0043] The first support surface 124 may be concentric to the
longitudinal axis and, for example, frustoconical, as illustrated
in FIG. 4. This arrangement provides the benefit that a valve
assembly 52 disposed thereon will seat to the lowest position, i.e.
having the smallest diameter. The valve assembly 52 may be disposed
in the proper position without a separate step required in the
manufacturing process. The second support surface 126 may be
concentric to the longitudinal axis and, for example,
frustoconical, as illustrated in FIG. 4. This arrangement provides
the benefit that a component disposed thereon may seat concentric
with and below the first support surface 124. The product delivery
device may be disposed in the proper position without a separate
step required in the manufacturing process. The first support
surface 124 and the second support surface 126 may be substantially
perpendicular to the longitudinal axis. The first support surface
124 and the second support surface 126 may form any angle with
respect to the longitudinal axis such that the valve assembly 52
and the product delivery device 56 may be supported by and/or
joined to the container 32 and product and/or propellant may be
sealed within the container 32.
[0044] The first support surface 124 and second support surface 126
may be contiguous. More particularly, the first support surface 124
and second support surface 126 may be mutually integral and
integral with the outer container 32.
[0045] The first support surface 124 may be the opening of the
container. Further, a single support surface may be used to join
the valve assembly to the container.
[0046] As illustrated in FIG. 4, the container 32 may include a
transition 128 between the first support surface 124 and the second
support surface 126. The transition 128 is any discernable break
that separates the first support surface 124 and the second support
surface 126. The transitions 128 may provide the benefit that each
of the first support surface 124 and second support surface 126 may
be specifically tailored to its particular function of sealingly
retaining the valve assembly 52 and product delivery device 56. The
transition 128 may include a step between the first support surface
124 and the second support surface 126. The step may be a
longitudinal break, between a mutually parallel or mutually skewed
first support surface 124 and second support surface 126.
[0047] The first support surface 124, the second support surface
126, and the transition 128 may include one or more surface
profiles to aid in sealing the valve to the container 32 and/or to
allow fluid, such as propellant, to be introduced into the
container 32 and/or to aid in positioning the components with
respect to one another, for example the product delivery device
with respect to the container. For example, the one or more surface
profiles may include ridges, grooves, protrusions, and/or added
surface roughness.
[0048] The valve assembly 52, including a valve body 54, may be
joined to the container 32. Referring to FIGS. 5A and 5B, the valve
body 54 may extend about a longitudinal axis 70. The valve body 54
may include an outer surface 72 and define an inner passageway 74.
The outer surface 72 may include the surface positioned farthest
from the longitudinal axis 70. The outer surface 72 may extend
about the longitudinal axis 70. The inner passageway 74 may include
a first passageway opening 76 and a second passageway opening 78
and a passageway surface 80 extending from the first passageway
opening 76 to the second passageway opening 78. The passageway
surface 80 may substantially surround the longitudinal axis 70.
[0049] A valve stem 62 may extend through the inner passageway 74
of the valve body 54. The valve stem 62 provides a product flow
path from the interior of the container 32 to the nozzle 60 and
operatively joins the actuator 46 to the valve assembly 52. The
valve stem 62 may be positioned with respect to the valve body 54
in a closed or sealed configuration such that a portion of the
valve stem 62 extends through the first passageway opening 76 of
the valve body 54, a second portion of the valve stem 62 may be
substantially surrounded by the passageway surface 80, and a third
portion of the valve stem 62 may extend through the second
passageway opening 78 of the valve body 54. The valve stem 62 may
be moveable with respect to the valve body 54, for example between
a closed or sealed configuration and/or an open configuration. A
closed or sealed configuration is one in which the product and/or
propellant is contained within the container 32 and no flow path is
provided to dispense product and/or propellant from the container
32. An open configuration is one in which product and/or propellant
may be dispensed from the container 32 to the environment. An open
configuration includes a dispensing configuration and a filling
configuration. Thus, the valve stem 62 may be positioned in other
configurations as the valve stem 62 moves. The valve stem 62 may
include an outer stem surface 92 and an inner stem surface 94
opposite the outer stem surface. The inner stem surface 94 may
define a channel 95 through which product and/or propellant may
flow either out from or into the container 32. The valve stem 62
may include a dispensing opening 116 that may be used to introduce
propellant and/or product into the container 32 or dispense product
and/or propellant from the container 32.
[0050] The valve assembly 52 may include a valve seal 82, such as
illustrated in FIGS. 5A and 5B. The valve seal may be disposed on
at least a portion of the passageway surface 80 and may extend
about at least a portion of the passageway surface 80. The valve
seal may be joined to the passageway surface 80 such that the valve
seal remains in position as the valve stem 62 moves from the closed
configuration to an open configuration. The valve seal may extend
from the passageway surface 80 toward the second passageway opening
78. The valve seal 82 may extend about the second passageway
opening 78. The valve seal 82 may extend from the passageway
surface 80 to the first passageway opening 76. The valve seal 82
may extend about the second passageway opening 78 without extending
from the passageway surface 80. The valve seal 82 may be any shape
such that a seal is formed with a portion of the valve stem 62 and
product and/or propellant is contained within the container 32.
[0051] The valve assembly 52 may include a resilient member 58. The
resilient member 58 may be disposed on a portion of the valve body
54. The resilient member 58 may be positioned adjacent to the first
passageway opening 76 and substantially surround the longitudinal
axis 70. The resilient member 58 may be any compliant member that
provides resistance to a force providing movement of the valve stem
62 when the valve stem 62 is moved, such as to an open
configuration, and returns the valve stem 62 to a closed
configuration, also referred to herein as a sealed configuration,
when the force is removed or lessened. The resilient member 58 may
be made from at least one of a metal and a polymer. The resilient
member 58 may be made from an elastomer such as a thermoplastic
elastomer (TPE). The resilient member 58 may be any shape such that
the resilient member 58 controls the movement of the valve
stem.
[0052] The valve assembly 52 may include an engagement member 68.
The engagement member 68 may be joined to a portion of the valve
stem 62 such that the engagement member 68 moves as the valve stem
62 moves. The engagement member 68 may extend from the outer stem
surface 92 towards the outer surface 72 of the valve body 54. The
engagement member 68 may be axisymmetric or non-axisymmetric. The
engagement member 68 is configured to operatively engage a portion
of the resilient member 58. The resilient member 58 may be
positioned between the engagement member 68 and a portion of the
valve body 54.
[0053] When the valve stem 62 is in a closed configuration, the
engagement member 68 may operatively engage the resilient member 58
such that the resilient member 58 is placed under a desired amount
of compression which biases the valve stem 62 to remain in a
position such that a seal is maintained. When the valve stem 62 is
in a dispensing configuration, a user or other mechanical device
may overcome an additional compression force of the resilient
member to move the valve stem 62 from the sealing configuration to
the dispensing configuration. As the valve stem 62 moves from the
sealing configuration to the dispensing configuration, the
engagement member 68 compresses the resilient member 58. It is also
to be appreciated that the resilient member 58 may be further
compressed to move the valve stem 62 from a dispensing
configuration to a filling configuration.
[0054] The valve stem 62 may include one or more orifices 108. The
orifices 108 may be used for filling the container 32 with product
and/or propellant and dispensing product and/or propellant from the
container 32. The one or more orifices 108 may be any shape or size
so long as product and/or propellant may be at least one of filled
and dispensed through such orifice. For example, the one or more
orifices may be circular, oval, rectangular, square, or any other
shape. The one or more orifices 108 may be tapered. For a valve
stem 62 including two or more orifices, each of the orifices may be
the same or different shapes and may be the same or different
sizes. For example, when both a dispensing orifice and a filling
orifice are included in the valve stem 62, the filling orifice may
have a larger cross-sectional open area than the dispensing
orifice. The orifice 108 may extend from the outer stem surface 92
to the inner stem surface 94. The orifice 108 may be in fluid
communication with the channel 95 defined by the inner stem surface
94 such that product and/or propellent may flow through the orifice
and into the channel 95. The product and/or propellant may flow
from the container 32, through the orifice, and into the channel
95. The product and/or propellant may also flow through the
channel, through the orifice, and into the container 32.
[0055] The one or more orifices 108 may be positioned about the
valve stem 62 such that the release of product and/or propellant is
controlled. The orifice 108 may be positioned between the
dispensing opening 116 of the valve stem 62 and at least a portion
of the valve seal 82. Stated another way, the one or more orifices
108 may be positioned such that at least a portion of the valve
seal 82 is located between the orifice and the portion of the valve
stem 62 adjacent to the retaining member 110 or the portion of the
valve stem 62 adjacent to the interior of the container 32 to
prevent product and/or propellant from freely flowing from the
container 32 and through the orifice. The portion of the valve seal
82 positioned between the orifice and the bottom portion of the
valve stem prevents product and/or propellant from flowing to the
orifice prior to the valve stem being moved to an open
configuration. When the valve stem is in a closed configuration,
the valve seal 82 prevents product and/or propellant from accessing
the orifice and contains the product and/or propellant within the
container 32. A second portion of the valve seal 82 may be located
between the orifice and the dispensing opening 116 of the valve
stem to prevent product and/or propellant from freely flowing
through the inner passageway 74 and out the first passageway
opening 76 as product and/or propellant flow through the
orifice.
[0056] The valve stem 62 may include a retaining member 110. The
retaining member 110 may be joined to the portion of the valve stem
62 adjacent the container or the retaining member 110 may be formed
with the remainder of the valve stem 62. The retaining member 110
may be formed from the same material as the other portions of the
valve stem 62 or with a different material. For example, the
retaining member 110 may be formed, at least in part, with a first
material and the remainder of the valve stem 62 may be formed with
one or more other materials that are different from the first
material. The first material may have a melting point or a glass
transition temperature (Tg) that is lower than the one or more
other materials to allow at least the portion of the retaining
member including the first material to melt, soften, deflect, or
deform at a given temperature that is relatively lower than the
remainder of the valve stem 62 or the valve body 54.
[0057] At least a portion of the retaining member 110 may extend
outward, such as radially outward, beyond the outer stem surface 92
and may be configured to engage a portion of the valve body 54
and/or the valve seal 82. The retaining member may be axisymmetric
or non-axisymmetric. The retaining member 110 may work in
cooperation with the resilient member 58 to position the valve stem
62 in a sealed position. The retaining member 110 may be any shape
such that a portion of the retaining member 110 may operatively
engage at least one of a portion of the valve body 54 and the valve
seal 82. The shape of the retaining member 110 may be such that the
retaining member 110 maintains the position of the valve stem 62
during safe operating conditions and aids in safely moving the
valve stem to vent the container during adverse operating
conditions, such as relatively elevated temperatures and over
pressurization of the aerosol dispenser.
[0058] The product delivery device 56 may be joined to at least one
of the valve assembly 52 and the container 32. The product delivery
device 56 and the valve assembly 52 may be disposed, at least in
part, in the neck of the container 32. For example, such as
illustrated in FIG. 5B, the bag 24 may be disposed in the container
such that a portion of the bag 24 is joined to the neck 40 of the
container 32 and a portion of the bag 24 extends into the container
32. The valve assembly 52 may be disposed on at least one of a
portion of the bag 24 and a portion of the neck 40. The bag and the
valve assembly are in fluid communication. Similarly, a dip tube
may be disposed in the container 32. The dip tube may be a unitary
member or may be a multi-piece member. A portion of the dip tube
extends into the container 32 and a portion of the dip tube, such
as the adaptor, is joined to at least one of the neck 40 of the
container 32 and the valve body 54. The valve assembly 52 may be
disposed on at least one of a portion of the dip tube, a portion of
the adaptor, and a portion of the neck 40. The dip tube and the
valve assembly are in fluid communication.
[0059] As illustrated in FIGS. 5A and 5B, the valve body 54 may
include one or more members that extend from at least one of a
first valve body surface 96 and a second valve body surface 98. The
valve body 54 may include a first brace member 162. The first brace
member 162 may be joined to the first valve body surface 96 and
extend away from the first valve body surface 96. The first brace
member 162 may extend continuously or discontinuously about the
inner passageway 74. The first brace member 162 may be positioned
adjacent to the outer surface 72 of the valve body 54. The first
brace member 162 may be positioned between the outer surface 72 and
the inner passageway 74 of the valve body 54. The first brace
member 162 may extend in a direction away from the first valve body
surface 96. The first brace member 162 may extend such that the
outer most portion of the first brace member 162 extends above at
least a portion of the resilient member 58. The first brace member
162 may extend above or be at the same height as the top of the
valve stem. The first brace member 162 may provide stability to the
valve body 54 when subject to relatively high temperatures and/or
pressures, for example. An actuator or other dispensing component
may be joined to a portion of the first brace member 162.
[0060] The valve body 54 may include a second brace member 164. The
second brace member 164 may be joined to the first valve body
surface 96 and extend away from the first valve body surface 96.
The second brace member 164 may be positioned between the outer
surface 72 and the inner passageway 74 of the valve body 54. The
second brace member 164 may extend continuously or discontinuously
about the inner passageway 74. The second brace member 164 may be
positioned between the first brace member 162 and the inner
passageway 74 of the valve body 54. The second brace member 164 may
extend in a direction away from the first valve body surface 96
such that the outer most portion of the second brace member 164
extends above a portion of the resilient member 58. The second
brace member 164 may extend above or be at the same height as the
top of the valve stem. The second brace member 164 may provide
stability to the valve body 54 when subject to relatively high
temperatures and pressures, for example. An actuator or other
dispensing component may be joined to a portion of the first brace
member 162 or the second brace member 164.
[0061] The second brace member 164 may function to aid in guiding
the engagement member 68 and/or the resilient member 58 as the
valve stem 62 moves between the closed configuration and the open
configuration. The second brace member 164 may substantially
surround the engagement member 68 and/or the resilient member 58
such that the engagement member 68 may slidably move and the
resilient member 58 may move, such as by deflecting or compressing.
A gap may be present between the second brace member 164 and the
engagement member 68. The engagement member 68 may slidably engage
a portion of the brace member 164.
[0062] The valve body 54 may include one or more ribs. A rib 166
may extend between the first brace member 162 and the second brace
member 164. The rib 166 may be joined to at least one of the first
brace member 162 and the second brace member 164. As illustrated in
FIG. 5A, the rib may be joined to both of a portion of the first
brace member 162 and a portion of the second brace member 164. The
rib may extend radially between the first brace member 162 and the
second brace member 164. The rib 166 may be joined to the first
valve body surface 96. The rib 166 may not be joined to the first
valve body surface 96 and, thus, a gap may be present between the
first valve body surface 96 and the rib 166. The one or more ribs
166 may aid in manufacturing the aerosol dispenser. For example,
the one or more ribs 166 may be used to grip the valve body 54 such
that the valve body 54 may be moved and/or attached to the
container 32. The one or more ribs 166 may be operatively engaged
by processing equipment during the manufacture of the aerosol
dispenser. The one or more ribs 166 may allow for joining, such as
by spin welding, the valve body 54 to the container 32. The one or
more ribs 166 may also provide structural stability to the valve
body 54. The one or more ribs 166 may aid in controlling the
deformation of the valve body 54 such as when the aerosol dispenser
is subject to relatively high temperatures, for example.
[0063] As illustrated in FIGS. 5A and 5B, the valve body 54 may
include one or more protrusions that extend from at least one of
the first valve body surface 96 and the second valve body surface
98. The valve body 54 may include a first attachment protrusion
168. The first attachment protrusion 168 may be joined to the
second valve body surface 98 and extend away from the second valve
body surface 98. The first attachment protrusion 168 may extend
continuously or discontinuously about the inner passageway 74. The
first attachment protrusion 168 may extend continuously or
discontinuously about the longitudinal axis 70. The first
attachment protrusion 168 may extend from the outer surface 72 of
the valve body 54 towards the inner passageway 74. The first
attachment protrusion may be positioned between the outer surface
72 and the inner passageway 74 of the valve body 54 or the
longitudinal axis 70. The first attachment protrusion 168 may be
configured to join the valve body to a portion of the neck of the
container 32. The first attachment protrusion 168 may be welded to
a portion of the neck of the container 32. It is to be appreciated
that first attachment protrusion may be joined to the neck such as
by a press fit, interference fit, solvent welding, laser welding,
sonic welding, ultrasonic welding, spin welding, adhesive, or any
combination thereof. The height and width of the first attachment
protrusion 168 may be selected to obtain a desired weld between the
valve body and the container 32. Generally, the greater the surface
area the greater the strength of the weld. The first attachment
protrusion 168 may include one or more grooves or other surface
profile such that fluid may pass between a portion of the first
attachment protrusion 168 and the neck prior to the valve body
being sealed to the container 32.
[0064] As illustrated in FIGS. 5A and 5B, the valve body 54 may
include a second attachment protrusion 170. The second attachment
protrusion 170 may be joined to the second valve body surface 98
and extend away from the second valve body surface 98. The second
attachment protrusion 170 may extend continuously or
discontinuously about the inner passageway 74. The second
attachment protrusion 170 may extend continuously or
discontinuously about the longitudinal axis 70. The second
attachment protrusion 170 may extend from the outer surface 72 of
the valve body 54 towards the inner passageway 74. The second
attachment protrusion 170 may be positioned between the outer
surface 72 and the inner passageway 74 of the valve body 54 or the
longitudinal axis 70. The second attachment protrusion 170 may be
positioned between the first attachment protrusion 168 and the
inner passageway 74 of the valve body 54 or the first attachment
protrusion 168 and the longitudinal axis 70.
[0065] The second attachment protrusion may have a height that is
greater than, less than, or equal to the height of the first
attachment protrusion. The difference in height of the first
attachment protrusion and the second attachment protrusion may
allow for the valve body to be supported by the second attachment
protrusion, which engages a portion of the neck of the container
32, while fluid, which may include product and/or propellant, is
passed between the neck of the container 32 and the first
attachment protrusion. The second attachment protrusion may form a
temporary seal with a portion of the neck of the container 32 or
the product delivery device to control the flow of fluid into the
container 32. The second attachment protrusion 170 may be welded to
a portion of the neck of the container 32 or a portion of the
product delivery device 56. It is to be appreciated that the second
attachment protrusion may be joined to the neck such as by a press
fit, interference fit, solvent welding, laser welding, sonic
welding, ultrasonic welding, spin welding, adhesive, or any
combination thereof.
[0066] The first attachment protrusion 168 and the second
attachment protrusion 170 may be spaced from one another such that
a gap is present between them. This gap may allow for control of
material when the first attachment protrusion 168 and the second
attachment protrusion 170 are joined to the neck of the container
32. For example, when the valve body 54 is welded, such as by spin
welding, the material of the first attachment protrusion 168 and
the second attachment protrusion becomes semi-fluid and may flow
and generate flash. Flash is the excess material that flows outside
of the region of the attachment area. Similarly, when the valve
body is joined by an adhesive, the adhesive may overflow also
generating flash. The gaps control the flow of flash. The flash
moves into the gaps and prevent the flash from interfering with the
valve body 54 and/or the container 32.
[0067] The valve body 54 may include a valve skirt 172. The valve
skirt 172 may be joined to the second valve body surface 98 and
extend away from the second valve body surface 98. The valve skirt
172 may extend continuously or discontinuously about the inner
passageway 74. The valve skirt 172 may extend continuously or
discontinuously about the longitudinal axis 70. The valve skirt 172
may be positioned between the outer surface 72 and the inner
passageway 74 of the valve body 54 or the longitudinal axis 70. The
valve skirt 172 may be positioned between the first attachment
protrusion 168 and the inner passageway 74 of the valve body 54 or
the longitudinal axis 70. The valve skirt 172 may be positioned
between the second attachment protrusion 170 and the inner
passageway 74 of the valve body 54 or the longitudinal axis 70. The
valve skirt may be used to prevent material from interfering with
the movement and operation of the valve assembly. The valve skirt
may be used to prevent flash from mixing with the product and/or
propellant. The valve skirt, for example, may prevent flash
generated during the welding or adhering process from interfering
with the movement and operation of the valve stem and the
dispensing and/or filling of product and/or propellant. The valve
skirt may control the flash such that the flash is contained in the
area between the valve skirt and the outer surface of the valve
body. It is to be appreciated that the valve skirt may or may not
be present, and this may be dependent on the type and geometry of
the product delivery device 56 and the means for joining the valve
assembly to the container. The valve skirt 172 may be configured to
operatively engage a portion of the adaptor, the dip tube and/or
the bag.
[0068] The aforementioned components of the aerosol dispenser 30
may be polymeric. By polymeric it is meant that the component is
formed of a material that includes polymers, and/or particularly
polyolefins, polyesters or nylons, and more particularly PET, PP,
or PE. Thus, the entire aerosol dispenser 30 or, specific
components thereof, may be free of metal. The container 32, and all
other components, may comprise, consist essentially of or consist
of PET, PEF, PEN, Nylon, EVOH, TPE (thermoplastic elastomer) or
combinations thereof. All or substantially all of the components of
the aerosol dispenser, excluding the propellant and product, may be
configured to be accepted in a single recycling stream. All such
materials, or a majority of the components of the aerosol dispenser
30 (excluding the propellant and product) may be comprised of a
single class of resin according to ASTM D7611. Particularly, the
majority of the aerosol dispenser 30 by weight may be PET. The
majority of the valve assembly by weight may be PET.
[0069] A permanent or semi-permanent seal may be used to join any
or all of the polymeric components of the aerosol dispenser 30.
Particularly, if the components have compatible melt indices, such
components may be sealed by welding to retain propellant therein.
Suitable welding processes may include sonic, ultrasonic, spin, and
laser welding. Welding may be accomplished with a commercially
available welder, such as available from Branson Ultrasonics Corp.
of Danbury, Conn.
[0070] It is to be appreciated that any method of joining the valve
to the container 32 to seal product and/or propellant within the
container 32 may be used. However, for the sake of brevity, the
following discussion will discuss welding, and, more specifically,
spin welding. Spin welding provides the benefit that the energy
plane is generally confined to a small vertical space, limiting
unintended damage of other components not intended to be welded or
receive such energy. Spin welding further provides the benefit that
the welding of the valve assembly to the container 32 and the
welding of the product delivery device 56 may occur simultaneously
or nearly at the same time, increasing production speed.
[0071] The process of manufacturing an aerosol dispenser may
include blow molding the container 32 and molding, such as by
injection molding, the components of the valve assembly. The
process also includes joining the valve assembly to the container
32 and introducing product and propellant into the container.
Further, an actuator may be joined to the valve assembly and/or the
container 32 to allow for controlled dispensing of the product
and/or propellant. More specifically, the process for joining the
valve assembly to the container 32 and introducing product and
propellant into the container 32 may include: providing the valve
assembly, a product delivery device, such as a bag, and a
container; disposing at least a portion of the product delivery
device and at least a portion of the valve assembly within the
opening of the neck of the container; forming a temporary seal
between a portion of the neck and the product delivery device;
introducing propellant into the container; joining the valve
assembly to the container to seal the valve to the container such
that propellant is sealed within the container; and controlling the
position of the product delivery device during the joining of the
valve assembly to the container such that the product delivery
device does not, for example, interfere with the integrity of the
seal between the valve assembly and the container or damage the
product delivery device.
[0072] As previously discussed, the product delivery device may be
a bag. The bag may be concentrically blow molded with the container
32, such as described in U.S. Pat. No. 10,220,562 and U.S. Patent
Publication No. 2018/0043604, or the bag 24 may be provided
separately from the container 32. The bag 24 may be made from a
relatively flexible material, such that when propellant is
introduced within the container 32, the bag may collapse.
Similarly, the bag may deform as product is introduced into and
dispensed from the bag. Due to the ability for the bag to collapse
and deform, the bag position may need to be controlled to prevent
the bag from interfering with the joining of the valve assembly to
the container 32 and from damaging the bag during the manufacturing
process.
[0073] At least a portion of the bag 24 and at least a portion of
the valve assembly 52 may be disposed within the container 32. A
portion of the bag 24 may be positioned between a portion of the
container 32 and the valve body 54 of the valve assembly 52. More
specifically, a portion of the bag 24 may be disposed on the second
support surface 126 of the container 32. The second attachment
protrusion 170 of the valve body 54 may be disposed on the portion
of the bag 24 disposed on the second support surface 126 of the
container 32. The first attachment protrusion 168 may be positioned
above the first support surface 124, such that a gap is present
between the first attachment protrusion 168 and the first support
surface 124. The gap includes any opening that allows a fluid, such
as propellant, to flow between the valve body 54 and the container
32.
[0074] A manifold, a device configured to supply fluid, such as
propellant, may be provided. The manifold may operatively engage at
least a portion of the container 32 and the valve assembly 52 to
form a seal, such as illustrated in FIGS. 6A and 6B. When the
manifold operatively engages the container 32 and/or the valve
assembly 52, a certain amount of force may be applied to the valve
assembly 52. Upon operative engagement of the manifold to the valve
assembly 52, a temporary seal may be formed between the valve
assembly 52 at least one of a portion of the neck of the container
32 and a portion of the bag 24. The temporary seal prevents
propellant from being introduced into the interior of the bag and
allows propellant to be introduced into the container 32 in the
area between the container 32 and the bag.
[0075] The manifold may supply propellant, under pressure, between
the valve assembly 52 and container neck 40. The manifold may be
retractingly disposed above the container 32. The manifold may be
brought into contact with the valve assembly 52, to form the
temporary seal. The geometry of at least one of the valve assembly
52 and the neck 40 of the container 32 may be such that the
propellant may flow between the valve assembly 52 and the neck 40
and into the container 32. For example, at least one of the valve
assembly 52 and the neck 40 may include one or more channels,
grooves, or notches. The propellant may be supplied through or
between the one or more channels, grooves, or notches. Suitable
channels may include those described in commonly assigned U.S. Pat.
No. 8,869,842. While the temporary seal is established, the
propellant may be introduced into the outer container 32.
[0076] It is to be appreciated that the manifold may be configured
to engage only the outer container 32. A separate device may be
used to apply a force to the valve assembly 52 to form the
temporary seal between the valve assembly 52 and at least one of
the container and the product delivery device.
[0077] A bag 24 may be disposed within the container 32 prior to
introducing propellant into the container. The bag 24 disposed in
the container 32 has a first bag volume and the pressure within the
bag is equal to atmospheric pressure or the pressure outside of the
container. Upon formation of the temporary seal between the valve
assembly and at least one of the container 32 and the bag 24 and as
propellant is introduced into the container 32, the volume and
pressure of the bag 24 change. To achieve the desired pressure
between the container and the bag, the bag may collapse to a second
volume, which is less than the initial, first bag volume. During
the collapse of the bag, the volume of fluid within the bag may be
controlled such that a desired pressure within the container and
within the bag is achieved and/or a certain volume may be retained
within the bag. A certain volume of fluid may be retained within
the bag prior to joining the valve assembly to the container so
that the bag does not adversely interfere with the seal between the
valve assembly and the container and the bag does not get damaged
during the joining of the valve to the container. If a volume of
fluid is retained within the bag prior to joining of the valve to
the container, that volume of fluid may be released from the bag
through the valve stem after the joining of the valve to the
container or prior to filling the bag with a product. Minimizing
the fluid within the bag prior to filling the bag with product may
prevent dispensing of unwanted fluid, such as air, with the
product.
[0078] It is to be appreciated that bags that are rolled and
secured prior to placement into a container, likely do not have
enough volume to interfere with pressurizing the container, through
the introduction of propellant. Further, a bag that is rolled and
secured in the rolled orientation is unlikely to interfere with the
joining of the valve to the container as the bag is in a secured
orientation that provides enough rigidity to prevent movement of
the bag into a position that interferes with this process.
[0079] As the propellant is being introduced into the container 32,
the valve stem 62 may be manipulated such that the volume and
pressure within the bag may be controlled in various ways. More
specifically, the methods to control the pressure and/or volume in
the bag during and/or after the introduction of propellant include:
blocked venting, vent profiling, slow venting, vent gassing and
pressurized joining, negative pressure to blocked vent, and open
vent to closed volume. These will be discussed in more detail
herein with reference to FIGS. 6 and 7. During one or more of these
methods, the bag may have a first bag volume and a second bag
volume. The first bag volume may be different than the second bag
volume. The first bag volume may be greater than the second bag
volume. The second bag volume may be from about 0.1% to about 5% or
from about 1% to about 5% or from about 5% to about 50% of the
volume of the container, also referred to as the internal container
volume. The first bag volume may be greater than about 20% of the
internal container volume and the second bag volume may be less
than about 15% of the internal container volume. The bag may have a
first bag pressure prior to propellant being introduced into the
container and a second bag pressure after propellant is introduced
into the container. The first bag pressure may be different from
the second bag pressure. The first bag pressure may be less than
the second bag pressure.
[0080] Using the blocked vent method to control the pressure and/or
volume of the bag includes the following. As the propellant is
being introduced into the container 32, the valve stem 62 may be
positioned in a closed configuration. A closed configuration means
that fluid is unable to flow through the valve stem. The valve stem
62 may remain in the closed configuration for the duration of the
introduction of propellant into the container. The fluid that is
present within the bag when the temporary seal is formed remains
trapped within the bag 24 and is compressed as propellant is
introduced into the container 32. The bag pressure Pb, which is the
pressure within the bag 24, will equilibrate with the propellant
pressure Pp, which is the pressure of the propellant between the
container and the bag, and the bag 24 will be collapsed. The first
or initial volume of the bag may be greater than the second volume
of the bag after the introduction of propellant. Stated another
way, the volume of the bag is decreased. After joining the valve
assembly to the container, the volume of fluid within the bag may
be released through the valve stem by positioning the valve stem in
the open configuration.
[0081] Using the vent profiling method to control the pressure
and/or volume of the bag includes the following. The valve stem 62
may be cycled between a closed configuration and an open
configuration. The open configuration allows fluid to flow through
the valve stem. As the propellant is being introduced into the
container 32, the valve stem 62 may be cycled any number of times
from the closed configuration to the open configuration. The number
of cycles and the duration of the cycles may be determined, in
part, based on the type of propellant and the characteristics of
the aerosol dispenser, such as the container volume and pressure of
the propellant and orifice dimensions disposed on the valve stem.
For example, the valve stem 62 may be cycled from the open
configuration to the closed configuration, or vice versa, once. The
bag is compressed as propellant is introduced into the container
32. As propellant is being introduced into the container, fluid is
allowed to be released from the bag through the valve stem when the
valve stem is in the open configuration. The bag 24 collapses as
the propellant is introduced into the container and fluid is
cyclically released through the valve stem. The bag may have a
first volume prior to propellant being introduced into the
container and a second volume once propellant has been introduced
into the container and an amount of fluid has been released from
the bag. The first volume may be greater than the second volume.
The bag pressure Pb will equilibrate with the propellant pressure
Pp between the bag and the bottle. The valve stem 62 may be
returned to the closed configuration prior to completion of the
introduction of propellant into the container. A predetermined
amount of fluid remains within the bag. The retention of some fluid
within the bag prevents the bag from being fully collapsed. and,
thus, the bag is not fully collapsed. By preventing the bag from
fully collapsing, the bag is prevented from interfering with the
joining of the valve assembly and the container. The bag retains
enough volume that the bag is not in contact with the valve
assembly. After joining the valve assembly to the container, the
volume of fluid within the bag may be released through the valve
stem by positioning the valve stem in the open configuration.
[0082] Using the slow venting method to control the pressure and/or
volume of the bag includes the following. A flow restrictor may be
joined to the valve stem 62 to control the release of fluid through
the valve stem as propellant is being introduced into the container
32. The flow restrictor controls the amount that the bag collapses
and the rate at which the bag collapses. The flow restrictor may be
connected to or be an integral part of the manifold. The valve stem
62 may be positioned in an open configuration during the
introduction of propellant. The flow restrictor allows for a
certain amount of fluid to be released during this process. The
flow restrictor may be configured to allow a substantially constant
flow of fluid to be released through the valve stem. The flow
restrictor may be configured to allow a flow of fluid to be
released for less than the duration of the introduction of
propellant into the container or for substantially the same
duration as the introduction of propellant into the container. The
flow restrictor may be configured to allow for a flow rate of fluid
to be released that is less than the rate of introduction of
propellant or substantially the same as the rate of introduction of
propellant. The valve stem 62 may be returned to the closed
configuration upon completion of the introduction of propellant
into the container and/or once the desired amount of fluid is
release through the valve stem. The bag may be compressed as
propellant is introduced into the container 32. As propellant is
being introduced into the container and fluid is allowed to be
controllably removed from the bag through the valve stem, the
volume within in the bag is changed. The bag may have a first
volume prior to propellant being introduced into the container and
a second volume once propellant has been introduced into the
container and the desired amount of fluid has been released from
the bag. The bag pressure Pb will equilibrate with the propellant
pressure Pp, the pressure between the bag and the bottle. A
predetermined amount of fluid may remain within the bag to prevent
the bag from fully collapsing. By retaining an amount of fluid
within the bag, the bag is prevented from interfering with the
joining of the valve assembly and the container. The bag retains
enough volume that the bag does not contact the valve assembly.
After joining the valve assembly to the container, the volume of
fluid within the bag may be released through the valve stem by
positioning the valve stem in the open configuration.
[0083] Using the vent gassing and pressurized joining method to
control the pressure and/or volume of the bag includes the
following. The valve stem 62 may be positioned in an open
configuration during the introduction of the propellant into the
container. As propellant is introduced, the fluid within the bag is
released through the valve stem. The bag may be fully collapsed.
Upon being collapsed, the bag may contact the valve assembly 52. If
the bag is collapsed such that the bag is in contact with the valve
assembly 52, a fluid may be introduced through the valve stem at a
pressure greater than the propellant pressure Pp, the pressure
between the bag and the container. The introduction of pressurized
fluid expands the bag such that the bag moves away from the valve
assembly and is no longer in contact with the valve assembly. By
positioning the bag away from the valve assembly, the bag may not
interfere with the joining of the valve assembly to the container.
After joining the valve assembly to the container, the volume of
gas within the bag may be released through the valve stem by
positioning the valve stem in the open configuration. It is to be
appreciated that if the bag collapses to a greater extent than is
expected or collapses such that the bag may interfere with the
joining process in any of the described methods, a fluid may be
introduced through the valve stem to move the bag away from the
valve assembly.
[0084] Using the negative pressure to blocked vent method to
control the pressure and/or volume of the bag includes the
following. The valve stem 62 may be positioned in an open
configuration. While the valve stem 62 is in the open
configuration, a negative pressure is pulled through the valve stem
62. The pressure may be from about 1 psia to about 15 psia. The
pressure may be reduced until the pressure within the bag is from
about 5 psia to about 10 psia. Maintaining a pressure of greater
than about 5 psia within the bag may prevent the bag from fully or
partially collapsing. As the negative pressure is being applied,
the bag may collapse from a first bag volume to a second bag
volume. The difference between the first bag volume and the second
bag volume may be less than about 5%. The second bag volume may be
greater than about 95% of the first bag volume. After the desired
pressure within the bag is reached, the valve stem 62 may be
positioned in the closed configuration. Once the valve stem is in
the closed configuration, propellant may be introduced into the
container between the valve assembly 52 and the container. By
starting the introduction of propellant when the bag has a
relatively lower pressure, the bag may collapse further before the
bag pressure Pb, the pressure within the bag, and the propellant
pressure Pp, the pressure between the bag and the container,
reaches equilibrium. The bag 24 may collapse from the second bag
volume to a third bag volume. The third bag volume may be less than
the second bag volume. The third bag volume may be less than the
first bag volume. Propellant may be introduced between the bag 24
and the container until the bag pressure Pb and the propellant
pressure Pp equilibrate. After the bag pressure and the propellant
pressure reach equilibrium, the valve assembly 52 may then be
joined to the container. After joining the valve assembly to the
container, the volume of gas within the bag may be released through
the valve stem by positioning the valve stem in the open
configuration.
[0085] Using the open vent to closed volume method to control the
pressure and/or volume of the bag includes the following. Once the
valve assembly 52 is disposed on the container 32, a manifold 130,
as previously described, and a fluid chamber 132 may be provided,
such as illustrated in FIGS. 7A and 7B. The fluid chamber may be
connected to or be an integral part of the manifold. The manifold
130 and the fluid chamber 132 may be positioned to contact at least
a portion of at least one of the valve assembly 52 and the
container 32. The manifold 130 and the fluid chamber 132 may form a
hermetic seal, which is a fluid tight seal, with at least a portion
of at least one of the valve assembly 52 and the container 32. The
fluid chamber may be moveable with respect to the valve assembly
52. The fluid chamber 132 may include a valve engagement tip 136.
The valve engagement tip 136 may be configured to operatively
engage the valve stem 62. The valve engagement tip 136 may move the
valve stem 62 to the open configuration when operatively engaged
with the valve stem and may allow the valve stem 62 to return to a
closed configuration when the valve engagement tip 136 is moved
away from the valve stem 62. When the valve stem 62 is in the open
configuration, a fluid path from the bag 24, through the valve stem
62, and into the fluid chamber 132 is formed. It is to be
appreciated that the valve engagement tip 136 may operatively
engage the valve stem 62 or another component of the valve assembly
that is joined to the valve stem 62, such as the engagement member
68.
[0086] The fluid chamber 132 may substantially surround the valve
stem 62 and may be in fluid communication with the valve stem 62
such that any fluid that is expelled through the valve stem 62 is
retained within the fluid chamber 132. The fluid chamber 132 may be
sized to hold a certain volume of fluid. The size of the fluid
chamber 132 may be based, at least in part, on the volume of the
container, the volume of the bag, and the desired pressure between
the container and the bag. The fluid chamber 132 may be sized such
that the ratio of the volume of the collapsed bag (the bag after
propellant is introduced into the container) and the volume of the
container is from about 0.1% to about 5% or from about 1% to about
5% or from about 5% to about 50%. The fluid chamber 132 may be
sized such that a certain amount of fluid remains within the bag as
the bag is collapsed due to the introduction of propellant into the
container. The fluid chamber may have a fluid chamber volume that
is variable or a fixed. For example, the fluid chamber may include
a piston 134. The piston 134 may be disposed within the fluid
chamber 132 and is moveable within the fluid chamber 132. The
volume of the fluid chamber 132 may be adjusted by moving the
piston 134. Thus, the volume of the fluid chamber 132 may be
adjusted for different sizes of containers 32 and to achieve
different volumes/pressures within the bag 24 and the container 32.
The fluid chamber volume may be less than the internal container
volume. The fluid chamber volume may be from about 30% to about 40%
of the container volume or from about 20% to about 50% of the
container volume or from about 10% to about 60% of the container
volume. After joining the valve assembly to the container, the
volume of gas within the bag may be released through the valve stem
by positioning the valve stem in the open configuration.
[0087] The manifold 130 and the fluid chamber 132 operatively
engage at least a portion of at least one of the valve assembly 52
and the container 32. The manifold 130 and the fluid chamber 132
are hermetically sealed to at least a portion of at least one of
the valve assembly 52 and the container 32. The valve stem 62 is
moved from a closed configuration, to an open configuration. The
open configuration allows fluid to move from the bag, through the
valve stem, and into the fluid chamber. The manifold 130 introduces
propellant into the container 32. The propellant may be introduced
between the container 32 and the bag 24. The valve stem 62 remains
in an open configuration as propellant is introduced into the
container. As propellant is introduced into the container 32, the
pressure within the container increases. As the pressure within the
container increases, a portion of the fluid volume is expelled from
the bag by moving from the bag, through the valve stem 62, and into
the fluid chamber 132. Because the fluid chamber 132 is a closed
volume, only a certain amount of fluid may flow into the fluid
chamber 132. The fluid chamber 132 is sized such that the complete
volume of fluid within the bag cannot be expelled from the bag and
into the fluid chamber. The fluid chamber 132 is sized such that a
certain volume of fluid remains within the bag. The first volume of
the bag prior to introduction of propellant into the container may
be greater than the second volume of the bag after introduction of
propellant. Upon introduction of propellant into the container, the
bag pressure Pb will equilibrate with the chamber pressure Pc, the
pressure of the fluid within the fluid chamber. Further, the bag
pressure Pb will reach an equilibrium with the propellant pressure
Pp. Stated another way, equilibrium is obtained when the propellant
pressure Pp, the bag pressure Pb, the chamber pressure Pc, the
pressure of the fluid within the fluid chamber, are substantially
equal. The bag may be partially collapsed but not fully collapsed
when an equilibrium of the pressures is reached. Stated another
way, the bag still has a volume, which may be relatively small, to
prevent the bag from interfering with the joining of the valve
assembly to the container when equilibrium is reached. It is to be
appreciated that increasing the size of the fluid chamber 132, will
allow the bag to collapse further and decreasing the size of the
fluid chamber, will allow the bag to collapse less. Once
equilibrium is obtained, the manifold discontinues providing
propellant to the container, the valve stem 62 may be returned to a
closed configuration, and the valve assembly 52 may be joined to
the container 32. It is to be appreciated that the valve stem 62
may remain in an open configuration as the valve assembly 52 is
joined to the container 32. The valve stem 62 may be moved from the
open configuration to the closed configuration after the valve
assembly 52 is joined to the container 32. The manifold 130 and the
fluid chamber 132 may be removed from contacting the container 32
and/or the valve assembly 52. The valve stem 62 may be moved from
the closed configuration to the open configuration to release any
fluid that was remaining in the bag 24 after joining.
[0088] For any of the aforementioned methods, product and an
actuator may be added to the container and/or valve assembly 52
after the valve assembly 52 is joined to the container. The
container may be filled with product by introducing product through
the valve stem 62 such that product flows through the valve stem 62
and into the bag 24 or the container 32. Product may flow through
the valve stem 62 while the valve stem is positioned in an open
configuration. An actuator may be joined to a portion of at least
one of the valve assembly 52 and the container 32.
[0089] Various methods may be used to join the valve assembly 52 to
the container 32. A permanent or semi-permanent seal may be used to
join the valve assembly 52 to the container 32. If the valve
assembly 52, more specifically, the valve body 54, and the
container 32, more specifically, the neck 40, have compatible melt
indices, such components may be sealed by welding to retain the
propellant therein. Suitable welding processes may include sonic,
ultrasonic, spin, and laser welding.
[0090] As previously discussed, the valve body 54 includes a first
attachment protrusion 168 and a second attachment protrusion 170.
The container 32 includes a first support surface 124 and a second
support surface 126. When the valve assembly 52 is disposed within
at least a portion of the neck 40 of the container 32, the first
attachment protrusion 168 may be aligned with the first support
surface 124 and the second attachment protrusion 170 may be aligned
with the second support surface 126. When the valve assembly 52 is
joined to the container 32, the first attachment protrusion 168 may
be joined to the first support surface 124 and the second
attachment protrusion 170 may be joined to the product delivery
device, such as a bag, an adaptor 64 joined to a bag, or an adaptor
64 joined to a dip tube, which is supported by the second support
surface 126. The first attachment protrusion 168 may be joined to
the first support surface 124 at the same time as or at a different
from than the second attachment protrusion 170 may be joined to the
bag 24. The second attachment protrusion 170 may be joined to the
bag 24 prior to the first attachment protrusion being joined to the
first support surface 124.
[0091] It is to be appreciated that the second support surface 126
may be joined to the second attachment protrusion 170 and/or the
product delivery device. For example, if a relatively high amount
of frictional energy, such as by spinning the valve, is delivered
to the area of the second support surface 126, the second support
surface 126 may become molten and join to the second attachment
protrusion 170 and/or the product delivery device 56, such as the
bag 24, the dip tube 26, an adaptor 64 joined to a bag, or an
adaptor 64 joined to a dip tube.
[0092] When welding the valve assembly 52 to the container 32, the
first attachment protrusion 168 may be joined to the first support
surface 124 at a first weld 88 and the second attachment protrusion
may be joined to the product delivery device at a second weld 90,
such as illustrated in FIG. 5B. As previously stated, the second
support surface 126 may also form part of the second weld 90. The
second weld 90 may occur prior to the first weld 88. The second
weld 90 may occur at the position of the temporary seal between the
valve assembly and at least one of the containers and the product
delivery device. The temporary seal prevents propellant from being
introduced into the bag as propellant is introduced into the
container 32. After propellant has been introduced into the
container 32, the second weld 90 may be completed, which provides
for containment of the propellant within the container 32 and
prevents propellant from entering the bag 24. The first weld 88 may
be radially spaced from the second weld 90.
[0093] The timing of the second weld 90 occurring after, or
preferably before the first weld 88 may be influenced by geometry
of the first attachment protrusion 168 and the second attachment
protrusion 170. If the protrusions equally contact the respective
support surfaces, the second weld 90, and first weld 88 will
generally simultaneously occur. However, the second attachment
protrusion 168, which engages a portion of the bag 24, may extend
further than the first attachment protrusion 168, so that welding
order allows for propellant to be introduced between the valve body
54 and the neck 40 of the container 32 as described herein.
[0094] If the product delivery device 56 is a dip tube 26, the
introduction of propellant and the introduction of product may
simultaneously occur. The propellant and product may be premixed so
that it may be introduced together, which occurs during the welding
operation. Alternatively, either a bag 24, piston, or a dip tube 26
aerosol dispenser 20 may have the product 42 later added through
the valve stem 62.
[0095] It is to be appreciated that if one or more of the first
weld 88 and the second weld 90 are relatively thick in the radial
dimension, and spaced relatively close to each other, the first
weld 88 and the second weld 90 may appear to merge. While two
radially spaced apart welds are discussed, any number of welds may
be utilized. Additional welds may be used to join additional
components as desired or to reinforce the first weld 88 and the
second weld 90.
[0096] The first weld 88 may circumscribe the second weld 90 in
concentric or eccentric fashion. The first weld 88 and the second
weld 90 may be of equal or unequal radial thickness, require equal
or unequal energy to affect a proper bond, and may be equally or
unequally spaced from each other and equally or unequally spaced
about the longitudinal axis. The first weld 88 and the second weld
90 may be in the same plane or in different planes. The first weld
88 and the second weld 90 may be of constant or variable thickness
in the radial direction, in the same plane or mutually different
planes with either being above or below the other, may be formed by
the same process or different processes, may be perpendicular to or
skewed to the longitudinal axis, and mutually eccentric and/or
eccentric to the longitudinal axis.
[0097] The valve assembly 52 may be spin welded by rotation about
the longitudinal axis. The valve assembly 52 may be subjected to
relative motion. The valve assembly 52 may be rotated while the
container 32 and the product delivery device 56 are held
stationary. The container 32 and product delivery device 56 may be
rotated about the longitudinal axis and the valve assembly 52 may
be held stationary to join the valve assembly 52 to the container
32. Any difference in rotation between the valve assembly 52 and
the outer container 32 and/or the product delivery device 56 that
produces sufficient frictional energy to create a seal that
contains the propellant and product within the container is
suitable.
[0098] An external drive may be used to provide relative motion
between the valve assembly 52, the product delivery device 56, and
the container 32. The external drive may be vertically actuated to
engage the ribs 166 of the valve body 54 to impart rotation to the
valve assembly 54. Upon welding, the valve assembly 52 may move
axially downward a distance corresponding to the melting of the
protrusions 168, 170.
[0099] Generally, the aforementioned disclosure may be used in the
gassing and welding of aerosol dispensers. A method for
manufacturing multiple aerosol dispensers include a bag and
container may include the following steps. Two or more containers
including a bag may be advanced to a turret. The two or more
containers may be advanced at a continuous or variable velocity.
The two or more containers including a bag may be advanced by, for
example, a star-wheel or conveyor. The bag and container are
introduced onto the turret. A valve assembly may be disposed on at
least a portion of the bag and/or the container prior to being
introduced onto the turret or after being introduced onto the
turret. The turret may rotate about an axis. Gassing and welding
stations may be internal to or external to the turret. The gassing
and welding stations may rotate with the turret or may be
stationary with respect to the rotating turret. The gassing and
welding station may perform a series of process steps outlined as
follows: (1) gripping the container around the neck of the
container (2) establishing a temporary seal between the valve
engagement tip and valve (3) establishing a temporary seal between
the gassing manifold and container neck (4) establishing a
temporary seal between the valve and bag components (5) controlling
the fluid, such as by removing the fluid from the headspace of
gassing manifold and between the bag and the container (6)
introducing fluid, such as a gas, by metering through, for example,
a flowmeter (mass or volume or pressure) while controlling the bag
collapse, such as the volume of the bag (7) rotating the valve with
respect to the container and the bag to initiate melt flow of the
materials for creating a weld (8) holding the valve stationary to
the container and the bag to allow for a weld to form and solidify
(9) using a computer, microprocessor, microcontroller, PLC, or
other computing, automated infrastructure to perform calculations
upon the welding response output, including torque, force, and
position, to characterize the quality of the weld and flagging for
rejection any container, bag, valve assembly where the weld does
not meet desired quality standards. Upon completion of these steps,
the turret would continue to transport the welded package, which
includes the container, bag, and valve to an unloading turret
position. At this position, the fully gassed and welded package
would be released from the turret. The package may be released onto
a device that transports the package away from the turret such as a
conveyor, star-wheel, or other transfer device. A downstream
process operation may fill product through the valve stem into the
pressurized bag. The aforementioned process of manufacturing
multiple aerosol dispenser may also be done with a dip tube. The
fluid may be introduced into the container to pressurize the
container and product may be later introduced after the gassing and
welding of the dip tube to the container. It is also to be
appreciated that product and/or propellant may be introduced
simultaneously. It is also to be appreciated that product may be
introduced into the container prior to the container being gassed
and welded. For example, product may be introduced into the
container prior to the container and valve assembly, including a
dip tube, being transferred to the turret where the gassing and
welding are to be performed.
[0100] 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."
[0101] It should be understood that every maximum numerical
limitation given throughout this specification will include every
lower numerical limitation, as if such lower numerical limitations
were expressly written herein. Every minimum numerical limitation
given throughout this specification will include every higher
numerical limitation, as if such higher numerical limitations were
expressly written herein. Every numerical range given throughout
this specification will include every narrower numerical range that
falls within such broader numerical range, as if such narrower
numerical ranges were all expressly written herein.
[0102] 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.
[0103] 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.
* * * * *