CN110650898A

CN110650898A - Protective sleeve for protecting aerosol valve rod

Info

Publication number: CN110650898A
Application number: CN201880030587.7A
Authority: CN
Inventors: 罗伯特·厄尔·马格内斯; 罗伯特·保罗·卡索尼; 凯瑞·劳埃德·韦弗
Original assignee: Procter and Gamble Ltd
Current assignee: Procter and Gamble Ltd
Priority date: 2017-05-26
Filing date: 2018-05-23
Publication date: 2020-01-03
Anticipated expiration: 2038-05-23
Also published as: WO2018217844A1; EP3630650A1; CN110650898B; EP3630650B1; US20180339841A1

Abstract

An aerosol dispenser (20) having a valve (28) for dispensing a product (42) through a valve stem (28S) is disclosed. The valve stem (28S) is protected by a sheath (28P) to reduce breakage. The sheath (28P) extends to a height equal to or greater than the valve stem (29S) to absorb axial compression loads and side impact loads. The sheath (28P) may be present in the aerosol dispenser (20), the aerosol container, the outer container (22), the preform, and/or in the valve (28). The aerosol dispenser (20) may include a bag (55), a piston, and a dip tube (56).

Description

Protective sleeve for protecting aerosol valve rod

Technical Field

The present invention relates to an aerosol dispenser having a sheath protected valve stem and components for making the same.

Background

Aerosol dispensers are well known in the art. Aerosol dispensers typically comprise an outer container that acts as a frame for the remaining components and as a pressure vessel for the propellant and the product contained therein. Outer containers made of metal are well known in the art. However, metal containers may be undesirable because of their high cost and limited recyclability. Attempts have been made in the art to use plastics. Related attempts in the art to use plastics in aerosol dispensers are found in US 2,863,699; 3,333,743, respectively; 4,969,577, respectively; 8,752,731, respectively; 9,296,550, respectively; 9,334,103 and 2009/0014679.

The outer container is typically, but not necessarily, cylindrical. The outer container may comprise a bottom for resting on a horizontal surface such as a stand, countertop, table or the like. The bottom of the outer container may comprise a re-entrant section as shown in US3,403,804 or a base as shown in commonly assigned 8,439,223 and 9,061,795. The side walls defining the shape of the outer container extend upwardly from the bottom to the open top.

The open top defines a neck for receiving additional components of the aerosol dispenser. The industry has typically determined a nominal neck diameter of 2.54cm for standardizing parts between various manufacturers, but smaller diameters such as 20mm are also used. Various neck shapes are shown at 6,019,252; 7,028,866, respectively; 7,279,207 and 7,303,087.

The valve seat is typically inserted into the neck. The valve seat seals against the neck to prevent propellant escape and loss of pressurization, such as 8,074,847; 8,096,327, respectively; 8,844,765, respectively; 8,869,842 and 9,505,509. The valve seat holds a valve member that is movable relative to the balance of the aerosol dispenser. Suitable valves are shown in commonly assigned 8,511,522 and 9,132,955. When the valve is open, product may be dispensed through a nozzle or the like, as described in commonly assigned 9,174,229.

The valve is insertable into the valve seat for selective actuation by a user. The valve is normally closed and may be opened to create a flow path for the product to the environment or a target surface. The valve may comply with local recirculation standards. Suitable valves are disclosed in commonly assigned 8,511,522 and 9,132,955.

If the valve is to be assembled into an aerosol, the valve cup is typically crimped onto the neck of the aerosol container. But this operation is expensive and difficult to perform with plastic valve seats. Separate interlocking components may be used to attach the valve to the valve seat, in particular using the plastic valve 28 and the plastic valve seat. Suitable interlocking components include bayonet fittings and threads as disclosed in commonly assigned P & G case No. 14458, serial No. 15/235,237, filed on 8/12/2016. 8,505,762, a pressure vessel with threaded holes is presented.

The pouch may be used to contain a product for selective dispensing by a user. Dispensing of product from the bag occurs in response to the user actuating the valve. A bag separates the product within the bag from a propellant disposed between the bag and the container. The bag limits or even prevents intermixing of the contents of the bag and the components outside the bag. Thus, the product can be contained in the bag. The propellant may be disposed between the exterior of the bag and the interior of the outer container. Upon actuation of the valve, a flow path is created outside the bag. This embodiment is commonly referred to as a can-in-can type and may be used, for example, to dispense shave cream gel. Alternatively, the bag may be joined directly to the valve housing in what is commonly referred to as a bag-on-valve configuration. A suitable pouch configuration is disclosed in commonly assigned P & G case No. 14458, serial No. 15/235,227, filed on 12.8.2016, which teaches the attachment of a pouch to a valve seat.

If a pouch configuration is desired, propellant may be disposed between the pouch and the outer container as disclosed in 5,219,005 and commonly assigned 8,631,632 and 8,869,842. Product filling may then take place in a separate remote operation, optionally at another location, which may be in the same country or in a different country, as disclosed in commonly assigned 2012/0291911. Such manufacturing processes may save costs in production, shipping, and/or storage.

An aerosol container having a bag therein may be made from a two-layer preform having multiple layers disposed inside one another. Related attempts include 3,450,254; 4,330,066, respectively; 6,254,820, respectively; RE 30093E; WO 9108099 and US 2011/0248035a 1. However, each of these attempts requires a separate operation to attach the bag to the relevant component. Each attachment step requires time in manufacturing and creates a chance of leakage if not properly done. Improvements to the dual layer preform are found in commonly assigned P & G case No. 14461, patent application 15/235,279 filed on 8/12/2016.

Alternatively, a dip tube may be used if it is desired to mix the product and propellant. When the user actuates the valve, product and propellant are dispensed together through the dip tube. This embodiment may utilize a dip tube. The dip tube takes the mixture of product and propellant from the bottom of the outer container. Or the piston may be used to expel the product, particularly when highly viscous, as described in 2002/0027146, 6,375,045 and commonly assigned 2016/0368700.

The bag, dip tube, piston, and associated hardware are collectively referred to as a product delivery device. Various forms of delivery devices may be required for different products, which often complicates production. For example, one product may require a dip tube product delivery device in combination with a very small nozzle. The next aerosol dispenser on the production schedule may simply need to be replaced with a new, larger, nozzle.

However, if it is desired to then manufacture an aerosol dispenser with a bag and then an aerosol dispenser with a dip tube in a particular production cycle, then a considerable replacement is required in subsequent production cycles. Different outer containers are often required to accommodate different product delivery devices. Also, different valves may be required. Where different valves are required, different outer containers must be matched to accommodate the different valves. Different valves may also require different valve seats, which may be plastic and welded in place, metal and crimped in place, or no valve seat at all may be required. The combination of the outer container, valve, product delivery device and associated hardware (if any) is referred to as a form of a particular aerosol dispenser.

But each valve has a stem that projects upwardly from the valve body. The valve stem is part of the flow path to the environment and is connectable to an actuator for dispensing product from the aerosol dispenser as required. The valve stem is preferably plastic and is prone to breakage during shipping and handling, such as occurs during shipping in a common box at the site of valve manufacture to valve assembly. The valve stem is also prone to breakage after assembly, during normal solder stacking of the aerosol container. If the valve stem breaks, it and associated component parts undergo scrapping, resulting in production downtime and waste. The present invention is therefore directed to mitigating the problem of valve stem breakage during aerosol dispenser manufacture.

Disclosure of Invention

In one embodiment, the present invention comprises an aerosol dispenser, in another embodiment an aerosol container for an aerosol dispenser, in another embodiment an outer container for an aerosol dispenser, in another embodiment a valve for an aerosol dispenser, in another embodiment a preform for an aerosol dispenser. All embodiments have an upwardly projecting sheath. The sheath extends to or beyond the valve stem, thereby protecting the valve stem. The sheath may or may not circumscribe the valve stem.

Drawings

As shown, the drawings are drawn to scale unless otherwise indicated.

Figure 1 is a vertical cross-sectional view of an aerosol dispenser according to the prior art and having an exposed valve stem.

Figure 2 is a side elevational view of an aerosol dispenser according to the invention showing the sheath, actuator and spray being schematically dispensed from the nozzle, shown in partial cross-section, and with the actuator and nozzle omitted in all subsequent figures.

Fig. 3 is a vertical cross-sectional view taken along line 3-3 of fig. 2 showing the aerosol container and with the actuator removed for clarity.

Figure 4A is a top plan view of a preform suitable for use with the present invention and having a valve thereon.

Fig. 4B is a side elevational view of the valve and preform of fig. 4A.

Fig. 4C is a bottom plan view of the valve and preform of fig. 4A.

Fig. 5 is a partial vertical cross-sectional view of an alternative embodiment of the valve and preform showing the moving assembly in the closed position and the valve having an annular protrusion that intercepts the inner edge of the sealing surface in the preform and schematically shows the preform as an outer container in dashed line.

Fig. 6a1 is a partial vertical cross-sectional view of a preform having a bag for a product delivery device and having an upstanding annular protrusion on the bag and a downwardly extending protrusion on the valve, the valve moving assembly and valve stem removed for clarity, and the outer blade on the valve shown schematically.

Fig. 6a2 is a partial vertical cross-sectional view of a preform having a bag for a product delivery device and having a downwardly extending annular protrusion on the valve that intercepts the bag and outer container, with the moving assembly of the valve and valve stem removed for clarity, and with the outer blade on the valve schematically shown.

Fig. 6B1 is a partial vertical sectional view of an aerosol container with a pouch for a product delivery device showing a raised valve stem prior to welding and with an inner blade on the valve and an illustrative outer blade on the outer container.

Fig. 6B2 is a partial vertical cross-sectional view of the aerosol container of fig. 6B1 showing the consistent height of the valve stem and the welded sheath.

Fig. 7a1 is a vertical cross-sectional view of the preform and valve of fig. 6A with a bag for a product delivery device welded to the preform and showing the valve in a closed position.

Fig. 7a2 is an enlarged partial view of the valve and preform of fig. 7a 1.

Fig. 7B1 is a vertical cross-sectional view of the preform and valve of fig. 7a1 prior to welding with the energy concentrator in place, the bag energy concentrator hanging below the outer container energy concentrator and showing the valve in an open position.

Fig. 7B2 is an enlarged partial view of the valve and preform of fig. 7B 1.

Fig. 7C1 is a vertical cross-sectional view of an alternative embodiment of the preform and valve of fig. 6A with a dip tube for the product delivery device with the energy concentrator in place, the dip tube concentrator hanging below the outer container energy concentrator.

Fig. 7C2 is an enlarged partial view of the valve and preform of fig. 7C1 showing the valve and dip tube welded in place.

FIG. 8A is a top perspective view of a valve that may be used with the present invention.

Fig. 8B is a side perspective view of the valve of fig. 8A.

Fig. 8C is a bottom perspective view of the valve of fig. 8A.

Fig. 9 is a schematic partial cross-sectional view of an alternative embodiment of an aerosol container having a valve threadably engaged to the neck of the outer container and having a sheath projecting upwardly from the outer container.

Fig. 10 is a side elevational view of a preform shown in partial cross-section and suitable for use with the aerosol container of fig. 9.

Fig. 11 is a schematic perspective view of an alternative embodiment of a valve having discrete upstanding struts for the sheath that also serve as vanes, with the valve stem omitted for clarity.

Fig. 12 is a schematic side elevation view of an alternative embodiment of a preform with discrete upstanding struts for the sheath that also serve as vanes.

Detailed Description

Referring to fig. 1, an aerosol dispenser 20 according to the prior art is shown. The aerosol container 22 has an exposed valve stem 28S. The exposed valve stem 28S protrudes above the neck 24 of the outer container 22. Such geometries expose the valve stem 28S to damage due to top loading (as occurs during solder stacking), and damage due to side impact (as occurs during conventional processing).

Referring to fig. 2 and 3, there is shown an aerosol dispenser 20 and an aerosol container 22, each having a longitudinal axis. The aerosol dispenser 20 includes a pressurizable outer container 22 useful with such aerosol dispensers 20. The outer container 22 has a neck 24 in which a valve cup 26 is sealingly arranged. A valve 28 and an actuator 29 may be disposed in the valve seat 26 for selectively dispensing the product 42 from the aerosol dispenser 20. A seal 30 having a surface for sealing the valve 28 to the valve seat 26 may be disposed below the valve seat 26 and the valve 28 to prevent the product 42 from escaping into the environment. As used herein, aerosol container 20C may be a subset of aerosol dispenser 20 and have an outer container 22, a valve cup 26 sealed thereto (with bag 55/dip tube 56, collectively referred to herein as

product delivery devices

55,56, joined to valve cup 26), and optionally propellant 40, but not necessarily valve 28, actuator 29, label, or the like. Optionally, the valve 28 may be joined directly to the outer container without a separate valve cup 26.

As used herein, the top of the aerosol dispenser 20 or outer container 22 is considered to be uppermost when the aerosol dispenser 20 or container 22 is oriented vertically in its normal use or storage position. As used herein, the bottom of the aerosol dispenser 20 or outer container 22 is considered to be the lowermost portion when the aerosol dispenser 20 or container 22 is vertically oriented in its normal use or storage position. The top and bottom are longitudinally opposed, with the top generally open at neck 24 and the bottom generally closed. The terms "above" and "below" refer to relative positions toward and away from the top, respectively. Likewise, the terms "above" and "below" refer to relative positions away from and toward the bottom, respectively.

The aerosol dispenser 20 and the outer container 22 have a longitudinal axis defining a major axis. The aerosol dispenser 20 and the outer container 22 may be longitudinally elongated, i.e. have an aspect ratio of longitudinal to transverse dimensions, such as a diameter greater than 1, an aspect ratio equal to 1, such as in a sphere or shorter cylinder, or an aspect ratio less than 1.

The outer container 22 may comprise metal or preferably plastic, as is known in the art. The plastic may be a polymer and in particular comprise polyethylene terephthalate (PET) or polypropylene (PP) for all components described herein. The outer container 22 may be injection molded or further blow molded in an ISBM process as is well known in the art. The outer vessel 22 defines a longitudinal axis and may have an opening at one end thereof. The opening is typically located at the top of the pressurizable container when the pressurizable container is in its use position.

The opening defines a neck 24 to which other components may be sealingly joined. The neck 24 has a neck diameter, which is considered to be the inner diameter at the top of the outer container 22.

The outer container 22 may have a neck 24 when the top of the outer container 22 is accessed. Neck 24 may be connected to the container sidewall by a shoulder 23. The shoulder 23 may be joined to the side wall more specifically by a radius. The shoulder 23 may have an annular flat surface. Neck 24 may have a greater thickness at the top of outer container 22 than at the lower portion of neck 24 to provide a differential thickness. Such differential thickness may be achieved by having an internal stepped neck 24 thickness.

A normally closed valve 28 may be disposed in neck 24. The valve 28 is openable by a user as required in response to manual operation of the actuator 29. The actuator 29 can be depressible, operable as a trigger or the like to spray the product 42 from the aerosol dispenser 20. Exemplary and non-limiting products 42 include shaving creams, shaving foams, body sprays, body washes, fragrances, cleansers, air treatments, astringents, foods, paints, insecticides, and the like.

An optional valve cup 26 may be sealed to the opening of the outer container 22. A class 1 TPE material may be used to seal the valve cup 26 to the neck 24 of the outer container 22. Polyester-based TPEs sold under the trade name HTC8791-52 by Kraiburg TPE GmbH & Co KG of Waldkraiburg (Germany) and under the trade name HYTEL by DuPont of Delaware are useful for good silicone resistance and good adhesion to PET. It is believed that such TPE materials are classified as PETE/PET resin identification code 1/01, as described above by the plastics industries Association and ASTM D7611. Alternatively, TPEs based on styrenic block copolymers, such as Kraiburg HTC8791-24 or Krayton elastomers, can be used, providing easier processing and lower density. Other sealing materials include silicones, rubbers, and similar conformable materials.

If desired, the valve cup 26 may be sealed to the outer container 22 using the following methods: a press fit, an interference fit, solvent welding, laser welding, sonic welding, ultrasonic welding, spin welding, adhesive, or any combination thereof. An intermediate component such as a sleeve or connector may optionally be disposed between the valve cup 26 and the neck 24 or top of the outer container 22. Any such arrangement is suitable, as long as the seal is sufficient to maintain the pressure results.

Referring to fig. 4A, 4B, and 4C, preform 60 may be manufactured in a single injection molding operation, providing tolerances suitable for mass production. The first preform 60 is then blow molded in a known manner to produce the outer container 22. The valve attachment 25, such as a thread, is above the blow molding operation, preventing excessive dimensional deformation thereof. The second preform 60 can be used to manufacture the valve seat 26 as a facing and the inner bag 55 as its body when blow molded. Those skilled in the art will appreciate that the blow molding step may also include stretching as is known in the art.

The present invention also includes a sheath 28P. The sheath 28P protects the valve stem 28S as described herein. If the valve stem 28S is damaged, or its movement (typically axially) is impeded, waste ensues. The sheath 28P has a sheath diameter, which is considered to be the inner diameter of the proximal end of the sheath 28P. The sheath 28P has a sheath distal end that is considered the uppermost portion of the sheath 28P but does not have an actuator 29 or other attachment. The distal end of the sheath 28P extends to a position at or above the distal end of the valve stem 28S.

Further, the sheath 28P may have inner or outer blades 28B. The vanes 28B may facilitate threadable assembly of the valve 28 to the outer vessel 22 or facilitate rotational welding of the valve 28 to the outer vessel 22. The blades 28B may intercept the external driver and then transmit torque to the sheath 28P about the longitudinal axis, thereby causing responsive rotation of the sheath 28P as desired. In particular, each vane 28P may have a face for engaging an external driver.

Preferably, a plurality of two or more blades 28P are used to distribute the torsional loads. The sheath 28P has an inner perimeter and an outer perimeter. The vanes 28 may extend radially outward from the outer periphery to provide the benefit of greater torque. Alternatively, the vanes 28 may extend radially inward from the inner periphery, thereby providing a space saving benefit.

Optionally, the bag 55 may be integral with the valve seat 26. By integral, it is meant that the bag 55 and valve seat 26 are integral, molded at the same time or molded from two different materials that are fused together in a permanent manner. The integrated bag 55 and valve seat 26 cannot be separated into two parts without tearing or excessive deformation. A container 22 made from a preform 60 using ISBM is referred to herein as a molded container 22.

Referring to fig. 5, the valve 28 may then be disposed within the valve seat 26. The valve 28 retains the product 42 within the aerosol dispenser 20 until the product 42 is selectively dispensed by a user. The valve 28 is selectively actuatable by an actuator 29. Depending on the desired dispensing and jetting characteristics, a nozzle 27 and associated valve 28 components may optionally be included. The valve 28 may be attached using conventional and known means. The valve 28 and actuator 29 may be conventional and do not form part of the claimed invention. Selective actuation of the valve 28 allows the user to dispense a desired amount of product 42 as desired.

Valve 28 may be provided for dispensing from the top of bag 55/dip tube 56 through one or more ports and into the valve stem. Optionally, the valve 28 may have a bypass outside the port to accommodate the relatively viscous product 42.

The valve 28 includes a moving assembly 28M disposed within a housing 28H. The housing 28H may be relatively rigid, however, once dispensing is complete, the moving assembly 28M may resiliently return to the closed position. The housing 28H has lateral components for attachment to the preform 60/outer container 22.

The valve 28 may be a normally closed valve 28. Normally closed valve 28 is closed in its rest position. The valve 28 is only opened by the user when actuated as required.

Valve stem 28S provides a product 42 flow path and engages actuator 29 in fluid communication with valve 28. The valve stem 28S may be disposed within the displacement assembly 28M and cause responsive movement therein. The valve stem 28S has a stem distal end, which is considered to be the uppermost portion of the valve stem 28S, but does not have an actuator 29 or other attachment.

Referring to fig. 6a1 and 6a2, the housing 28H of the valve 28 may have an upwardly projecting sheath 28P. The upstanding sheath 28P may circumscribe and extend longitudinally beyond the valve stem 28S. By longitudinally extending beyond, it is meant that the distal end of the sheath 28P is disposed above the distal end of the valve stem 28S when the valve stem 28S is in the normally closed position. The tabs shown in fig. 6a1 and 6a2 may facilitate optional welding, particularly spin welding (if used to join various components).

The sheath 28P has optional outer blades 28B to facilitate spin welding or other joining operations. It should be understood that the optional outer blade 28B may be disposed on the valve 28 as shown or on the preform 60/neck 24. Likewise, optional inner blade 28B may be disposed on valve 28 as shown or on preform 60/neck 24.

Referring to fig. 6B1 and 6B2, the assembly may have both inner vanes 28B and outer vanes 28B. This arrangement provides the following advantageous effects: two coaxial external drivers may be used. An external drive may be used to reverse rotation, or one may hold one set of blades 28B stationary while the other blades 28B respond to the rotational force applied via twisting. Fig. 6B1 shows the valve stem 28S protruding a vertical distance 'H' above the level of the sheath 28P prior to welding. Fig. 6B2 shows that, as a result of the welding operation, the valve stem 28S has been lowered to a height that coincides with and is protected by the sheath 28P.

Referring back to fig. 1-2, the

product delivery devices

55,56 may be used to contain the product 42 and/or deliver the product from the aerosol dispenser 20, as desired. Suitable

product delivery devices

55,56 include pistons, bags 55, dip tubes 56, and do not form part of the claimed invention except as specifically claimed herein. If desired, the

product delivery devices

55,56 may also include metering devices for dispensing predetermined, metered amounts of the product 42, as described in 2,815,889, 4,142,652, and 5,421,492. The

product delivery devices

55,56 may also include diverter valves having balls therein to alter the flow path of the product 42.

The

product delivery devices

55,56 may include a dip tube 56 disposed within the bag 55, if desired. Such dip tubes 56 may reach almost to the bottom of the bag 55, or be juxtaposed near the middle of the bag 55. The dip tube may be prepared according to 8,091,741.

The pressurizable container may also contain a propellant 40. Propellant 40 may include hydrocarbons, nitrogen, air, and mixtures thereof. The propellants 40 listed in US Federal Register 49CFR 1.73.115, class 2, section 2.2 are also considered acceptable. The propellant 40 may specifically include trans-1, 3,3, 3-tetrafluoropropan-1-ene, and optionally a gas having a CAS number of 1645-83-6. One such propellant 40 is commercially available under the trade name HFO-1234ze or SOLSTICE from Honeywell International of Morristown (New Jersey).

Propellant 40 may be condensable, if desired. Generally, the highest pressure occurs after the aerosol dispenser 20 is filled with the product 42 but before the user first dispenses the product 42. Condensable propellant 40 provides the benefit of a flatter pressure reduction curve at vapor pressure when condensed when product 42 is used up during use. Condensable propellant 40 also provides the following benefits: a larger volume of gas can be placed into the container at a given pressure. Condensable propellants 40, such as HFO-1234ze, may be charged to a gauge pressure of 100kPa to 400kPa at 21 ℃.

The outer container 22, valve cup 26, valve 28 and/or piston may be polymeric, if desired. By polymeric is meant that the component is formed from a plastic material, including polymers, and/or specifically polyolefins, polyesters or nylons, and more specifically PET. Accordingly, the entire aerosol dispenser 20, or specific components thereof, may be free of metal, thereby allowing microwave treatment. Microwave heating of the aerosol dispenser 20 or pressurizable container thereof provides heating of the product 42 prior to dispensing. If the product 42 is to be applied to the skin, heating the product 42 prior to dispensing may be desirable because it is more effective at lower viscosities or it is intended to be eaten.

The valve seat 26 may have a valve seat 26 perimeter that is complementary to the perimeter of the neck 24. At least one of the valve cup 26 and/or the container neck 24 may have one or more passages therethrough. Additionally or alternatively, a channel may be formed at the interface between the valve cup 26 and the container neck 24. The passages may be formed by irregularities between the valve cup 26 and/or the container neck 24, such as crews, gray tenons, serrations, notches, teeth, and the like.

Optionally in addition to the TPE seal, the outer container 22 and all other components may comprise, consist essentially of, or consist of PET, PEN, nylon, EVOH, or blends thereof to meet DOT SP 14223. All such materials may be selected from a single class of recyclable materials, as set forth above by the plastic industry association and ASTM D7611. Specifically, all of the components of aerosol dispenser 20 may include the aforementioned TPE and PET/PETE, resin identification code 1/01. This material selection provides the following benefits: the entire aerosol dispenser can advantageously be recirculated in a single stream.

Alternatively, the valve seat 26 and/or the bag 55 may include multiple layers, such as nylon with EVOH, PET, and/or polyolefin materials. Three layers may be used, such as PET/nylon/PET or PET/EVOH/PET. These layers may be co-molded or over-molded. The multi-layer arrangement may provide increased barrier resistance and reduced failure rates.

The outer container 22 and/or optionally the

product delivery devices

55,56 may be transparent or substantially transparent. This arrangement provides the following benefits: the consumer knows when the product 42 is near end of use and allows for improved delivery of product 42 attributes such as color, viscosity, and the like. Further, if the background to which such decoration is applied is light transmissive, the label or other decoration of the container may be more visible.

Suitable decorations include labels 57. Label 57 may be shrink wrapped, printed, etc., as is known in the art.

The outer container 22 may define a longitudinal axis of the aerosol dispenser 20. The outer vessel 22 may be axisymmetric as shown, or may be eccentric. Although shown as circular in cross-section, the present invention is not so limited. The cross-section may be square, oval, irregular, etc. Further, the cross-section may also be substantially constant as shown, or may be variable. If a variable cross-section is selected, the outer container 22 may be cylindrical, hourglass-shaped, or monotonically tapered.

The height of the outer vessel 22 may be in the range 6cm to 60cm, and in particular 10cm to 40cm, taken in the axial direction, and if a circular footprint is chosen, the diameter may be in the range 3cm to 60cm, and in particular 4cm to 10 cm. The outer container 22 may have a volume in the range of 40cc to 1000cc, excluding any components therein, such as the

product delivery devices

55, 56. The outer container 22 may be injection stretch blow molded. If so, the injection stretch blow molding process may provide an overall stretch ratio of greater than 8, 8.5, 9, 9.5, 10, 12, 15, or 20 and less than 50, 40, or 30.

The outer container 22 may be placed on a base. The base is disposed on the bottom of the outer container 22. Suitable bases include petaloid bases, champagne bases, hemispherical or other convex bases used in conjunction with a base. Alternatively, the outer container 22 may have a generally flat base with optional recesses.

The manifold may supply propellant 40 under pressure through at least one passage between valve cup 26 and container neck 24. The manifold may be retractably disposed above the container 22. The manifold may contact the valve seat 26, forming a temporary seal therebetween. Suitable channels are described in particular in commonly assigned US8,869,842 to Smith in column 7, line 57 through column 8, line 2 and column 8, lines 44-60 of fig. 8. Propellant 40 may be filled into the outer container 22 when a temporary seal is established between the manifold and the valve cup 26.

The aerosol dispenser 20 may have an initial pressure when provided to a user. This initial pressure is the highest pressure encountered by a particular filling operation and corresponds to a situation when no product 42 has been dispensed from the

product delivery device

55, 56. When the product 42 is exhausted, the outer container 22 approaches the final pressure. This final pressure corresponds to the situation when substantially all of the product 42 is used up from the

product delivery devices

55,56, except for a small amount of residue. One benefit of the present invention is that the residual product 42 remaining at the end of life is unexpectedly minimized.

This arrangement provides the following benefits: the propellant 40 may be charged to a lower pressure than the desired starting pressure, thereby reducing the propellant 40 charging time and reducing the pressure applied to the charging machine. Another benefit is that when the aerosol dispenser 20 is ready for sale, the propellant 40 is set for the end use as needed, the product 42 is filled, and after the product 42 is depleted, it can be refilled with the product 42 and reused.

The outer vessel 22 may be pressurized to an internal gauge pressure of 100kPa to 1300kPa, 110kPa to 490kPa, or 270kPa to 420kPa at 21 ℃. A particular aerosol dispenser 20 may have an initial propellant 40 pressure of 1100kPA and a final propellant 40 pressure of 120kPA, an initial propellant 40 pressure of 900kPA and a final propellant 40 pressure of 300kPA, an initial propellant 40 pressure of 500kPA and a final propellant 40 pressure of 0kPA, and any value therebetween.

Referring to fig. 7a1, 7a2, 7B1, 7B2, 7C1, and 7C2, a permanent seal is required between the components of the aerosol dispenser 20, which can be welded. In particular, if the parts have compatible melt indices, such parts may be sealed by welding to retain the propellant therein. Suitable welding methods may include sonic, ultrasonic, rotary, and laser welding. Welding can be accomplished using a commercially available welder such as that available from Branson Ultrasonics Corp. of Danbury (Connecticut). Alternatively or in addition, the channels may be pre-plugged by plugs or sealed by adhesive bonding. Suitable sealing methods for the channels are described in particular in commonly assigned US8,869,842 to Smith in fig. 9 and column 8, lines 30 to 43.

Spin welding has been found to be particularly preferred. Spin welding provides the following benefits: the energy plane is typically limited to a small vertical space, limiting accidental damage to other components that are not intended to be welded or receive such energy. Spin welding also provides the following benefits: the outer vessel weld 22W and the weld 55W of the bag 55/the weld 56W of the dip tube 56 may occur simultaneously or nearly simultaneously, thereby increasing production speed.

Or if desired, the product delivery device welds 55W,56W may occur first, providing a pressure boundary between the

product delivery devices

55,56 and the valve 28. Propellant 40 charging may occur during the establishment of the pressure boundary or once the pressure boundary has been established, allowing for simultaneous welding and charging. After product delivery device welds 55W,56W and propellant 40 fill occur, outer container weld 22W may be completed, containing propellant 40 within outer container 22.

The timing of the product delivery device welds 55W,56W occurring after or preferably before the outer vessel weld 22W may be affected by the

respective projections

22E,55E, 56E. In particular, valve 28 may have depending product

delivery device tabs

55E,56E circumscribing outer container tab 22E. Product delivery device welds 55W,56W and outer vessel weld 22W will typically occur simultaneously if the projections uniformly contact the respective mating surfaces. Preferably, the product delivery device tab 55E for the bag 55/product delivery device tab 56E for the dip tube 56 hangs lower than the outer container tab 22E such that the welding sequence allows for propellant filling 40 as described herein.

If the

product delivery device

55,56 is a dip tube 56, propellant 40 filling and product 42 filling may occur simultaneously. The propellant 40 and product 42 may be premixed into a single charge, which occurs during the welding operation. Alternatively, the bag 55 or dip tube 56 of the aerosol dispenser 20 may later add the product 42 through the valve 28, as is known in the art.

Valve 28 is welded in fluid tight relation to outer vessel 22 by outer vessel weld 22W. Outer vessel weld 22W occurs between valve 28 and the first annular sealing surface. Likewise,

product delivery devices

55,56 are welded in fluid tight relation to valve 28 or outer vessel 22 by product delivery device welds 55W, 56W. The

product delivery device

55,56 welds occur between the

product delivery devices

55,56 and the second annular sealing surface. Product delivery device welds 55W,56W are radially spaced from outer vessel weld 22W.

The valve 28 may be welded directly to the second sealing surface or may be welded to the

product delivery device

55,56 if desired. Such component geometries provide flexibility for a variety of geometries depending on the particular aerosol dispenser and product 42 combination desired.

The outer container 20C according to the present invention has two welds: product delivery device welds 55W,56W and outer vessel weld 22W, which are radially spaced from one another. If one or more of the product delivery device welds 55W,56W and outer vessel weld 22W are relatively thick in radial dimension and relatively closely spaced to the other, the product delivery device welds 55W,56W and outer vessel weld 22W may appear to merge. Such embodiments are contemplated and within the scope of the present invention. While two radially spaced

welds

55W,56W, 22W are shown, the skilled artisan will recognize that any plurality of welds may be utilized. The add-on welds may be used to join additional components or to enhance the product delivery device welds 55W,56W and outer vessel weld 22W as desired.

Outer vessel welds 22W may circumscribe product delivery device welds 55, 56W in a concentric or eccentric manner. The outer vessel weld 22W and the product delivery device welds 55, 56W may have equal or unequal radial thicknesses, require equal or unequal energy to achieve proper bonding, and may be equally or unequally spaced from one another, and equally or unequally spaced about the longitudinal axis.

The outer container 22 and propellant 40 may be assembled at a first location, if desired. Products 42, decorations, etc. may be added at the second location as described in commonly assigned 2012/0292338 and 2012/0291911.

Accordingly, the aerosol dispenser 20 may be manufactured by providing a nested preform 60 comprising an outer preform 60 and an inner preform 60 disposed therein. The inner preform 60 has a valve seat 26 at its open end.

The preforms 60 are blown together to form the outer container 22 and have an open end and an inner bag 55 hanging from the open end towards the closed end of the outer container. Propellant 40 is filled between the bag 55 and the outer container 22. The valve cup 26 is sealingly joined to the open end of the outer container 22 to contain propellant 40 therein and form the aerosol container 20C. The aerosol container 20C may then be stored or shipped directly for product 42 filling, valve 28 installation, actuator 29, labeling, etc., as desired.

Alternatively, an integrated inner bag 55/valve cup 26 combination may be provided and inserted into the outer container 22. The inner bag 55 is inserted into the open end of the outer container 22. Propellant 40 is filled between the bag 55 and the outer container 22. The integral valve cup 26 is sealingly joined to the open end of the outer container 22 to contain propellant 40 therein and form the aerosol container 20C. The aerosol container 20C may then be stored or shipped directly for product 42 filling, valve 28 installation, actuator 29, labeling, etc., as desired. In an alternative embodiment, the inner preform 60 may have a neck 24 according to the present invention with a first annular sealing surface 31 and a second annular sealing surface 32 as described and claimed herein.

Although a circular outer container 22 is described, the invention is not so limited. The outer container 22, and thus the valve attachment, the first annular sealing surface 31 and the second annular sealing surface 32, may have any desired shape, as long as the circumference of the second annular sealing surface 32 is smaller than and inside the circumference of the first annular sealing surface 31, which in turn is smaller than and inside the circumference of the valve attachment. Preferably, the valve attachment circumference, the first annular sealing surface 31 circumference and the second annular sealing surface 32 circumference are concentric.

Referring to fig. 8A, 8B and 8C, the valve 28 may be injection molded as a housing 28H having a longitudinally projecting sheath 28P and a radially extending valve seat 26. Optional vanes 28B may be integrally formed with the sheath 28P or added later. The optional blades 28B may be internal to the sheath 28P, external to the sheath 28P, or any combination thereof. Later, the displacement assembly 28M and the valve stem 28S may be added as separate components.

Referring to fig. 9-10, alternatively or additionally, a jacket 28P may depend from the top of the outer container 22. In such embodiments, the jacket 28P may be joined to the outer container 22 after blow molding. Alternatively, and preferably, the sheath 28P may be integrally formed with the preform 60. This arrangement eliminates the assembly step and possible disassembly. Any such embodiment having an circumscribing sheath 28P has the following benefits: increasing the stiffness of the respective components and protecting the valve stem from side impacts over the full 360 degrees.

An optional seal 30 may be used to improve the pressure boundary below or at the thread 25. The seal 30 may separate a first sealing surface 31 and a second sealing surface 32.

Referring to fig. 11-12, alternatively, the upstanding sheath 28P can include at least one, and preferably three or more circumferentially spaced upstanding struts 28P. Brace 28P may depend from valve housing 28H. Each strut 28P extends longitudinally beyond valve stem 28S. If discretely spaced struts 28P are selected, preferably such struts 28P are equally circumferentially spaced and also equally radially spaced about the longitudinal axis to more evenly distribute the compressive load.

The struts 28P may be oriented parallel to the longitudinal axis, radially inward or radially outward as desired. This arrangement provides the following benefits: the struts 28P may serve the dual function of protecting the valve stem 28S and as optional vanes 28B for imparting rotational motion while retaining material over the circumscribing sheath 28P.

The sheath 28P may be directly coupled to the valve 28 or may be indirectly coupled to the valve 28. For example, the sheath 28P may be coupled to and stand upright from a

product delivery device

55,56, which in turn is coupled to the valve 28. All such embodiments are contemplated to be within the scope of the claimed invention and are considered to include a sheath 28P joined to the valve 28.

Struts 28P and circumscribing sheaths 28P are shown concentric with the longitudinal axis and having a constant geometry. But the invention is not limited thereto. The sheath 28P may be eccentric, of variable thickness, of variable height, serrated, fully or partially circumscribing the valve stem 28S, etc., so long as the valve stem 28S is protected. Likewise, the valve stem 28S may be concentrically positioned, as shown, or eccentric with respect to the longitudinal axis, and/or may be parallel to the longitudinal axis or skewed with respect to the longitudinal axis. A single valve stem 28S may be used or multiple valve stems 28S may be used.

Either geometry protects valve stem 28S during storage and assembly. For example, if the aerosol container 20C is solder stacked prior to filling and adding the actuator 29 with product 42, the sheath 28P protects the valve stem 28S from compressive loading due to the stacked layers described above.

The invention includes various embodiments and combinations, as shown by way of example and not limitation below. It should be understood that any of the variations and combinations listed in each embodiment of outer container 22, aerosol container 20C, aerosol dispenser 20, and/or preform 60 may be used in any other such embodiment without limitation.

Each of the combinations and variations described herein for an implementation in the form of a preform, a valve, an outer container, an aerosol container, or an aerosol dispenser is applicable to and deployable in any other implementation.

A. An aerosol container 20C having a longitudinal axis and comprising:

an outer container 22 comprising a closed end bottom and an open neck 24 longitudinally opposed thereto,

the open neck 24 has a valve 28 joined in fluid-tight relationship to the outer container 28,

the valve 28 has a valve stem 28S projecting upwardly to a distal end of the valve stem 28S,

a product delivery means 55,56 joined in fluid-tight relationship to at least one of said valve 28 and said outer container 22, and

a sheath 28P extending upwardly to a sheath distal end, the distal end of the sheath 28P being at or above the valve stem 28 distal end.

B. The aerosol container 20C of paragraph a, wherein the sheath circumscribes the valve stem 28S.

C. The aerosol container 20C of paragraphs a and B, wherein the sheath 28P protrudes upwardly from a sheath proximal end that is joined to the valve 28.

D. The aerosol container 20C of paragraphs A, B and C, wherein the sheath 28P protrudes upward from a proximal end of the sheath that is joined to the valve 28, the sheath 28P being integral with the valve 28.

E. The aerosol container 20C of paragraphs a and B, wherein the sheath 28P protrudes upwardly from a proximal end of the sheath that is joined to the outer container 22.

F. The aerosol container 20C according to paragraphs A, B and E, wherein the sheath 28P protrudes upwardly from a proximal end of the sheath joined to the outer container 22, the sheath 28P being integral with the outer container 22 and further containing propellant 40 within the outer container 22.

G. A normally-closed valve 28 for an aerosol container 20C, the normally-closed valve 28 having a longitudinal axis and comprising:

a housing 28H, a displacement assembly 28M disposed in the housing 28H, a valve stem 28S disposed in the displacement assembly 28M, the valve stem 28S projecting longitudinally to a valve stem 28S distal end, a sheath 28P disposed radially outward of the valve stem 28S and projecting longitudinally to at least one sheath distal end, the sheath distal end projecting more longitudinally than the valve stem 28S distal end.

H. The valve 28 of paragraph G, wherein the sheath 28P includes at least one discrete upstanding strut 28P radially spaced from the valve stem 28S.

I. The valve 28 of paragraphs G and H, wherein the sheath 28P comprises at least three discrete, equally circumferentially spaced, upstanding struts 28P, each strut 28P being parallel to the longitudinal axis.

J. The valve 28 of paragraph G, wherein the sheath 28P circumscribes and extends longitudinally above the valve stem 28S.

K. The valve 28 of paragraphs G and J, wherein the shroud 28P circumscribes the valve stem 28S, the shroud 28P having an inner periphery and an outer periphery opposite thereto, the shroud 28P further comprising a plurality of longitudinally oriented vanes 28B engaged to and extending radially from one of the inner and outer peripheries.

L. the valve 28 of paragraphs G, J and K, wherein the sheath 28P circumscribes the valve stem 28S, the sheath 28P having an inner periphery and an outer periphery opposite thereto, the sheath 28P further comprising a plurality of longitudinally oriented vanes 28B integral with and extending radially inward from the inner periphery.

M. the valve 28 of paragraphs G, J, K and L, wherein the sheath 28P circumscribes the valve stem 28S, the sheath 28P having an inner periphery and an outer periphery opposite thereto, the sheath 28P further comprising a plurality of longitudinally oriented vanes 28B joined to and extending radially from one of the inner and outer peripheries, wherein the sheath 28P comprises PET, the housing 28H comprises PET and the moving component 28M comprises TPE.

N. the valve 28 of paragraph G, wherein the sheath 28P includes at least four discrete, equally circumferentially spaced, upstanding struts 28P, each strut 28P being parallel to the longitudinal axis, each strut 28P having a face such that the struts 28P can act as vanes responsive to axial torque applied thereto.

O. an outer container 22 for an aerosol container 20C usable as an aerosol dispenser 20, said outer container 22 having a longitudinal axis and comprising:

a closed end bottom and an open neck 24 longitudinally opposite thereto, said neck 24 having a neck diameter, a sheath 28P projecting longitudinally upwardly from said neck 24, said sheath 28P having a sheath diameter greater than said neck diameter.

P. an outer container 22 according to paragraph O, further comprising:

a valve cup 26 joined in fluid-tight relation to the outer container 22,

a valve 28 disposed within the valve seat 26, the valve 28 having an upwardly projecting valve stem 28S, the valve stem 28S disposed longitudinally at or below the sheath 28P,

a

product delivery device

55,56 joined in fluid-tight relationship to at least one of the valve 28 and the outer container 22, and

a propellant 40 disposed within the outer container 22.

Q. an outer container 22 according to paragraphs O and P, further comprising:

a valve cup 26 joined in fluid-tight relation to the outer container 22,

product delivery means 55,56 joined in fluid-tight relationship to either the outer container 22 or the valve 28, and

a propellant 40 disposed within the outer container 22,

wherein the

product delivery device

55,56 comprises a bag 55 joined in fluid-tight relation to at least one of the valve 28 and the outer container 22.

R. an outer container 22 according to paragraphs O, P and Q, further comprising:

a valve cup 26 joined in fluid-tight relation to the outer container 22,

a propellant 40 disposed within the outer container 22,

wherein the

product delivery device

55,56 comprises one of a bag 55 and a dip tube 56 joined in fluid tight relation to at least one of the valve 28 and the outer container 22,

wherein the sheath 28P circumscribes the valve stem 28S.

S. an outer container 22 according to paragraphs O, P, Q and R, further comprising:

a valve cup 26 joined in fluid-tight relation to the outer container 22,

product delivery means 55,56 engaged in fluid-tight relationship to the valve 28, an

A propellant 40 disposed within the outer container 22,

wherein the

product delivery device

55,56 comprises at least one of a bag 55 and a dip tube 56 joined in fluid tight relation to at least one of the valve 28 and the outer container 22,

wherein the sheath 28P circumscribes the valve stem 28S, the sheath 28P projecting upwardly from the proximal end in a direction substantially parallel to the longitudinal axis and having a constant wall thickness.

T. an outer container 22 according to paragraphs O, P and Q, further comprising:

a valve cup 26 joined in fluid-tight relation to the outer container 22,

a valve 28 disposed within the valve seat 26, the valve having an upwardly projecting valve stem 28S, the valve stem 28S disposed longitudinally at or below the sheath 28P,

A propellant 40 disposed within the outer container 22,

wherein the

product delivery device

wherein the sheath 28P includes at least three circumferentially spaced upstanding struts 28P, the struts 28P being disposed radially outwardly of the valve stem 28S and integral with the outer container 22.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Rather, 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 size disclosed as "40 mm" is intended to mean "about 40 mm" and a pressure disclosed as "about 1100 kPa" is intended to include 1103.2 kPa.

Each document cited herein, including any cross-referenced or related patent or application, is hereby incorporated 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 any disclosure of the invention or the claims herein or that it alone, or in combination with any one or more of the 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. All limitations to the defined ranges set forth herein can be used with any other limitations to the defined ranges. That is, the upper limit of one range can be used with the lower limit of another range, and vice versa.

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.

Claims

1. An aerosol container 20C having a longitudinal axis and comprising:

the open neck 24 has a valve 28 joined in fluid-tight relationship to the outer container 22,

a product delivery device 55,56 joined in fluid-tight relationship to at least one of the valve 28 and the outer container 22, and

a sheath 28P extending up to a sheath distal end, characterized in that the distal end of the sheath 28P is at or above the valve stem 28 distal end.

2. The aerosol container 20C of claim 1, wherein the sheath circumscribes the valve stem 28S.

3. The aerosol container 20C of claims 1 and 2, wherein the sheath 28P protrudes upwardly from a proximal end of the sheath that is joined to the valve 28.

4. The aerosol container 20C of claims 1, 2, and 3, wherein the sheath 28P protrudes upwardly from a proximal end of the sheath that is coupled to the valve 28, the sheath 28P being integral with the valve 28.

5. The aerosol container 20C of claims 1 and 2, wherein the sheath 28P protrudes upwardly from a proximal end of the sheath that is joined to the outer container 22.

6. The aerosol container 20C of claims 1, 2, and 5, wherein the sheath 28P protrudes upwardly from a proximal end of the sheath joined to the outer container 22, the sheath 28P being integral with the outer container 22 and further containing propellant 40 within the outer container 22.

7. A normally-closed valve 28 for an aerosol container 20C, the normally-closed valve 28 having a longitudinal axis and comprising:

a housing 28H, a displacement assembly 28M disposed in said housing 28H, a valve stem 28S disposed in said displacement assembly 28M, said valve stem 28S projecting longitudinally to a valve stem 28S distal end, a sheath 28P disposed radially outward of said valve stem 28S and projecting longitudinally to at least one sheath distal end, characterized in that said sheath distal end projects more longitudinally than said valve stem 28S distal end.

8. The valve 28 of claim 7, wherein the sheath 28P includes at least one discrete upstanding strut 28P radially spaced from the valve stem 28S.

9. The valve 28 according to claims 7 and 8, wherein the sheath 28P includes at least three discrete, equally circumferentially spaced, upstanding struts 28P, each strut 28P being parallel to the longitudinal axis.

10. The valve 28 of claim 7, wherein the sheath 28P circumscribes and extends longitudinally above the valve stem 28S.

11. The valve 28 as set forth in claims 7 and 10, wherein the shroud 28P circumscribes the valve stem 28S, the shroud 28P having an inner periphery and an outer periphery opposite thereto, the shroud 28P further including a plurality of longitudinally oriented vanes 28B engaged to one of the inner and outer peripheries.

12. The valve according to claims 7, 8, 9 and 10, wherein said sheath 28P comprises PET, said housing 28H comprises PET and said moving member 28M comprises TPE.

13. An outer container 22 for an aerosol container 20C usable as an aerosol dispenser 20, said outer container 22 having a longitudinal axis and comprising:

14. An outer container 22 according to claim 13 further comprising:

a valve cup 26 joined in fluid-tight relation to the outer container 22,

a propellant 40 disposed within the outer container 22.

15. An outer container 22 according to claims 13 and 14 further comprising:

a valve cup 26 joined in fluid-tight relation to the outer container 22,

A propellant 40 disposed within the outer container 22,

wherein the product delivery device 55,56 comprises at least one of a bag 55 and a dip tube 56 joined in fluid tight relation to at least one of the valve 28 and the outer container 22,