US20120291911A1 - Method of manufacturing an aerosol dispenser - Google Patents

Method of manufacturing an aerosol dispenser Download PDF

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Publication number
US20120291911A1
US20120291911A1 US13/108,238 US201113108238A US2012291911A1 US 20120291911 A1 US20120291911 A1 US 20120291911A1 US 201113108238 A US201113108238 A US 201113108238A US 2012291911 A1 US2012291911 A1 US 2012291911A1
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US
United States
Prior art keywords
product
container
location
outer container
delivery device
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US13/108,238
Other languages
English (en)
Inventor
Scott Edward Smith
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Procter and Gamble Co
Original Assignee
Procter and Gamble Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Procter and Gamble Co filed Critical Procter and Gamble Co
Priority to US13/108,238 priority Critical patent/US20120291911A1/en
Priority to US13/108,269 priority patent/US8869842B2/en
Priority to US13/108,198 priority patent/US9701430B2/en
Assigned to THE PROCTER & GAMBLE COMPANY reassignment THE PROCTER & GAMBLE COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SMITH, SCOTT EDWARD
Priority to CN201280023581.XA priority patent/CN103534179B/zh
Priority to PCT/US2012/038020 priority patent/WO2012158731A2/en
Priority to RU2013149150/12A priority patent/RU2561322C2/ru
Priority to MX2013013419A priority patent/MX343317B/es
Priority to MX2013013420A priority patent/MX362640B/es
Priority to JP2014511471A priority patent/JP5809352B2/ja
Priority to CN201280023839.6A priority patent/CN103534173B/zh
Priority to PCT/US2012/038039 priority patent/WO2012158744A1/en
Priority to PCT/US2012/038034 priority patent/WO2012158741A2/en
Priority to EP12723790.7A priority patent/EP2709915B1/en
Priority to RU2013149143/12A priority patent/RU2582942C2/ru
Priority to EP12723056.3A priority patent/EP2709930B1/en
Priority to EP12723052.2A priority patent/EP2709908B1/en
Priority to BR112013027936A priority patent/BR112013027936A2/pt
Priority to CA2834884A priority patent/CA2834884C/en
Priority to MX2013013421A priority patent/MX2013013421A/es
Priority to JP2014511470A priority patent/JP2014513656A/ja
Priority to JP2014511467A priority patent/JP2014513655A/ja
Priority to CA2835129A priority patent/CA2835129C/en
Priority to CN201280023555.7A priority patent/CN103562095B/zh
Publication of US20120291911A1 publication Critical patent/US20120291911A1/en
Priority to US14/516,594 priority patent/US9505509B2/en
Priority to US14/736,296 priority patent/US20150284117A1/en
Priority to JP2015247895A priority patent/JP2016101987A/ja
Priority to US15/057,196 priority patent/US9950821B2/en
Abandoned legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B31/00—Packaging articles or materials under special atmospheric or gaseous conditions; Adding propellants to aerosol containers
    • B65B31/003—Adding propellants in fluid form to aerosol containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B3/00—Packaging plastic material, semiliquids, liquids or mixed solids and liquids, in individual containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, or jars
    • B65B3/04—Methods of, or means for, filling the material into the containers or receptacles
    • B65B3/045—Methods of, or means for, filling the material into the containers or receptacles for filling flexible containers having a filling and dispensing spout, e.g. containers of the "bag-in-box"-type
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B31/00—Packaging articles or materials under special atmospheric or gaseous conditions; Adding propellants to aerosol containers
    • B65B31/02—Filling, closing, or filling and closing, containers or wrappers in chambers maintained under vacuum or superatmospheric pressure or containing a special atmosphere, e.g. of inert gas
    • B65B31/025—Filling, closing, or filling and closing, containers or wrappers in chambers maintained under vacuum or superatmospheric pressure or containing a special atmosphere, e.g. of inert gas specially adapted for rigid or semi-rigid containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D83/00—Containers or packages with special means for dispensing contents
    • B65D83/14—Containers or packages with special means for dispensing contents for delivery of liquid or semi-liquid contents by internal gaseous pressure, i.e. aerosol containers comprising propellant for a product delivered by a propellant
    • B65D83/38—Details of the container body
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D83/00—Containers or packages with special means for dispensing contents
    • B65D83/14—Containers or packages with special means for dispensing contents for delivery of liquid or semi-liquid contents by internal gaseous pressure, i.e. aerosol containers comprising propellant for a product delivered by a propellant
    • B65D83/42—Filling or charging means
    • B65D83/425—Delivery valves permitting filling or charging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D83/00—Containers or packages with special means for dispensing contents
    • B65D83/14—Containers or packages with special means for dispensing contents for delivery of liquid or semi-liquid contents by internal gaseous pressure, i.e. aerosol containers comprising propellant for a product delivered by a propellant
    • B65D83/60—Contents and propellant separated
    • B65D83/62—Contents and propellant separated by membrane, bag, or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B9/00—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour
    • B05B9/03—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour characterised by means for supplying liquid or other fluent material
    • B05B9/04—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour characterised by means for supplying liquid or other fluent material with pressurised or compressible container; with pump
    • B05B9/08—Apparatus to be carried on or by a person, e.g. of knapsack type
    • B05B9/0805—Apparatus to be carried on or by a person, e.g. of knapsack type comprising a pressurised or compressible container for liquid or other fluent material
    • B05B9/0838—Apparatus to be carried on or by a person, e.g. of knapsack type comprising a pressurised or compressible container for liquid or other fluent material supply being effected by follower in container, e.g. membrane or floating piston, or by deformation of container
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B61/00—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages
    • B65B61/26—Auxiliary devices, not otherwise provided for, for operating on sheets, blanks, webs, binding material, containers or packages for marking or coding completed packages
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D35/00—Pliable tubular containers adapted to be permanently or temporarily deformed to expel contents, e.g. collapsible tubes for toothpaste or other plastic or semi-liquid material; Holders therefor
    • B65D35/22—Pliable tubular containers adapted to be permanently or temporarily deformed to expel contents, e.g. collapsible tubes for toothpaste or other plastic or semi-liquid material; Holders therefor with two or more compartments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D77/00—Packages formed by enclosing articles or materials in preformed containers, e.g. boxes, cartons, sacks or bags
    • B65D77/04—Articles or materials enclosed in two or more containers disposed one within another
    • B65D77/06—Liquids or semi-liquids or other materials or articles enclosed in flexible containers disposed within rigid containers
    • B65D77/062—Flexible containers disposed within polygonal containers formed by folding a carton blank
    • B65D77/065—Spouts, pouring necks or discharging tubes fixed to or integral with the flexible container
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D83/00—Containers or packages with special means for dispensing contents
    • B65D83/0005—Containers or packages provided with a piston or with a movable bottom or partition having approximately the same section as the container

Definitions

  • the present invention relates to aerosol dispensers and the manufacture of components thereof.
  • Aerosol dispensers are well known in the art. Aerosol dispensers typically comprise an outer container which acts as a frame for the remaining components and as a pressure vessel for propellant and product contained therein. Outer containers made of metal are well known in the art. However, metal containers can be undesirable due to high cost and limited recyclability.
  • the outer containers are typically, but not necessarily, cylindrical.
  • the outer container may comprise a bottom for resting on horizontal surfaces such as shelves, countertops, tables etc.
  • the bottom of the outer container may comprise a re-entrant portion as shown in U.S. Pat. No. 3,403,804.
  • Sidewalls defining the shape of the outer container extend upwardly from the bottom to an open top.
  • the open top defines a neck for receiving additional components of the aerosol dispenser.
  • the industry has generally settled upon a neck diameter of 2.54 cm, for standardization of components among various manufacturers, although smaller diameters, such as 20 mm, are also used.
  • Various neck shapes are shown in US 2007/02782531 A1; 7,303,087; 7,028,866; and commonly assigned Ser. No. 6,019,252.
  • valve cup is inserted into the neck.
  • the valve cup is sealed against the neck to prevent the escape of the propellant and loss of pressurization.
  • the valve cup holds the valve components which are movable in relationship to the balance of the aerosol dispenser.
  • Aerosol dispensers having a valve cup and movable valve components, may comprise different embodiments for holding, storing, and dispensing product used by the consumer.
  • the product and propellant are intermixed.
  • the product and propellant are dispensed together.
  • This embodiment may utilize a dip tube.
  • the dip tube takes the product and propellant mixture from the bottom of the outer container. By dispensing from the bottom of the outer container, the user is more likely to achieve dispensing of the product/propellant mixture and not dispense pure propellant from the headspace.
  • This embodiment may be used, for example, to dispense shaving cream foams.
  • the dip tube embodiment of an aerosol dispenser has the disadvantage that when the user tips the aerosol dispenser from a vertical orientation, dispensing of gas from the headspace, rather than dispensing of product/propellant mixture, may occur. This disadvantage may occur when the aerosol dispenser contains a product such as a body spray, which the user dispenses all over his/her body, often from inverted positions.
  • a collapsible, flexible bag may be sealed to the opening on the underside of the valve cup or may be placed between the valve cup and the container.
  • This bag limits or even prevents intermixing of the contents of the bag and the components outside of the bag.
  • product may be contained in the bag.
  • Propellant may be disposed between the outside of the bag and the inside of the outer container.
  • Gage pressure from the propellant disposed between the bag and the outer container causes pressurization of the product, forcing the product to flow into ambient pressure.
  • This embodiment is commonly called a bag on valve and may be used, for example, in dispensing shaving cream gels.
  • flow to the ambient may comprise droplets, as used for air fresheners or may comprise deposition on a target surface, as may occur with cleansers.
  • the process for manufacturing a bag on valve type aerosol dispenser is complicated.
  • One the filling operation is used to pressurize the outer container with propellant.
  • This filling operation may utilize hydrocarbon propellant and/or inert gas propellant, such as Tetrafluoroprop-1-ene commercially available from Honeywell Company of Morristown, N.J.
  • Propellant filling of aerosol dispensers presents its own challenges. Propellant must be added to the outer container, without contaminating the inside of the bag, if present. Further, leakage to the ambient must be minimized. And the relevant portions of the aerosol container must be sealed in a manner to prevent later leakage and depressurization after shipment, handling and storage.
  • each manufacturing site must have the complex and highly regulated propellant pressurizing equipment and safety systems. Yet, multiple manufacturing sites may be desirable if the product is to be shipped to several geographies.
  • a single manufacturing site is used to source multiple geographies, that site must be knowledgeable in specific products and consumer preferences for each geography. Some of the geographies may be remote. A single manufacturing site may not be able to quickly respond to changes in consumer preference or to tailor the product to the unique consumer preferences in different geographies. Different geographies may further have different labeling requirements and languages. Additionally, import duties and taxes for finished products are typically higher than the duties and taxes for intermediates exported to that same country.
  • the invention comprises a method of manufacturing an aerosol dispenser.
  • a pressurized container is provided at a first location.
  • the pressurized container comprises an outer container having a neck therein, a valve assembly mounted in the neck for selectively dispensing product therefrom, a product delivery device for holding product within the outer container, and optionally propellant within the outer container for pressurizing the outer container and product delivery device.
  • the pressurized container is transported to a second location remote from the first location. Product is installed into the product delivery device at the second location.
  • FIG. 1 is a perspective view of an aerosol dispenser according to the present invention having a plastic outer container and a bag.
  • FIG. 2A is an exploded perspective view of the aerosol dispenser of FIG. 1 having a collapsible bag.
  • FIG. 2B is an exploded perspective view of the aerosol dispenser of FIG. 1 having a dip tube.
  • FIG. 3A is a perspective view of the pressurizable container of the aerosol dispenser of FIG. 1 having a plastic outer container.
  • FIG. 3B is a perspective view of a perspective view of a pressurizable container according to the present invention having a metal outer container and a clinched valve cup.
  • FIG. 4 is an exploded perspective view of the pressurizable container of FIG. 3A and having an outer container, bag, valve cup and valve assembly.
  • FIG. 5 is a vertical sectional view of the pressurizable container of FIG. 3A .
  • FIG. 6 is a perspective view of a representative valve assembly usable with the aerosol dispenser of the present invention.
  • FIG. 7 is a vertical sectional view of the valve assembly of FIG. 6 , as inserted into a sleeve.
  • FIG. 8 is a fragmentary exploded perspective view of the valve cup and neck of the outer container of FIGS. 3A , 4 and 5 .
  • FIG. 9 is a schematic sectional view of a representative manifold engaging a presurrizable outer container for filling with propellant.
  • FIG. 10 is a vertical sectional view an aerosol dispenser having a bag and plural valve assemblies in a single outer container.
  • FIG. 11A is a schematic block diagram of a divided manufacturing process according to the present invention having the container pressurized at the point of manufacture.
  • the aerosol dispenser 20 comprises a pressurizeable outer container 22 usable for such a dispenser.
  • the outer container 22 may comprise plastic or metal, as are known in the art.
  • the outer container 22 may have an opening. The opening is typically at the top of the pressurizeable container when the pressurizeable container is in its-in use position. The opening defines a neck 24 , to which other components may be sealed.
  • a valve cup 26 may be sealed to the opening of the outer container 22 , as described in further detail below.
  • a valve assembly 28 may be disposed within the valve cup 26 .
  • the valve assembly 28 provides for retention of product 42 within the aerosol dispenser 20 until the product 42 is selectively dispensed by a user.
  • the valve assembly 28 may be selectively actuated by an actuator 30 . Neither the valve assembly 28 nor the actuator 30 form any part of the claimed invention.
  • the product delivery device may comprise a collapsible bag 32 as shown in FIG. 2A .
  • the collapsible bag 32 may be mounted in sealing relationship to the neck 24 of the container and/or to the valve assembly 28 . This arrangement is known in the art as a bag-on-valve.
  • the collapsible bag 32 may hold product 42 therein, and prevent intermixing of such product 42 with propellant 40 .
  • the propellant 40 may be stored outside the collapsible bag 32 , and inside the outer container 22 .
  • the collapsible bag 32 may expand upon being charged with product 42 . Such expansion decreases the available volume inside the outer container 22 . Decreasing the available volume increases the pressure of any propellant 40 therein according to Charles law.
  • the product delivery device may alternatively or additionally comprise a dip tube 34 as shown in FIG. 2B .
  • the dip tube 34 extends from a proximal end sealed to the valve assembly 28 .
  • the dip tube 34 may terminate at a distal end juxtaposed with the bottom of the outer container 22 .
  • This embodiment provides for intermixing of the product 42 and propellant 40 . Both are co-dispensed in response to selective actuation of the valve assembly 28 by a user. Again, insertion of product 42 and/or propellant 40 into the outer container 22 increases pressure therein according to Charles law.
  • the aerosol dispensers 20 may have a longitudinal axis, and may optionally be axi-symmetric with a round cross section.
  • the outer container 22 , product delivery device, valve assembly 28 , etc. may be eccentric and have a square, elliptical or other cross section.
  • any number of known valve assemblies may be usable with the present invention.
  • a rigid sleeve 54 may be attached to the top of the bag with an impermeable seal.
  • An elastically deformable plug may be tightly inserted into the sleeve 54 . Longitudinal movement of the plug, in the downward direction and within the sleeve 54 may allow product 42 to be selectively dispensed.
  • the sleeve 54 may be impermeably joined to an optional valve cup 26 .
  • the valve cup 26 in turn, may be joined to the neck 24 of the outer container 22 .
  • a suitable plug and sleeve 54 type valve assembly 28 may be made according to the teachings of commonly assigned publications 2010/0133301A1 and/or 2010/0133295A1.
  • the pressurizeable container may further include a propellant 40 .
  • the propellant 40 may be disposed between the outer container 22 and the product delivery device.
  • propellant 40 may be disposed in the outer container 22 and/or the collapsible bag 32 .
  • the pressure in the outer container 22 is greater than the pressure in the collapsible bag 32 , so that product 42 may be dispensed from within the bag.
  • a dip tube 34 is selected for the product delivery device, the propellant 40 and product 42 may be intermixed, and thus co-dispensed.
  • the pressure of the propellant 40 within the outer container 22 provides for dispensing of the product 42 /co-dispensing of product 42 /propellant 40 to ambient, and optionally to a target surface.
  • the target surface may include a surface to be cleaned or otherwise treated by the product 42 , skin, etc. Such dispensing occurs in response to the user actuating the valve assembly 28 .
  • the pressure boundary for the propellant 40 is formed, in part, by the collapsible bag 32 . If the product delivery device comprises a dip tube 34 , the pressure boundary for the propellant 40 is formed, in part by the underside of the valve assembly 28 when the valve is closed.
  • the outer container 22 , valve cup 26 , valve assembly 28 , dip tube 34 and/or collapsible bag 32 may be polymeric.
  • polymeric it is meant that the component is formed of a material which is plastic, comprises polymers, and/or particularly polyolefin, polyester or nylons.
  • the entire aerosol dispenser 20 or, specific components thereof, may be free of metal, allowing exposure to microwave energy.
  • an aerosol dispenser 20 or pressurizable container therefor, according to the present invention may be microwavable.
  • Microwave heating of the aerosol dispenser 20 or pressurizable container therefor provides for heating of the product 42 prior to dispensing. Heating of the product 42 prior to dispensing may be desirable if the product 42 is applied to the skin, becomes more efficacious at lower viscosities, or is to be eaten.
  • the outer container 22 may define a longitudinal axis of the aerosol dispenser 20 .
  • the outer container 22 may be axisymmetric as shown, or, may be eccentric. While a round cross-section is shown, the invention is not so limited.
  • the cross-section may be square, elliptical, irregular, etc.
  • the cross section may be generally constant as shown, or may be variable. If a variable cross-section is selected, the outer container 22 may be barrel shaped, hourglass shaped, or monotonically tapered.
  • a punt is a concavity in the bottom of the container and extending towards the neck 24 of the container.
  • a punt is distinguishable from a general concavity in the bottom of a container, as a punt has a smaller diameter than is defined by the footprint of the bottom of the container.
  • the punt may be axisymmetric about the longitudinal axis. The vertex of the punt may be coincident the longitudinal axis.
  • the outer container 22 sidewall also defines a diameter.
  • the sidewall and bottom of the container may be connected by a chamfer.
  • a chamfer refers to an angled wall which is substantially flat as taken in the radial direction.
  • the chamfer may be angled, relative to the longitudinal axis, at least 30, 35 or 40° and not more than 60, 55 or 50°. In a degenerate case, the chamfer may be angled at 45° relative to the longitudinal axis.
  • the bottom of the container may comprise radially oriented internal ribs.
  • the ribs may be of like geometry, and be spaced outwardly from the longitudinal axis. Each rib may intercept the sidewall of the outer container 22 .
  • the ribs may be equally circumferentially spaced from adjacent ribs.
  • the aerosol dispenser 20 may have an initial pressure.
  • the initial pressure is the highest pressure encountered for a particular filling operation, and corresponds to no product 42 yet being dispensed from the product delivery device.
  • the outer container 22 approaches a final pressure.
  • the final pressure corresponds to depletion of substantially all product 42 , except for small residual, from the product delivery device.
  • a suitable outer container 22 can be made without excessive material usage and the associated cost and disposal problems associated therewith. By reducing material usage, the user can be assured that excessive landfill wasted is not produced and the carbon footprint is reduced.
  • the outer container 22 may have a neck 24 .
  • the neck 24 may be connected to the container sidewall by a shoulder 25 .
  • the shoulder 25 may more particularly be joined to the sidewall by a radius.
  • the shoulder 25 may have an annular flat.
  • the neck 24 may have a greater thickness at the top of the outer container 22 than at lower portions of the neck 24 to provide a differential thickness. Such differential thickness may be accomplished through having an internally stepped neck 24 thickness.
  • propellant 40 provide the benefit that they are not flammable, although the invention is not limited to inflammable propellant 40 .
  • One such propellant 40 is commercially available from Honeywell International of Morristown, N.J. under the trade name HFO-1234ze or GWP-6.
  • a condensable propellant 40 provides the benefit that a greater volume of gas may be placed into the container at a given pressure. Upon dispensing of a sufficient volume of product 42 from the space between the outer container 22 and the product delivery device, the condensable propellant 40 may flash back to a gaseous state of matter.
  • the optional valve cup 26 may be sealed to the top of the outer container 22 while the outer container 22 is pressurized. The sealing process may be accomplished by providing the outer container 22 and valve cup 26 .
  • the optional valve cup 26 may be omitted. In such an embodiment, the valve assembly 28 is directly sealed to the neck 24 . While the following description is directed to incorporating a valve cup 26 , one of skill will recognize the invention is not so limited.
  • the valve cup 26 may have a valve cup 26 periphery complementary to the neck 24 periphery. At least one of the valve cup 26 and/or container neck 24 may have a channel 50 therethrough. Additionally or alternatively, the channel 50 may be formed at the interface between the valve cup 26 and container neck 24 .
  • a channel 50 is considered to be functional, so long as it allows fluid communication from the ambient, or more particularly a filling manifold 52 , into the outer container 22 .
  • the channel 50 may be coincident a radial direction or parallel to the longitudinal axis.
  • a plurality of radial channel 50 may be provided, to allow for faster filling of the propellant 40 .
  • the plurality of radial channel 50 may be generally equally circumferentially spaced or unequally spaced about the periphery of the outer container 22 and/or valve cup 26 .
  • the plurality of radial channel 50 made be of equal or unequal cross-section and of constant or variable cross-section. In a degenerate case, a single radial channel 50 may be provided.
  • the filling manifold 52 is applied over the valve cup 26 .
  • the manifold 52 is in fluid communication with a supply of propellant 40 and with at least one channel 50 .
  • the manifold 52 temporarily seals to an anvil.
  • the anvil provides a temporary seal for the moving portion of the manifold 52 .
  • the anvil may comprise a sleeve 54 into which the outer container 22 is placed.
  • the sleeve 54 may be used to transport the pressurizable/pressurized container between stations during manufacture. Additionally or alternatively, the shoulder 25 of the outer container 22 may be used as the anvil.
  • the temporary seal may be accomplished through compression, applied in the longitudinal direction, between the manifold 52 and the anvil.
  • at least one channel 50 may be disposed through the sidewall, bottom, neck 24 and/or other suitable positions on the outer container 22 . Any such arrangement may be used, so long as a seal is established and the channel 50 is sealed, as described below.
  • propellant 40 is introduced into the manifold 52 and flows, under pressure, from the supply, through one or a plurality of channel 50 , and into the outer container 22 . This step provides pressure to the inside of the outer container 22 . If a compressible flexible bag is selected for the product delivery device, the propellant 40 remains outside of the bag and the bag remains empty.
  • valve cup 26 When the desired propellant 40 pressure is reached, the valve cup 26 may be sealed to the neck 24 or top of the outer container 22 to prevent leakage therefrom. If channel 50 are used in a location other than at the interface between the valve cup 26 and container neck 24 , such channel 50 may likewise be sealed.
  • Sealing may occur through sonic welding or untrasonic welding as are known in the art. Alternatively or additionally, sealing may occur through spin welding, vibration welding, adhesive bonding, laser welding, or fitting a plug into the port as are known in the art. If desired, the valve cup 26 and the outer container 22 may have identical, or closely matched, melt indices, to improve sealing.
  • a welding apparatus is available from Branson Ultrasonics Corp., of Danbury Conn.
  • the channel 50 may not be radially oriented, but instead may be axially oriented.
  • Axial channel 50 may have an orientation primarily in the axial direction and provide fluid communication from the ambient to the inside of the outer container 22 .
  • channel 50 may be oriented in a skewed direction relative to the radial direction and the longitudinal direction.
  • channel 50 having a combination of orientations may be utilized, so long as a filling manifold 52 having complementary sealing is provided.
  • plural manifold 52 may be utilized.
  • Plural manifold 52 provide the benefit that each manifold 52 may have a different propellant 40 , and the propellant 40 are not intermixed until filling occurs.
  • Plural manifold 52 may also provide the benefit that different manifold 52 may be tailored to different channel 50 , so that a proper seal occurs during filling.
  • the manifold 52 may be removed.
  • the valve cup 26 and outer container 22 are sealed while under pressure from the manifold 52 propellant 40 .
  • the sealing step may occur during or after the propellant 40 charging step.
  • the collapsible bag 32 may be opened with a plunger.
  • the plunger allows air within the bag to escape.
  • air will be evacuated therefrom. Such evacuation minimizes problems during the sealing operation.
  • valve cup 26 may be sealed to the container utilizing a press fit, interference fit, solvent welding, laser welding, vibration welding, spin welding, adhesive or any combination thereof.
  • An intermediate component such as a sleeve 54 or connector may optionally be disposed intermediate the valve cup 26 and neck 24 or top of the outer container 22 . Any such arrangement is suitable, so long as a seal adequate to maintain the pressure results.
  • valves may be used with a single outer container 22 .
  • This arrangement provides the benefit that product 42 and propellant 40 are mixed at the point of use, allowing synergistic results between incompatible materials.
  • This arrangement also provides the benefit that delivery of the propellant 40 provides motive force to the product 42 , often resulting in smaller particle size distributions. Smaller particle size distributions can be advantageous for uniform product 42 distribution and minimizing undue wetting.
  • FIG. 10 illustrates an aerosol dispenser 20 having two valve assemblies, one of skill will recognize the invention is not so limited.
  • the aerosol dispenser 20 may have three, four or more valve assemblies, with a like number of or lesser number of chambers 60 to isolate different product 42 materials until the point of use.
  • the manufacture of the pressurizeable container according to the present invention may be divided into two or more phases according to time and/or location.
  • the outer container 22 , valve cup 26 , valve assembly 28 , product delivery device and propellant 40 may be manufactured as a unit.
  • Such a unit may comprise a pressurizeable container.
  • the product delivery device as manufactured, is empty. By empty it is meant that the product delivery device contains no product 42 or traces thereof. Further, an product delivery device has never contained product 42 . Further, the product delivery device contains no air other than atmospheric or residual air inherent to the manufacturing process. If the product delivery device has been filled and depleted, it is no longer considered empty. Empty is a state which exists only prior to the first filling of the product delivery device with product 42 . Further the empty state must last longer than an incidental period of a few seconds during transport between stations to be considered a state.
  • the empty product delivery device comprises a collapsible bag 32
  • the bag may have an open end joined and sealed to the valve cup 26 .
  • the bag has no product 42 and no air at a pressure greater than atmospheric therein.
  • the dip tube 34 is open to the inside of the outer container 22 .
  • the inside of the empty outer container 22 contains no product 42 , but may contain propellant 40 at a pressure greater than atmospheric pressure.
  • the pressurizeable container may be manufactured to have a propellant 40 therein.
  • Propellant 40 is contained between the outer container 22 and the bag or within the outer container 22 if a dip tube 34 is used.
  • the pressurized but container has propellant 40 sealed and pressurized therein but no product 42 .
  • the propellant 40 pressure may be selected according to the dispensing conditions.
  • the pressure within the pressurized container as manufactured and prior to charging with the product 42 may correspond to the final pressure that the user encounters when product 42 is depleted.
  • Product 42 may be charged into the container through the valve assembly 28 , as is known in the art.
  • the product 42 increases the pressure of the propellant 40 .
  • the increase in propellant 40 pressure occurs due to the increase in volume of the collapsible bag 32 if such a bag is used as a product delivery device.
  • the increase in propellant 40 pressure occurs due to the increase in the number of moles of product 42 in the outer container 22 if a dip tube 34 is selected.
  • the pressurizeable container may be charged with an amount of product 42 which brings the pressure, as initially presented to the user, sufficient to dispense and substantially deplete the product 42 from the aerosol dispenser 20 .
  • the final pressure, after substantially all product 42 is depleted, is less than the initial pressure.
  • the pressure of the propellant 40 at the end of the first phase of manufacture may correspond to the pressure at the end of the usable life of the aerosol dispenser 20 , herein referred to as the final pressure.
  • the pressure of the propellant 40 at the end of the second phase of manufacture may correspond to the pressure as initially presented to the user.
  • a limited number of plants may be selected to manufacture the pressurizeable container of the present invention.
  • the pressurized containers may be shipped from the limited number of plants to other plants for completing the manufacturing process in a second phase, or in a plurality of later phases. Such plants may be at a first location or a respective plurality of first locations.
  • the plants used to complete the second and later phases of the manufacturing process may be the same plant is used to complete the first phase. But, advantageously, the plants used to complete the second and later phases, if necessary, of the manufacturing process may be remote from the plant used to complete the first phase and produce the pressurizable container.
  • Such plants may be disposed at a second location or a respective plurality of second locations.
  • the second locations may be remote from, and domestically located in the same country as the first locations.
  • the second locations may be remote from, and located in one or more foreign countries as the first locations.
  • one or more plants at first locations may feed pressurizable containers to remote second locations one or more of which is domestic relative to the first location and to one or more second locations located in one or more foreign countries as the first locations.
  • a pressurized container may be shipped from a first plant in a generic form having propellant 40 therein.
  • the generic form has no label, no actuator 30 or other valve opening device and no product 42 therein.
  • the pressurizable container may then be shipped to a second, different and/or remotely located plant for local completion of the second phase of manufacture.
  • the remotely located plant may be in the same country as the first plant, or may be in a different country, so that international shipping is only with the subcombination having the generic form.
  • remote it is meant that the first plant and second plant are functionally separated so that specific transport therebetween is necessary. Transport may occur by truck, train, ship, combinations thereof, etc. Remote locations do not include separate rooms or facilities at a common plant.
  • the pressurizeable container is charged with product 42 .
  • the product 42 may be customized to the local country, or region thereof, where the second phase of manufacture is completed. For example, users in one particular country may prefer particular scents or greater amounts of scents. Users in another country may prefer greater amounts of disinfectant or product 42 free of a scent. Users in yet another country may prefer product 42 tinted to a particular color.
  • a label made in one country may not be optimum for aerosol dispensers 20 sold in another country.
  • preferences may change or a particular fad may occur which would be desirable to add to the labeling or product 42 .
  • Localized label graphics may provide more efficient use of space, providing improved communication and greater value to the consumer. With the divided manufacture of the present invention, this efficiency and rapid changes may be accommodated more readily than if a single, plant conducts both phases of manufacture remote from the point of sale.
  • the pressurized container may be refilled with a new charge of product 42 .
  • the user simply takes the pressurized container which is depleted of product 42 to filling station at yet another location. At this location, a new charge of product 42 installed into the product delivery device.
  • the refill could occur through the same valve assembly 28 utilized for the initial product 42 charge.
  • the refill may be the same product 42 as originally presented to the consumer or may be a different product 42 to accommodate changing consumer preferences.
  • the user may purchase relatively larger pressurized container of product 42 .
  • the product 42 When the product 42 is depleted from the aerosol dispenser 20 , the user simply refills the product 42 from the larger pressurized container, which acts as a reservoir. This arrangement provides the convenience of not requiring a special trip to continue using the product 42 .
  • the divided manufacturing process described herein may be further and advantageously subdivided to achieve even further unpredicted benefits.
  • the pressurizable container may be manufactured at a first location, and sealed, but not filled with propellant 40 .
  • the pressurizable container having no propellant 40 may be transported to a second location.
  • the pressurizable container may be filled with propellant 40 .
  • This arrangement provides the benefit that a separate cleaning operation, as is typical in the art after shipping open containers, may be advantageously omitted and obviated.
  • the now pressurized container may also be filled with product 42 at the second location. Or, if desired, the now pressurized container may be transported to a third location. The pressurized container may be filled with product 42 at such third location. Of course, decorating and other ancillary operations may occur at the first, second, third or later location.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Dispersion Chemistry (AREA)
  • Containers And Packaging Bodies Having A Special Means To Remove Contents (AREA)
  • Vacuum Packaging (AREA)
  • Colloid Chemistry (AREA)
  • Packages (AREA)
US13/108,238 2011-05-16 2011-05-16 Method of manufacturing an aerosol dispenser Abandoned US20120291911A1 (en)

Priority Applications (27)

Application Number Priority Date Filing Date Title
US13/108,238 US20120291911A1 (en) 2011-05-16 2011-05-16 Method of manufacturing an aerosol dispenser
US13/108,269 US8869842B2 (en) 2011-05-16 2011-05-16 Method of filling and sealing an aerosol dispenser
US13/108,198 US9701430B2 (en) 2011-05-16 2011-05-16 Components for aerosol dispenser
CN201280023555.7A CN103562095B (zh) 2011-05-16 2012-05-16 制造气溶胶分配器的方法
EP12723790.7A EP2709915B1 (en) 2011-05-16 2012-05-16 Method of filling and sealing an aerosol dispenser
BR112013027936A BR112013027936A2 (pt) 2011-05-16 2012-05-16 método de fabricação de um aplicador de aerossol
RU2013149150/12A RU2561322C2 (ru) 2011-05-16 2012-05-16 Компоненты для дозатора аэрозоля
MX2013013419A MX343317B (es) 2011-05-16 2012-05-16 Método para el llenado y sellado de un dispensador de aerosol.
MX2013013420A MX362640B (es) 2011-05-16 2012-05-16 Componentes para un dispensador de aerosol.
JP2014511471A JP5809352B2 (ja) 2011-05-16 2012-05-16 エアゾールディスペンサを充填及び封止する方法
CN201280023839.6A CN103534173B (zh) 2011-05-16 2012-05-16 装填并密封气溶胶分配器的方法
PCT/US2012/038039 WO2012158744A1 (en) 2011-05-16 2012-05-16 Method of filling and sealing an aerosol dispenser
PCT/US2012/038034 WO2012158741A2 (en) 2011-05-16 2012-05-16 Components for aerosol dispenser
CN201280023581.XA CN103534179B (zh) 2011-05-16 2012-05-16 用于气溶胶分配器的部件
RU2013149143/12A RU2582942C2 (ru) 2011-05-16 2012-05-16 Способ изготовления дозатора для аэрозоля
EP12723056.3A EP2709930B1 (en) 2011-05-16 2012-05-16 Components for aerosol dispenser
EP12723052.2A EP2709908B1 (en) 2011-05-16 2012-05-16 Method of manufacturing an aerosol dispenser
PCT/US2012/038020 WO2012158731A2 (en) 2011-05-16 2012-05-16 Method of manufacturing an aerosol dispenser
CA2834884A CA2834884C (en) 2011-05-16 2012-05-16 Method of manufacturing an aerosol dispenser
MX2013013421A MX2013013421A (es) 2011-05-16 2012-05-16 Componentes para dispensador de aerosol.
JP2014511470A JP2014513656A (ja) 2011-05-16 2012-05-16 エアゾールディスペンサのための構成要素
JP2014511467A JP2014513655A (ja) 2011-05-16 2012-05-16 エアゾールディスペンサの製造方法
CA2835129A CA2835129C (en) 2011-05-16 2012-05-16 Components for aerosol dispenser
US14/516,594 US9505509B2 (en) 2011-05-16 2014-10-17 Method of filling and sealing an aerosol dispenser
US14/736,296 US20150284117A1 (en) 2011-05-16 2015-06-11 Components for aerosol dispenser
JP2015247895A JP2016101987A (ja) 2011-05-16 2015-12-18 エアゾールディスペンサの製造方法
US15/057,196 US9950821B2 (en) 2011-05-16 2016-03-01 Components for aerosol dispenser

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US13/108,238 US20120291911A1 (en) 2011-05-16 2011-05-16 Method of manufacturing an aerosol dispenser
US13/108,198 US9701430B2 (en) 2011-05-16 2011-05-16 Components for aerosol dispenser
US13/108,269 US8869842B2 (en) 2011-05-16 2011-05-16 Method of filling and sealing an aerosol dispenser

Publications (1)

Publication Number Publication Date
US20120291911A1 true US20120291911A1 (en) 2012-11-22

Family

ID=52298281

Family Applications (6)

Application Number Title Priority Date Filing Date
US13/108,238 Abandoned US20120291911A1 (en) 2011-05-16 2011-05-16 Method of manufacturing an aerosol dispenser
US13/108,269 Active 2033-03-30 US8869842B2 (en) 2011-05-16 2011-05-16 Method of filling and sealing an aerosol dispenser
US13/108,198 Active 2031-09-06 US9701430B2 (en) 2011-05-16 2011-05-16 Components for aerosol dispenser
US14/516,594 Active 2031-07-25 US9505509B2 (en) 2011-05-16 2014-10-17 Method of filling and sealing an aerosol dispenser
US14/736,296 Abandoned US20150284117A1 (en) 2011-05-16 2015-06-11 Components for aerosol dispenser
US15/057,196 Active 2031-06-22 US9950821B2 (en) 2011-05-16 2016-03-01 Components for aerosol dispenser

Family Applications After (5)

Application Number Title Priority Date Filing Date
US13/108,269 Active 2033-03-30 US8869842B2 (en) 2011-05-16 2011-05-16 Method of filling and sealing an aerosol dispenser
US13/108,198 Active 2031-09-06 US9701430B2 (en) 2011-05-16 2011-05-16 Components for aerosol dispenser
US14/516,594 Active 2031-07-25 US9505509B2 (en) 2011-05-16 2014-10-17 Method of filling and sealing an aerosol dispenser
US14/736,296 Abandoned US20150284117A1 (en) 2011-05-16 2015-06-11 Components for aerosol dispenser
US15/057,196 Active 2031-06-22 US9950821B2 (en) 2011-05-16 2016-03-01 Components for aerosol dispenser

Country Status (8)

Country Link
US (6) US20120291911A1 (es)
EP (3) EP2709915B1 (es)
JP (3) JP2014513656A (es)
CN (3) CN103562095B (es)
CA (2) CA2835129C (es)
MX (3) MX362640B (es)
RU (1) RU2561322C2 (es)
WO (3) WO2012158744A1 (es)

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