WO2001044057A2

WO2001044057A2 - Aerosol can having reduced diameter dome

Info

Publication number: WO2001044057A2
Application number: PCT/US2000/041967
Authority: WO
Inventors: Edward F. Owens
Original assignee: U.S. Can Company
Priority date: 1999-11-09
Filing date: 2000-11-08
Publication date: 2001-06-21
Also published as: WO2001044057A3; AU4902401A; WO2001044057B1

Abstract

An aerosol dispenser (10) having a reduced diameter dome (16) has a can body (12), dome (16), bottom end (14), and overcap (20). The body (12) has a substantially flat cylindrical wall whose diameter (D) is sufficiently large enough to prevent the overcap (20) from being detached from the can (10) when squeezed. The body (12) also has at least one tapered surface to accommodate a reduced diameter dome (16), and may also have a flat surface (26) to accommodate a lithograph label.

Description

AEROSOL CAN HAVING REDUCED DIAMETER DOME

TECHNICAL FIELD OF THE INVENTION

The present invention relates generally to an aerosol can and, more particularly, to an aerosol can having a reduced diameter dome and an overcap support region.

BACKGROUND OF THE INVENTION

Conventional multi-staged cans, such as three-piece cans, are comprised of a body rolled into a cylinder and welded at a seam, a bottom end cover attached to the bottom of the body, and a dome attached to the top of the body. After being filled with fluid, the can is usually sealed using a valve cup having a valve for dispensing the fluid.

Typically, the body of the can is imprinted with labels including decorative information that identifies the product to a consumer and instructional information, such as directions for using the product. It is also desirable to print additional labels on the dome in order to gain the consumer's attention at the time of use. However, placing labels on the dome prevents a can manufacturer from keeping large stocks of pre-formed domes since each order from a can filler may require a different label on the dome. Furthermore, the deformation of the metal that occurs during the shaping of a dome can cause the text to become misaligned and contorted. Thus, it can be seen that there is a need for a can on which labels may be printed, but does not interfere with the dome-making process.

It will be appreciated that a single manufacturer may make vast numbers of aerosol cans so that reducing the material in a single aerosol can by small amounts may result in significant material savings for the manufacturer. In aerosol cans, the dome generally has indentations along its surface that make the dome more vulnerable to deformation than the can body. Consequently, the dome is usually made of thicker material. Smaller domes have been developed for unibody aerosol cans. However, unibody cans are expensive and time consuming to produce. Unfortunately, attempts to reduce the size of the dome in three-piece aerosol cans without changing the standard diameter of the can body have been unsuccessful. Thus, there is a need for a multistage aerosol can with a reduced diameter dome.

SUMMARY OF THE INVENTION

In view of the foregoing, it is a general object of the present invention to provide an aerosol can which uses less material. It is a related object of the present invention to provide an aerosol can which has a reduced diameter dome.

Another object of the present invention is to provide an aerosol can which minimizes inventory requirements to make multiple size cans.

It is a more specific object of the invention to provide an aerosol can having a reduced diameter dome which can accommodate a standard diameter overcap.

It is a further object of the invention to provide a substantially flat surface on the overcap support region on which a text block may be printed.

It is yet another object to provide a method of configuring an aerosol can body so that it can accommodate a reduced diameter dome and a standard diameter overcap. Finally, it is another object of the present invention to provide a more visually and esthetically attractive aerosol container.

In accordance with these and other objects of the invention, the reduced dome can comprises a can body, dome, bottom end, overcap, and overcap support region. The overcap support region has a surface whose diameter is sufficiently large enough to prevent the overcap from being detached from the can when squeezed. The overcap support region has at least one tapered surface to accommodate a reduced diameter dome, and may also have a flat surface to accommodate a block of text. Additional features, advantages, and objects of the invention will be apparent from the following detailed description of an illustrative embodiment made in accordance with the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

While the appended claims set forth the features of the present invention with particularity, the invention may be best understood from the following detailed description taken in conjunction with the accompanying drawings of which:

FIG. 1 is a cross-sectional view of an aerosol can in accordance with an illustrative embodiment of the invention;

FIG. 2 is an elevational view of the aerosol can without a valve and overcap; FIG. 3 is a perspective view of the aerosol can in Fig. 2 with a valve cup but no valve.

FIG. 4 is an exploded view of the aerosol can in Fig. 2 with a valve and a valve cup;

FIG. 5 is a top view of the aerosol can in Fig. 2 without the overcap; FIG. 6 is a bottom view of the aerosol can; and

FIG. 7 is a cross-sectional view of an alternative embodiment of an aerosol can in accordance with the invention.

DETAILED DESCRIPTION OF THE INVENTION Referring to the figures, and particularly Figs. 1 and 4, an exemplary aerosol dispensing can 10 in accordance with an illustrative embodiment of the invention is shown. The can 10 has a body 12, a bottom end cover 14, a top end cover or dome 16, and a valve cup 50.

The body 12 has a preferably cylindrical and metallic tubular configuration. The body 12 has opposing bottom and top openings which are sealed by the bottom end cover 14 and top cover 16. The covers 14, 16 -ire secured to the body 12 by a conventional double seam 32, 34, respectively. The outer diameter D of aerosol cans typically come in standard sizes including, for example, 2 2/16 inches, 2 5/16 inches, 2 11/16 inches, and 2 14/16 inches, but any size can may be used. In conventional aerosol containers the outer diameter of the upper dome will be substantially the same as the outer diameter of the container body.

The bottom end cover 14 is preferably constructed from a metallic material and includes a generally upwardly dome-shaped or arcuate shaped panel 17. The upper end cover or dome 16 has a generally dome-like or conical configuration defining an outer periphery which is secured to the body by the conventional double seam 32. The dome 16 has a valve opening 21 defined by the inner surface of a curl 23 for receiving a valve assembly. In accordance with certain objects of the invention, the dome 16 has a smaller outer diameter d than the container body 12. It will be appreciated that the end cover 16 with a smaller diameter requires less material than a larger diameter cover having the same thickness. Reducing the outer diameter of the dome 16 also reduces the total force on the dome 16 and the requisite thickness of the material necessary to withstand those forces. Since a manufacturer makes vast numbers of aerosol containers, significant savings may result from the smaller and thinner top dome.

The valve assembly comprises a valve cup 50 and a valve 62. The valve cup 50 has a base 52, a cylindrical wall 54 and an arcuate-shaped curl or skirt 22. The cup wall 54 is dimensioned for slidable insertion into the valve opening 21. The internal surface of the skirt 22 is adapted to receive the curl 23 of the valve opening 21 to form an air-tight seal at the interface of the curl 23 and the skirt 22 when the valve cup 50 is crimped in place. The air-tight seal prevents the escape of the product or propellant contained in the can 10. The base 52 of the valve cup 50 is also adapted to receive a conventional valve 62 having a dispensing member 60 for selectively dispensing the product. In order to secure the smaller diameter dome 16 to the significantly wider can body 12, an upper end 27 of the body 12 is tapered inwardly so that the body 12 may be attached to the dome 16. Referring to the embodiment shown in Fig. 7, the upper end 27a of the container body 12 is defined by a single straight, conical tapered wall 29. In the preferred embodiment shown in Figs. 1-6, the upper end 27 of the body 12 is defined by a plurality of necked wall portions. In the preferred embodiment, the necked in end portion 27 comprises three wall portions. The first portion is defined by an inwardly tapered conical wall 28. The second portion is defined by a substantially flat cylindrical wall 26, which is preferably parallel to the body 12. The third portion is defined by an inwardly tapered conical wall 30. A flanged end 25

(Fig. 4) of the inwardly tapered conical wall 30 disposed at the end of the third portion 30 may be attached to the dome 16 by a conventional double seam 32 (Figs. 1-3). It will of course be appreciated that, in other embodiments, the upper end 27 of the container body 12 may have other configurations and dimensions which permit the substantially wider body 12 to achieve a smaller diameter and receive the outer peripheral edge of a narrower dome 16.

In accordance with certain objects of the invention, a standard container body 12 may be configured and dimensioned to receive multiple size domes 16, ranging from domes having the same outer diameter as the body to substantially smaller- diameter domes. Thus, it will be appreciated that the present invention simplifies container production and minimizes the inventory necessary to make a variety of container sizes. Similarly, a specifically sized dome 16 may be attached to different size container bodies. In an illustrative embodiment, a Type "211 " can body 12 having a 2 11/16 inches outer diameter may be configured to accept (1) a Type "211" dome having a 2 11/16 inch diameter, (2) a Type "205" dome having a 2 5/16 inch diameter, (3) a Type "202" dome 16 having a 2 2/16 inch outer diameter or another suitable dome having a diameter less then the 2 11/16 inches. Similarly, in aerosol cans made in accordance with the invention, the Type 202 dome 16 may also be used „, ,_, .-„ 01/44057

6 with a (1) Type 202 straight side can body, (2) a Type 205 necked-in can body, (3) a Type 211 necked-in can body, or (4) or other dimension can bodies having a diameter at least 2 2/16 inches. Of course, other combinations of domes and can bodies will be known to those skilled in the art. The upper end 27 of the body 12 may be formed to the desired configuration and dimension using conventional aerosol container assembly equipment including, for example, die neckers, spin neckers, or a combination of the two. As is conventional, the die necker may require several stages to taper the container walls to a desired dimension depending, in part, on the thickness of the material and the desired dimensions. The die necker, for example, may require eight to ten stages to taper the upper end of a Type 211 can body to accommodate a Type 202 dome. Alternatively, a spin necker may be used for the entire tapering process provided that a sufficiently flexible metal, such as single reduced tin-plated steel, is used.

Referring to the preferred embodiment shown in Figs. 1-6, it is preferred that a die necker process be used to create the inwardly tapered conical wall 28 and the substantially flat cylindrical wall 26, and a spin necker process be used to create the inwardly tapered conical wall 30. For example, to form the upper end 27 of a Type 211 can body to receive a smaller diameter Type 202 dome, it is preferred that a two- stage die necking process be used to taper the outer diameter of the body from 2 11/16 inches to 2 15/32 inches to create the inwardly tapered conical wall 28. The diameter of the upper end 27 may be left unaltered at 2 15/32 inches to create the substantially flat cylindrical surface 26. Finally, a spin necking process is preferably used to taper the upper end 27 from 2 15/32 inches to 2 2/16 inches to create the inwardly tapered conical wall 30. Thus, in this example, the need for stocking two sets of domes (one for Type 211 cans and another for Type 202 cans) is eliminated.

The upper end cover 16 also defines a valve opening 21. The peripheral edge of the valve opening 21 forms a smooth surfaced, arcuate shaped curl 23 which extends upwardly and outwardly from the center of the opening 21. To assemble the can 10, the bottom end cover 14 is crimped or otherwise attached to the body 12 to form the double seam 34. The dome 16 is crimped or otherwise attached to the flanged end 25 of the body 12 to form the double seam 32. An aerosol product may be introduced into the can through the valve opening 21. Using a conventional gasser, a gas or propellant may also be injected through the valve opening 21. The valve cup 50 having the valve 62 inserted therein may be crimped or otherwise attached to the dome 16 so that the skirt 23 of the valve cup 50 and the curl 22 of the valve opening 21 form an air tight seal. The can 10 may hold many types of aerosol products, including, but not limited to hair spray, cooking spray, whipped cream, shaving cream, furniture polish, cleaners, automotive products, and paint.

One embodiment of overcap 20 is shown in Figs. 1 and 7. The overcap 20 has a cylindrical outer wall 64. The bottom peripheral edge 31 of the overcap 20 is preferably dimensioned to be substantially flush with the body 12 or the double seam 32 for aesthetic reasons. The overcap 20 has a circular inner wall 18 which is dimensioned to attach to the skirt 22 of the valve cup 50 in a snap fit manner, thereby allowing the overcap 20 to fit securely on top of the can 10. The overcap 20 may be removed from the can 10 by pulling in an axial direction.

In the embodiment illustrated in Fig. 7, it will be appreciated that excessive squeezing of the overcap 20 near the bottom peripheral edge 31 A may slightly deform and bend the overcap 20 so it may inadvertently disengage from the curl 22. In accordance with certain objects of the invention, the outer diameter of the substantially flat cylindrical wall 26 of the preferred embodiment shown in Figs. 1-6 may be dimensioned to be slightly smaller than the inner dimension of the peripheral edge 31. Thus, as shown in Fig. 1 supports the peripheral edge 31 of the overcap 20 in response to inward pressure exerted on the peripheral edge 31 and resists upward force on the overcap 20 near the curl 22 which may cause inadvertent removal of the overcap 20 from the container body 12 when the overcap 20 is inadvertently squeezed.

In accordance with certain objects of the invention, lithograph labels may be applied to the upper end 27 of the can 10 on, for example, the substantially flat cylindrical wall 26, the inwardly tapered conical wall 28 or the inwardly tapered conical wall 30, without interfering with the dome-making process. During manufacture of the can 10, a sheet of material, such as double reduced or single reduced tin plated steel, may be cut into a square or rectangle and coated with conventional protective material. Text, designs, logos, and the like as well as any material intended to be displayed on the upper end 27 may then be printed on the flat sheet material. The sheet may then be rolled into the cylindrical shape for the body 12, and seam welded (not shown). The printed information will not be deformed during the dome-making process, thereby providing clear and legible labels. Additionally the overcap 20 may be dimensioned to fit onto a snap-lock area 19 or the double seam 32 to expose the labeling on the upper end 27 to a consumer when the product is displayed on a store shelf.

It will thus be seen that a novel and improved aerosol can has been provided. In view of the many possible embodiments to which the principals of this invention may be applied, it should be recognized that the embodiment described herein with respect to the drawing figures is meant to be illustrative only and should not be taken as limiting the scope of the invention. The illustrated embodiment can be modified in arrangement and detail without departing from the spirit of the invention. Therefore, the invention as described herein contemplates all such embodiments as may come within the scope of the following claims and equivalents thereof.

Claims

WHAT IS CLAIMED IS:

1. An aerosol can comprising: a cylindrical body having upper and bottom ends and a first diameter, a bottom cover attached to the bottom end of the body to seal the bottom end for receiving aerosol products, a top cover having an outer periphery defining a second diameter which is smaller than the first diameter, a valve opening centrally disposed in the top cover for receiving a valve assembly, the upper end of the body having a outer peripheral configuration which reduces from the first diameter to the second diameter to receive the top cover wherein a seam is formed at the connection between the outer periphery of the top cover and the upper end of the body.

2. The aerosol can set forth in claim 1 wherein the first diameter is about

2 11/16 inches and the second diameter is about 2 2/16 inches.

3. The aerosol can set forth in claim 1 wherein the first diameter is about 2 11/16 inches and the second diameter is about 2 inches.

4. The aerosol can set forth in claim 1 wherein the first diameter is about 2 14/16 inches and the second diameter is about 2 2/16 inches.

5. The aerosol can set forth in claim 1 wherein the upper end comprises first, second and third walls, wherein the first and third walls have inwardly tapered cross sections, the second wall is disposed between and connects the first and second walls and has a substantially cylindrical cross section -_. ,_ „--_.- 01/44057

10 and the third wall tapers to the second diameter.

6. The aerosol can set forth in claim 5 comprising an overcap for covering the top cover, the overcap having cylindrical walls and an outer periphery which extends over the second wall so that the cylindrical second wall resists inward lateral movement of the overcap walls and provides lateral support for the overcap walls.

7. The aerosol can set forth in claim 6 wherein the overcap attaches to the seam between the body and the top cover to cover the top cover.

8. The aerosol can set forth in claim 6 wherein the overcap has a depending interior wall which attaches to the valve opening to cover the top cover.

9. A family of aerosol cans comprising: at least one cylindrical body having upper and bottom ends and dimensioned to have a first diameter, a bottom cover attached to the bottom end of the body to seal the bottom end receiving aerosol products, and at least first and second top covers having different dimensioned outer peripheral dimensions, the first top cover having an outer periphery dimensioned to be about the first diameter and the second top cover dimensioned to have a second diameter that is smaller than the first diameter, the upper end of the body having an outer peripheral configuration to receive the first top cover and be reduced from the first diameter to the second diameter to receive the second top cover wherein a seam is formed at the connection between the outer periphery of the top cover and the upper end of the body.

10. The family of aerosol cans set forth in claim 9 comprising a second cylindrical body dimensioned to have peripheral dimensions of about the second diameter, and an upper end configured to receive the second top cover.

11. A method for forming an aerosol can comprising: cutting substantially flat sheet material into a rectangle, forming the sheet material into a cylindrical body having upper and bottom ends and a first diameter, attaching a bottom cover to the bottom end of the body, forming a top cover having a second diameter which is smaller than the first diameter and a centrally disposed opening dimensioned to receive a valve assembly, reducing the diameter of the upper end of the body from the first diameter to the second diameter so the top cover and the upper end may be attached together, and attaching the top cover to the upper end of the body.

12. The method set forth in claim 11 comprising: filling the body through the central opening in the top cover with aerosol products and propellant, and attaching the valve assembly to the top cover and sealing the products and propellant within the container.

13. The method set forth in claim 11 comprising: printing lithographic labels, prior to forming the cylindrical body, on the portion of the flat sheet material to be formed into the upper end of the cylindrical body.

14. The method set forth in claim 11 comprising: tapering the upper end of the cylindrical body to form a first inwardly tapered wall wherein the first wall tapers from the first diameter to a third diameter and the third diameter is dimensioned between the first and second diameters.

15. The method set forth in claim 14 comprising: tapering one end of the first wall to form a second inwardly tapered wall wherein the second wall tapers from the third diameter to the second diameter to receive the top cover.

16. The method set forth in claim 15 comprising: forming a cylindrical wall disposed between the first and second tapered walls.

17. The method set forth in claim 14 comprising: tapering the first wall using a die necking process.

18. The method set forth in claim 17 comprising: tapering the second wall using a spin flow necking process.

19. The method set forth in claim 15 comprising: printing lithographic labels, prior to forming the cylindrical body, on the portion of the flat sheet material which be the upper end of the cylindrical body.

20. A family of aerosol cans comprising: at least one cylindrical body having upper and bottom ends and dimensioned to have a first diameter, a bottom cover attached to the bottom end of the body to seal the bottom end for receiving aerosol products, at least first and second top covers having different dimensioned outer peripheral dimensions, the first top cover having an outer periphery dimensioned to be about the first diameter and the second top cover dimensioned to have a second diameter that is smaller than the first diameter, the upper end of the body having an outer peripheral configuration to receive the first top cover and be reduced from the first diameter to the second diameter to receive the second top cover wherein a seam is formed at the connection between the outer periphery of the top cover and the upper end of the body.