Abstract:
A nozzle is provided for dispensing a viscous material. The nozzle includes an elongated nozzle body defining a hollow passage formed between a base and the tapered end. The tapered end is initially closed for preventing discharge of material from within the passage. A removable tip portion is formed within the tapered end of the nozzle body. The removable tip is formed by a tear tab projecting from the tapered end and a removable tear strip formed within the sidewall of the nozzle body and connected to the tab. The tear strip is defined by spaced, longitudinally extending tear lines within the sidewall and includes at least two removable sections along the length of the strip. The tear tab forms a starting mechanism for transferring an opening force to the tear strip to remove the sections of the strip to form a discharge opening.

Description:
FIELD OF THE INVENTION 
       [0001]    The present application relates to a dispensing nozzle for flowable materials, such as caulk or other viscous liquids or slurries. The nozzle is molded and includes a removable portion for selectively controlling the size of the discharge opening. 
       BACKGROUND OF THE INVENTION 
       [0002]    A number of forms of nozzles for dispensing flowable materials are known. 
         [0003]    U.S. Pat. No. 3,278,085 to Brown shows a flexible pouch having an interior reservoir that is tapered toward one end. A first score line defines a removable portion that opens the dispensing end of the pouch. A second score line defines a closure flap for sealing the pouch after initial opening. 
         [0004]    U.S. Pat. No. 5,221,029 to Stull shows a nozzle structure for a container having a molded closure end. A number of forms of removable tabs are formed on the closure end. The tabs may be frangibly removed from the nozzle tip to open the closure and define a dispensing opening. 
         [0005]    U.S. Pat. No. 7,073,692 to Weyts shows a removable tab formed on the closure end of the dispensing nozzle. A tear strip is shown as a means for assisting in the removal of the tab. A secondary dividing line is formed on the nozzle body defining a resealing area. 
         [0006]    U.S. Pat. No. 4,917,267 to Layerdure shows a self-closing valve structure formed on a nozzle for a tube shaped package. A score line is provided in the walls of the nozzle for removal of a top portion and to open the nozzle. The top portion is used as an overcap for resealing the nozzle. 
         [0007]    US 2007/0138216 to DeLaossa shows a number of variations of caulk tube nozzles. In one embodiment shown, the nozzle extension includes multiple score lines that serve as break points for removing a portion of the nozzle to vary the overall length of the nozzle. 
         [0008]    U.S. Pat. No. 6,789,971 to Tsaur shows a multi-channel cylindrical container with multiple break lines at either end for opening the container and for controlling discharge. 
         [0009]    US 2006/0097088 to Wilers et al shows a caulk tube nozzle having a semi-circular or triangular cross section for defining the size of the discharge opening. 
         [0010]    U.S. Pat. No. 3,743,144 to Marg et al shows a reclosable caulk tube nozzle having various forms of resealing mechanisms attached to the tube. In one embodiment, a cap is tethered to the base of the tube and may be used to close a tube that has been cut open at a desired discharge angle. 
       SUMMARY OF THE INVENTION 
       [0011]    A nozzle is provided for dispensing a viscous material. In one aspect of the invention, the nozzle is attached to a cartridge for storing the material to be discharged through the nozzle. The nozzle includes an elongated nozzle body defining a hollow passage formed between a base and the tapered end. The tapered end being initially formed in a closed condition for preventing discharge of material from within the passage. A removable tip portion is formed within the tapered end of the nozzle body. The removable tip is formed by a tear tab projecting from the tapered end and a removable tear strip formed within the sidewall of the nozzle body and connected to the tab. The tear strip is defined by spaced, longitudinally extending tear lines within the sidewall and includes at least two removable sections along the length of the strip. The tear tab forms a starting mechanism for transferring an opening force to the tear strip to remove the sections of the strip along the tapered end to form a discharge opening. Each section of the tear strip defines a length of the nozzle opening. 
         [0012]    In another aspect of the contemplated invention, the nozzle passage tapers inwardly from the nozzle base to the discharge tip. 
         [0013]    In another aspect of the contemplated invention, the nozzle body tapers along the nozzle axis. 
         [0014]    In a further aspect of the contemplated invention, the longitudinal lines diverge from one another as the lines extend toward the base. 
         [0015]    In another aspect of the contemplated invention, the nozzle body has a circular cross-section at positions along its length between the base and the tapered end. 
         [0016]    In another aspect of the contemplated invention, the tear strip portion of the nozzle is generally arched between the spaced lines. 
         [0017]    In further aspect of the contemplated invention, the tear strip is generally flat between the spaced longitudinal lines. 
         [0018]    Other features of the present invention will become apparent from the detailed description to follow, taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]    For the purpose of illustrating the invention, the drawings show forms that are presently preferred. It should be understood that the invention is not limited to the precise arrangements and instrumentalities shown. 
           [0020]      FIG. 1  shows a nozzle attached to a storage tube and positioned within an discharge activation mechanism. 
           [0021]      FIG. 2  shows an embodiment of the nozzle as contemplated by the present invention. 
           [0022]      FIG. 3  shows in the cross section the nozzle embodiment of  FIG. 2  as taken along line  3 - 3 . 
           [0023]      FIG. 4  shows the nozzle embodiment of  FIGS. 2-3  wherein a discharge opening is created by selective removal of a portion of the nozzle tip. 
           [0024]      FIG. 5  shows the nozzle embodiment of  FIGS. 2-4  wherein a discharge opening is enlarged by selective removal of a further portion of the nozzle tip. 
           [0025]      FIG. 6  shows a further embodiment of a nozzle as contemplated by the present invention. 
           [0026]      FIG. 7  shows in cross section the nozzle embodiment of  FIG. 6  as taken along line  7 - 7 . 
           [0027]      FIG. 8  shows the nozzle embodiment of  FIGS. 6-7  wherein a discharge opening is created by selective removal of a portion of the nozzle tip. 
           [0028]      FIG. 9  shows the nozzle embodiment of  FIGS. 6-8  wherein a discharge opening is enlarged by selective removal of a further portion of the nozzle tip. 
           [0029]      FIG. 10  shows a further nozzle embodiment as contemplated by the present invention. 
           [0030]      FIG. 11  shows a side elevation of the nozzle of  FIG. 10 . 
           [0031]      FIG. 12  shows a cross-sectional view of the nozzle embodiment of  FIGS. 10 and 11 . 
           [0032]      FIGS. 13 and 14  show partial cross-sectional views of the tip portion of the nozzle of  FIGS. 10-12 . 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    In the figures, where like numerals identify like elements, there is shown a number of embodiments of a nozzle as contemplated by the present invention. In  FIG. 1 , the nozzle is generally designated by the numeral  10 . The nozzle  10  is molded from a plastic material and is secured at the end of a storage tube  12  or cartridge. The nozzle  10  and cartridge  12  combination are removably retained within a discharge gun  14 . These structures are commonly used in the application of caulk, condiments or similar viscous materials. The gun includes a trigger mechanism  16  that functionally causes movement of a piston (not shown) located on the end of a piston shaft  18 . The piston movement pushes against a moveable end wall (not shown) located within the cartridge  12 , to create a discharge pressure in the direction of the nozzle  10 . 
         [0034]    In  FIGS. 2-5  the nozzle  10  is shown separate from the cartridge. A removable tip  20  is provided on a tapered end  28  of a nozzle body  26  and a flange  22  is provided at a base end  24 , opposite of the tip  20 . The flange may be used to position the nozzle within an opening at the end of the tube or may be use to form the top end of the tube by being sealed thereto. Alternatively, the nozzle may be integrally molded with the body of the storage tube (or the like). The nozzle body  26  is hollow and tapers inwardly from the base end  24 . The passage defined by the hollow of the nozzle  10  is initially closed at the tapered end  28 . The removable tip  20  is formed by a projecting tab  30  and a series of removable sections A, B and C. The tab  30  projects from a blunt end wall  32  formed at the tapered end  28 . The removable sections A, B, C are aligned with the tab  30  and form a part of the wall of the tapered end  28 . The removable sections A, B, C are defined in part by two longitudinal tear lines  36 ,  38  that extend substantially in an axial direction along the narrowed portion  28  of the body  26 . The longitudinal tear lines  36 ,  38  start at the blunt end  32 . Two transverse lines  42 ,  44  are provided within the removable tip portion  20 . The transverse lines  42 ,  44  also form tear lines and connect to the longitudinal tear lines  36 ,  38  to define the removable sections A, B, C of the tip  20 . 
         [0035]    In  FIG. 2 , the tip  20  is shown in the as molded condition for the nozzle  10 . The tab  30  projects beyond the blunt end  32  and the tear lines  36 ,  38 ,  40 ,  42  define thinned or weakened portions of the body wall. In  FIG. 3 , the tapered end  28  of the body  26  is shown in cross section. The removable tip  20  may be separated from the adjacent sections of the wall along the longitudinal tear lines  36 ,  38 . The tear lines  36 ,  38  appear to diverge as they extend downwardly from the tab  30  along the wall toward the tapered portion  28 . However, the longitudinal tear lines may be parallel, may converge or may be non-linear, as desired. 
         [0036]    Initiation of the removal of the tip portion  20  is shown in  FIG. 4 . The tab  30  is broken away from the blunt end  32  and the tearing of the sidewall is started along the longitudinal tear lines  36 ,  38 . Section A is connected to the tip  30  and is first removed. Transverse tear line  42  allows for section A of the tip  20  to be separated from the remainder of the tip  20 , leaving an initial discharge opening  34 A. Viewing  FIG. 5 , the second section B may be removed to make a discharge opening  34 B that is relatively larger than that shown in  FIG. 4 . The sections A and B may be removed sequentially, one at a time, using the separate transverse tear lines  42 ,  44  or may be removed continuously by tearing straight along the longitudinal tear lines  36 ,  38  all the way to the second transverse tear line  44 , bypassing the first tear line  42 . Likewise, section C of the tip  20  may be removed to create a still larger discharge opening (not shown). Section C may be removed sequentially after first separately removing sections A and B, or by continuously removing the entire length of the tip  20 . An end tear line  46  at the relatively lower end of section C is provided to permit removal of section C and to create the larger opening. A startup tear line (not shown) may also be provided between the tab  30  and the nozzle end  32  to assist in the initial start-up. 
         [0037]    In  FIGS. 6-9  there is shown a further embodiment of a nozzle  110  having a removable tip  120  at the tapered end  128  of the nozzle body  126 . Opposite the tapered end  128 , the nozzle body  126  includes a retention flange  122  for mounting the nozzle within a storage tube (such as that shown in  FIG. 1 ). The removable tip  120  includes three sections A, B, C defined by longitudinal tear lines  136 ,  138 , transverse tear lines  142 ,  144  and end line  146 . The starting tab  130  projects from the end of tapered portion  128 . A start line  148  is formed between the tab  130  and the sidewalls of the tapered portion  128  of the nozzle  10 . The start line  148  makes it relatively easy for the tab  130  to initiate the separation of the tip  120  by bending the tab  130  relative to the tapered end  128 . 
         [0038]    In the cross section of  FIG. 7 , it can be seen that the longitudinal tear lines  136 ,  138  are formed in the side wall of the tapered portion  128  and are directed towards one another. The two lines  136 ,  138  are diametrically opposed. The position and direction of the longitudinal lines,  136 ,  138 , as shown, create a wide opening, such as opening  134 B in  FIG. 8 . The edges of the opening may be used to direct the material discharge against the work surface. Further, the three sections A, B, C of the removable tip  120  are arched along the length of the tip  120 . 
         [0039]    As shown in  FIGS. 8 and 9 , sections B and C of the tip  120  may be removed sequentially, by tearing along the transverse tear lines  142  and  144 .  FIG. 9  shows that the removal of segment C is made possible by separation along end line  146 . Removal of section C creates a relatively large opening  134 C, providing a greater discharge area than the opening  134 B in  FIG. 8 . In the drawings, the sections are shown as being substantially the same in height and width. However, the direction of the longitudinal tear lines  136 ,  138  (as well as lines  36 ,  38  in  FIGS. 2-5 ) and the relative position of the transverse tear lines  142 ,  144  and end line  146  (as well as lines  42 ,  44  and  46 ) may be changed as desired. Further, additional segments may be added within a longer tip portion  120  ( 20 ) or the size and number of the segments may be adjusted as desired. 
         [0040]    Another embodiment of the present invention is shown in  FIGS. 10-14 . In  FIG. 10 , a nozzle  210  is shown to have a structure similar to that of nozzle  110  of  FIG. 6 . However, the removable tip portion  220  within the tapered end  228  of the nozzle body  226 , is defined by a relatively flat surface extending between the longitudinal tear lines  236 ,  238 . The contours of the removable tip  220  are more particularly shown in  FIGS. 11 and 12 . In the elevation view of  FIG. 11 , the tab portion  230  is shown projecting from the tapered end  228 . In this side view, the tear lines  236 ,  238  are hidden, as are the removable sections A, B, C. In the cross section of  FIG. 12 , the relative positions of the sections A, B, C are shown within the side wall of the tapered end  228 . The tab  230  is connected to the first removable section A. Prior to removal, the tab  230  is connected to the side wall of the tapered portion  228 , with a corresponding starting line  248  being provided. Sections A and B are connected by tear line  242 . Sections B and C are connected by tear line  244 . Removable section C is connected to the side wall at its lower end along end line  246 . 
         [0041]    In  FIGS. 13 and 14 , the tapered end  228  of the nozzle  210  is shown in cross section with the removable sections A and B being removed in sequence. In operation, the tab  230  is broken away from the nozzle end  228  along the start line  248 . Pulling the tab  230  in the longitudinal direction, towards the base  224 , initiates the tearing action along the longitudinal tear lines  236 ;  238  and the separation of the first section A. In  FIG. 13 , the first section A has been separated from the remainder of the removable tip portion, by tearing along the transverse tear line  242 . Removal of section A results in a discharge opening  234 A being formed at the end of the tapered portion  228  of the nozzle  210 . If a larger opening is desired for increasing discharge flow, the second removable section B is also removed from the nozzle  210 . Removal of section B results in the formation of discharge opening  234 B, which has a length equal to the combined length of sections A and B. Further removal of section C (not shown) will result in an even larger discharge opening being formed. Removal of sections A and B can be performed on a continuous basis. Thus, during pulling of the tab  230 , the tip sections A and B can be torn away, along the longitudinal tear lines  236 ,  238  up to the position of transverse line  244 . Similarly, all three removable sections A, B, C can be torn away on a continuous basis by tearing along the longitudinal lines to end line  246 . 
         [0042]    The creation of multiple sections within the removable tear strip is to provide for a relatively easy way of defining the size of the discharge opening within the nozzle. In typical nozzles used for caulk or the like, a portion of the nozzle tip is cut from the end of the nozzle by means of a knife. Because the nozzle is typically tapered, increasing the amount of the tip that is cut off the nozzle serves to increase the size of the discharge opening. In the present idea, the opening of the nozzle and the adjustment in the size of the discharge opening is preferably achieved by the structures provided within the formed nozzle. 
         [0043]    The nozzle may be made of normally used materials for nozzle tips or the like, including low density polyethylene and linear low density polyethylene. The nozzle may be formed in an injection molding process. As shown in the drawings, the nozzle is formed as a separate component from the cartridge or tube ( 12 ). The base flange ( 22 ,  122 ) is formed to be retained within an opening provided at the top end of the tube. Alternatively, the nozzle may be integrally formed with the tube as part of the molding process. The nozzle is preferably formed in a single molding step, although multi-shot molding processes may be used. 
         [0044]    A fixed mold cavity is preferred, although movement within the mold structures during the formation or separation is possible. In addition, other structures may be added to those shown in the present embodiments as part of the molding process or otherwise. As illustrated, the tear lines are formed by grooves in the outside surface of the sidewall of the tapered portion of the nozzle. The grooves may be formed on the inside surface of the sidewalls by structures provided on the outside surface of the interior mold member or by some combination of structures on the interior mold portion and (the inside surface of) the outside member of the mold. The form and position of the thinned areas within the nozzle may vary for operation purposes or for ease of molding. In a preferred molding process, the line-of-draw of the inside and outside portions of the mold would be parallel to the longitudinal axis of the nozzle. Thus, clearance needs to be provided to permit this direction of movement during ejection of the molded part. 
         [0045]    The tear lines are preferably thinned areas within the nozzle wall, formed by appropriate structures within the mold cavity. It is contemplated that the ratio of the wall thickness of the tear lines with respect to the wall of the adjacent portions would normally be about ten (10) percent, although a range between about five (5) percent to fifteen (15) percent may be appropriate. Preferably, the maximum wall thickness of the nozzle is about 0.060 inches. The thickness of the tear lines preferably falls within the range of 0.006 inches to 0.008 inches. Changes in the material used to form the nozzle and variations in the operational pressures or materials to be dispensed may affect these measurements as well as the form of the nozzle. 
         [0046]    The present invention has been described and illustrated with respect to a number of exemplary embodiments thereof. It should be understood by those skilled in the art from the foregoing that various other changes, omissions and additions may be made therein, without departing from the spirit and scope of the present invention, with the scope of the present invention being described by the foregoing claims.