Abstract:
A container has a body, a spout fitment, and a cap. The body has a body opening. The spout fitment is within the body opening and secured by a backlocked mechanical engagement. The cap is threadingly mounted to at least one of the body and spout fitment. The cap has a sealing surface sealingly contacting a sealing surface of at least one of the body and spout fitment.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    Benefit is claimed of U.S. Patent Application Ser. No. 60/771,091, filed Feb. 6, 2006, and entitled “Pour Spout”, the disclosure of which is incorporated by reference herein as if set forth at length. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The invention relates to containers. More particularly, the invention relates to pour spouts for containers for liquid laundry detergent and the like. 
         [0003]    There has been an evolution in the configuration of containers for liquid laundry detergent, fabric softener, and the like. The dominant form of container is a wide mouth bottle having an attached spout with a drain-back trough and aperture (often identified as a drain back spout (DBS) configuration). In a typical group of container configurations and their methods of assembly, a bottle body, spout fitment, and cap are individually molded (e.g., of high density polyethylene (HDPE) for the body, polypropylene for the cap, and low density polypropylene (LDPE) for the spout fitment). Exemplary bottle body molding is via roto-molding whereas exemplary spout fitment and cap molding are by injection molding. An exemplary spout fitment includes the spout and a continuation of the spout defining the base and outboard wall of the trough. The fitment further typically includes a flange (e.g., extending outward at an upper end of the outboard extremity of the outboard wall). 
         [0004]    The spout fitment may be inserted through a mouth of the bottle body (e.g., so that an outer surface of the outboard trough wall, or another wall outboard thereof, engages the inner surface of the bottle neck). The spout fitment may be secured and sealed to the bottle body such as by spin welding. The bottle may be filled and the cap may be installed. Exemplary caps typically have either an externally threaded skirt for engaging an internally threaded portion of the fitment or an internally threaded skirt for engaging an externally threaded portion of the fitment or bottle body neck. With a typical externally threaded skirt, the cap includes an outwardly projecting flange above the skirt. Upon installation of the cap to the fitment, the flange underside contacts and seals with the fitment flange upper surface to seal the bottle. 
         [0005]    Various examples of bottles are shown in U.S. Pat. Nos. 6,923,341, 5,941,422, 5,566,862, and 5,603,787, the disclosures of which are incorporated by reference herein as if set forth at length. 
       SUMMARY OF THE INVENTION 
       [0006]    One aspect of the invention involves a container having a body, a spout fitment, and a cap. The body has a body opening. The spout fitment is within the body opening and secured by a backlocked mechanical engagement. The cap is threadingly mounted to at least one of the body and spout fitment. The cap has a sealing surface sealingly contacting a sealing surface of at least one of the body and spout fitment. 
         [0007]    The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0008]      FIG. 1  is a sectional view of a spout fitment and cap installed to a neck area of a bottle body. 
           [0009]      FIG. 2  is an enlarged view of the bottle body neck area of  FIG. 1 . 
           [0010]      FIGS. 3 and 4  are views of an assembly of the cap and spout fitment of  FIG. 1 . 
           [0011]      FIGS. 5-7  are views of the spout fitment mounted to the bottle body neck. 
           [0012]      FIG. 8  is a view of the bottle body neck. 
           [0013]      FIG. 9  is a sectional view of a second spout fitment and cap installed to a neck area of a bottle body. 
           [0014]      FIG. 10  is an enlarged view of the bottle body neck area of  FIG. 9 . 
           [0015]      FIG. 11  is a sectional view of a third spout fitment and cap installed to a neck area of a bottle body. 
           [0016]      FIG. 12  is an enlarged view of the bottle body neck area of  FIG. 11 . 
           [0017]      FIG. 13  is a sectional view of a fourth spout fitment and cap installed to a neck area of a bottle body. 
           [0018]      FIG. 14  is an enlarged view of the bottle body neck area of  FIG. 13 . 
           [0019]      FIG. 15  is a side view of the spout fitment and cap of  FIG. 13 . 
           [0020]      FIG. 16  is a view of the bottle body neck area circumferentially offset from the view of  FIG. 14 . 
           [0021]      FIG. 17  is a view of the spout fitment of  FIG. 13 . 
           [0022]      FIG. 18  is a second view of the spout fitment of  FIG. 13 . 
           [0023]      FIG. 19  is a view of a fifth spout fitment and cap installed to a neck area of the bottle. 
           [0024]      FIG. 20  is a sectional view of the spout fitment, cap, and bottle of  FIG. 20 . 
           [0025]      FIG. 21  is an enlarged view of the fitment, cap, and body of  FIG. 20 . 
       
    
    
       [0026]    Like reference numbers and designations in the various drawings indicate like elements. 
       DETAILED DESCRIPTION  
       [0027]      FIG. 1  shows a container  20  comprising the assembly of a bottle body  22 , a spout fitment  24 , and a cap  26  (which may serve as a measuring/dispensing cup). Each may be made as a unitary plastic molding. Exemplary bottle body material is high density polyethylene (HDPE). Exemplary spout fitment and cap material is polypropylene. 
         [0028]    The body  22  comprises a unitary combination of a base  30 , a sidewall  32  extending upward from the base, a shoulder  34  at an upper end of the sidewall, and a neck  36  extending upward from the shoulder to a rim  38  and defining an opening  40  ( FIG. 8 ) having a central longitudinal axis  500 . The bottle body has an interior surface  42  and an exterior surface  44 . A handle  46  may extend from the sidewall and the body interior may extend through the handle 
         [0029]    The spout fitment includes an inner wall  50  and an outer sidewall  52  joined by a lower wall  54  so as to define a trough  56 . One or more drain-back apertures  58  are opened to the trough (e.g., through the wall  54 ). The wall  50  has an upper end  60  defining a spout opening  62 . The upper end  60  peaks along a forward portion and dips along a rearward portion so that the opening  62  is asymmetric and defines a preferential direction for pouring. 
         [0030]    The cap  26  includes a sidewall  70 , a transverse web  72  at the upper end of the sidewall, and an outwardly projecting flange  74  spaced a short distance above a lower end  76  of the sidewall. 
         [0031]      FIG. 2  shows the spout fitment sidewall  52  as having an inboard surface  80  bearing an internal thread  82 . The sidewall has an external/outboard surface  84 . The sidewall has an upper end  86  and a lower end  88 . A circumferential array of hook barbs  90  is formed along the sidewall extending upward from the lower end  88 . Each barb  90  has a proximal junction/hinge  92  with the remainder of the sidewall and an upper/distal end surface  94 . As is discussed in further detail below, the surface  94  engages an adjacent surface of the bottle body to retain the spout fitment in an installed condition. 
         [0032]      FIG. 2  further shows the bottle body neck as having an intermediate portion  100  along which the body interior surface contacts the spout fitment sidewall exterior surface  84 . The neck further includes an upper portion  102  extending to the rim  38  and radially outwardly offset from the portion  100  (e.g., at a shoulder  104 ). Similarly, a lower portion  106  is offset (e.g., by a shoulder  108 ). The barb surface  94  contacts the bottle interior surface  42  along the shoulder  108  to resist upward extraction of the spout fitment. 
         [0033]    A lower portion  120  of the cap sidewall  70  depends below the flange  74  and bears an external thread  122  engaging the internal thread  82 . Depending from the underside of the flange are an inboard annular projection  130  having a lower end  132 , an intermediate annular projection  134 , and an outboard annular projection  136 . A channel  138  is defined between the projections  134  and  136 . In an installed condition, a portion of the bottle body neck near the rim  38  is sealingly captured in the channel  138 . 
         [0034]    In an exemplary method of assembly, the cap is fully or partially screwed onto the spout fitment. The spout fitment is then inserted into the bottle neck. In an initial stage of insertion, the barbs  90  are accommodated by the radially outwardly offset upper portion  102  of the neck. This accommodation permits further insertion to flex the barbs inward (e.g., compressing the gap between the barb and the sidewall and/or flexing the sidewall  52 ). This compression may occur in a number of ways, the portion  102 , near the rim  138  may flex a distal portion of the barb. Additionally, the inner surface of the interior surface of the bottle at the shoulder  104  may inwardly flex a proximal portion and the sidewall  52 . 
         [0035]    Eventually, the barbs  90  pass over the portion  100  and relax into the locking engagement described above. Dimensions may be such that interference contact between the surface  84  and the bottle interior surface along the portion  100  provides a sealing under normal loads associated with pouring. 
         [0036]    Advantageously, in a storage condition with the cap installed, there is direct cap-to-bottle body sealing. Exemplary sealing is caused by the interaction of the projections  134  and  136  with the bottle body rim (shown interfering in  FIG. 2  due to artifacts of solid modeling). This interaction may upwardly flex the flange  74  to maintain effective sealing bias. 
         [0037]    There may also be a sealing contact between the cap and spout fitment. In the exemplary embodiment, this contact is between the projection end  132  and sidewall upper end  86 . 
         [0038]    In one exemplary installation operation, the cap is only partially screwed on to the spout fitment (e.g., so that there is a gap between the projection end  132  and the sidewall upper end  86 ). Insertion of the spout fitment is in this condition. This may ease insertion due to a reduced need to flex the flange in the final stage of insertion. If the bottle was not filled prior to insertion, the cap may be unscrewed and removed so that the bottle may then be filled. The cap may be further tightened (screwed back on) to a more fully installed condition (e.g., with a final stage of flex in the flange as the body neck rim portion is accommodated in the channel  138 ). There may, advantageously, be a relatively lighter engagement between the projection end  132  and sidewall end  86 . 
         [0039]    Angular registration and retention of the spout fitment may be provided.  FIGS. 3 and 4  show a segmented flange  140  extending radially outward from the spout fitment sidewall at the upper end  86 . In the exemplary embodiment, the segments of the flange  140  are aligned with gaps  142  between the barbs  90 . The exemplary flange  140  has a series of gaps  144  and  146 . There are a plurality of the gaps  144  of equal circumferential extent. The single gap  146  is of a smaller extent. The exemplary gap  146  is at the rear of the spout fitment. The bottle body neck has an inward projection  150  ( FIGS. 7 and 8 ) which may span the junction between the upper portion  102  and shoulder  104 . Upon spout fitment insertion, engagement of the flange  140  to the bottle interior surface at the shoulder  102  resists further insertion beyond the installed position thus longitudinally retaining the spout fitment. Engagement between the gap  146  and the projection  150  resists rotation of the spout fitment. 
         [0040]    The second embodiment is otherwise similar except for the cap flange and its interaction with the spout fitment and bottle. The flange  74  is replaced by a series of a lower flange  220 , an intermediate flange  222 , and an upper flange  224 . There may be sealing engagement between the underside of the flange  220  and the sidewall upper end  86 . There may be sealing engagement between the underside of the flange  222  and the bottle body rim  38 . The flanges are positioned so that the flange  222  is relatively more deformed by its engagement with the bottle body than the flange  220  is by its engagement with the spout fitment sidewall. In a fully installed condition, an outboard portion of the flange  222  may be relatively substantially deflected toward the flange  224 . The flange  224  may serve as a backstop essentially preventing further deformation of the flange  222  beyond a maximum point. This may prevent over-tightening damage to the flange  222 . 
         [0041]    The third embodiment also modifies the cap flange. The flange  320  has an inboard projection  322  which may be similar to that of the first embodiment. At an outboard end of the flange  320  there is a stepped depending skirt having a distal portion  324  extending to a rim  326 . A proximal portion  328  has a small downward projection  330 . A combined sealing engagement may involve abutting of the projection  330  with the bottle rim  38  and inwardly compressive engagement between a tapering interior surface  332  and the bottle exterior surface along the portion  102 . 
         [0042]    In the fourth embodiment, the cap has lower and upper flanges  420  and  422 . The underside of the flange  420  seals with the bottle rim and is deflected toward the upper flange  422  which serves as a backstop. Additionally, the barbs  440  are solid (e.g., as opposed to hook-like barbs with an outboard portion capable of flexing toward an inboard portion). The solid barbs increase sidewall rigidity. Accordingly, to ease sidewall insertion, there may be thinning slots  442  between the barbs. 
         [0043]    In the fifth embodiment of  FIGS. 19-21 , the interlocking feature of the neck is external and that of the spout fitment is internal. With a blow-molded bottle body, this allows greater precision in forming the body&#39;s interlocking and sealing features than if such features were internal. 
         [0044]      FIG. 21  shows the bottle body neck  520  extending to an upper rim  522 . An upper portion  524  of the neck  520  proximal of the rim  522  is positioned radially between an outboard/outer sidewall  526  and an intermediate sidewall  528  of the spout fitment  530 . The walls  526  and  528  are joined by an upper rim flange  532 . The underside  534  of the flange  532  seals against the rim  522 . 
         [0045]    There may also be a radial sealing between the spout fitment and neck. In the exemplary implementation, an outboard surface  536  of a protuberance  538  of the neck at the rim  522  sealingly engages an inner/inboard surface  540  of the outer sidewall  526 . The spacing between the intermediate and outer sidewalls  528  and  526  at the neck protuberance  538  may be such as to provide a radial interference fit for sealing. 
         [0046]    The backlocking of the spout fitment to the neck is provided by interaction of an outward radial projection  550  on the outer surface  552  of the neck  520  cooperating with an inward radial projection  554  of the surface  540 . The exemplary projections  550  and  554  are full annulus projections. Shown interfering, the projection  550  has an underside  556  and the projection  554  has an upper surface  558  sharply angled (e.g., close to radial) to provide mechanical backlocking. To facilitate installation, the upper surface  560  of the projection  550  and the underside  562  of the projection  554  are shallower to provide a camming action as the spout fitment is downwardly inserted for installation to the neck. 
         [0047]    In the exemplary implementation, the underside  570  of a cap flange  572  may seal against the upper surface  574  of the flange  532  when the cap is fully installed. An exemplary intermediate wall  528  may be otherwise similarly positioned and configured to the outer walls of the other fitments and may similarly cooperate with the cap. The inner wall  576  may also be similarly configured to that of the other embodiments. 
         [0048]    To maintain spout fitment orientation in the installed condition, the exemplary outer wall  526  includes a recess  528  ( FIG. 19 ) which receives a projection  580 .  FIG. 20  shows the exemplary projection  580  as a local elevation in the upper wall  582  of a hollow flange  584 . The flange  584  may serve as a transfer ring, allowing automated equipment to handle the bottle by supporting the underside  586  of the lower wall  588  of the flange  584 . The bottle body may be supported via the flange  584  during fill and then the spout fitment/cap installation. Such support isolates the portion of the bottle body below the flange  584  from the pressures/forces of insertion. Thus, insertion forces may be higher than if the bottle body were supported only by its base (and with reduced chances of damage, overflow, and the like). 
         [0049]    Various implementations may have one or more of various advantages. One group of advantages relate to elimination of welding or adhering of the spout fitment to the bottle body. In addition to the economy of a saved step, this may facilitate delivery of the liquid before attaching the spout fitment to the bottle body which may allow more efficient processing (e.g., including higher flow delivery or less precisely aimed delivery through an opening in the bottle body larger than the spout opening). The spout fitments and caps may be delivered to the bottler as units and installed in units, thereby easing installation. Other potential advantages include weight reduction and reduced intrusion of the spout fitment into the bottle body (thereby permitting higher fill levels). Other potential advantages include improved sealing. Finally, there may be greater flexibility in aesthetics by permitting relatively easy use of differently-styled spout fitments with a given bottle body or differently styled bottle bodies with a given spout fitment. 
         [0050]    One or more embodiments of the present invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, when implemented in the reengineering of an existing container configuration, details of the existing configuration may influence or dictate details of any particular implementation. Accordingly, other embodiments are within the scope of the following claims.