Container with molded bag on valve assembly

The present disclosure provides a container and a process for producing the container. In an embodiment, the process includes placing a sleeve bag on valve assembly (SBoV) in a blow mold apparatus. The blow mold apparatus has two opposing and movable molds. The SBoV has a valve seat. The process includes extending a parison of flowable polymeric material around the SBoV and between the opposing molds. The process includes moving the opposing molds to a closed position and pressing an upstream portion of the parison against the valve seat. The process includes blow molding a downstream portion of the parison into a container-shape within the closed mold. The process includes forming a container with the valve seat melt bonded to a neck portion of the container.

BACKGROUND

The present disclosure is directed to a dispenser for pressurized material and a dispenser for propellant-free pressurized material in particular.

Known are sleeve bag-on-valve (SBoV) dispensing systems that utilize an elastic sleeve disposed around a fluid-filled inner bag. Actuation of the valve releases pressure and the elastic sleeve contracts expelling the fluid contents from the bag without a propellant. A drawback of conventional SBoV systems is the need for an outer support container. Conventional SBoV support containers typically top-load the empty SBoV through the neck of a container and subsequently secure the SBoV to the container neck. Conventional support containers are typically metal with the valve seat of the SBoV assembly attached by way of crimping, threaded screws, or welded to the top opening of the container. Once secured to the neck, the sleeve-on-bag portion of the SBoV hangs freely from the neck and into the container interior. The SBoV is then filled under pressure through the valve with fluid composition.

The art recognizes the need for alternate ways to secure the SBoV assembly to the support container, and, in particular, SBoV installment that avoids insertion through the top opening of the support container.

SUMMARY

The present disclosure provides a dispenser for pressurized material and a process for producing a dispenser for pressurized material.

The present disclosure provides a process. In an embodiment, the process includes placing a sleeve bag on valve assembly (SBoV) in a blow mold apparatus. The blow mold apparatus has two opposing and movable molds. The SBoV has a valve seat. The process includes extending a parison of flowable polymeric material around the SBoV and between the opposing molds. The process includes moving the opposing molds to a closed position and pressing an upstream portion of the parison against the valve seat. The process includes blow molding a downstream portion of the parison into a container-shape within the closed mold. The process includes forming a container with the valve seat melt bonded to a neck portion of the container.

The present disclosure provides a container. In an embodiment, a container is provided and includes a neck portion, a body portion, and a bottom portion defining an interior chamber. The container is composed of a polymeric material. The container includes a sleeve bag on valve assembly (SBoV) comprising a valve seat. A portion of the SBoV is located in the container interior. The valve seat is melt bonded to the neck portion.

The present disclosure provides another process. In an embodiment, a process is provided and includes placing a sleeve bag on valve assembly (SBoV) in an injection mold apparatus. The injection mold apparatus has two opposing and movable molds. The SBoV has a valve seat. The process includes moving the opposing molds to a closed position. The two opposing molds define a flowpath in the closed position. A portion of the valve seat is located in the flowpath. The process includes injecting flowable polymeric material into the flowpath, and overmolding a portion of the valve seat with the injected flowable polymeric material. The process includes forming a container part, wherein the valve seat is melt bonded to the container part.

The present disclosure provides another container. In an embodiment, a container is provided and includes a container part composed of a polymeric material, the container part having a proximate end and a distal end. The container includes a sleeve bag on valve assembly (SBoV) comprising a valve seat. The valve seat is melt bonded to the proximate end of the container part. The distal end of the container part has an exposed edge and a closure member at the distal end. The container includes a body portion having a reciprocal closure member at a reciprocal exposed edge. The closure member and the reciprocal closure member are matingly engaged along the exposed edges to attach the container part to the body portion to form a closed container.

An advantage of the present disclosure is a SBoV support container made of a moldable polymeric material that can be formed into a variety of consumer-appealing shapes and configurations for SBoV support.

An advantage of the present disclosure is a container for dispensing a fluid material under pressure and with no propellant. The spray system of the present disclosure can deliver a propellant-free aerosol spray of product, such as a fluid material.

DETAILED DESCRIPTION

The present disclosure provides a process. In an embodiment, a process is provided and includes placing a sleeve bag on valve assembly (SBoV) in a blow molding apparatus. The blow molding apparatus has two opposing and movable container mold halves. The SBoV has a valve seat. The process includes affixing the SBoV to the blow molding head. The process includes extending a parison of flowable polymeric material around the SBoV and between the opposing mold halves. The process includes moving the opposing molds toward each other to a closed position. In the closed position, the opposing molds press an upstream portion of the parison against the valve seat. The process includes blow molding a downstream portion of the parison into a container-shape within the closed molds. The process includes forming a container with the valve seat melt bonded to a neck portion of the container.

1. Blow Molding Apparatus

The process includes placing a sleeve bag on valve assembly (SBoV) in a blow molding apparatus. As shown inFIGS. 1-3 and 5, blow molding apparatus10includes a die head12, and opposing container molds14,16.

Hereafter, the container molds14,16may be referred to collectively as “container molds,” or “molds.” Each mold is cast as a container half, the two molds, when moved to a closed position, forming the shape of a closed container having a neck portion, a body portion, and a bottom portion. The blow molding apparatus10includes suitable structure and mechanism for moving the two molds14,16toward and away from each other.FIGS. 1 and 2show the molds14,16away from each other in an open position. Upstream of the die head12is an extruder (not shown), or multiple extruders, which are in fluid communication with the die head12. The extruder provides flowable polymeric material for discharge through the die head12.

2. Sleeve and Bag on Valve Assembly

A sleeve bag on valve assembly100(“SBoV”) is releasably attached to the die head12as shown inFIGS. 1-3. Nonlimiting attachments for the SBoV to the die head12include pneumatic clamps, hydraulic clamps, magnets (electro-magnets), and combinations thereof.

Best shown inFIG. 1, the SBoV100includes a valve housing102, a valve seat104, a lip portion105, an optional core tube106, a bag108, and a sleeve110.

The valve housing102is configured to hold a valve112, as shownFIG. 1.FIG. 1shows a nonlimiting example of a spring valve. The valve housing102is securely attached to the valve seat104. Secure attachment between the valve housing102and the valve seat104can occur by way of (i) crimping the valve seat104onto the valve housing102, (ii) adhesive attachment between the valve housing102and the valve seat104, and (iii) a combination of (i) and (ii).

The valve seat104is composed of a rigid material. Nonlimiting examples of suitable material for the valve seat104include metal (steel, aluminum) and polymeric material.

The lip portion105is composed of a rigid material. Nonlimiting examples of suitable material for the lip portion105include metal (steel, aluminum) and polymeric material.

The SBoV100may or may not include the core tube106. In an embodiment, the SBoV100does not have the core tube.

In an embodiment, the SBoV includes core tube106. As shown inFIG. 1, the core tube106is present in the interior of the bag108, with the bag108surrounding the core tube106. The bag108is a flexible film structure composed of a polymeric material. The bag108can be a single layer flexible film or a multilayer flexible film. Nonlimiting examples of suitable polymeric material for the bag108includes propylene-based polymer, ethylene-based polymer, and combinations thereof. The bag108may include a barrier layer such as a metal foil film. The barrier layer may be laminated to the flexible film.

In an embodiment, the outer surface of the bag108has a low coefficient of friction (COF) with respect to the sleeve110to allow easy filling of the bag108.

In an embodiment, the bag108is a multilayer film having a thickness from 100 micrometers (μm), or 200 μm to 225 μm, or 250 μm and the multilayer film is chemically resistant and a barrier to the fluid composition it contains. In a further embodiment the bag108is a multilayer film and includes an oxygen barrier layer, a carbon dioxide barrier layer, a water barrier layer, and combinations thereof.

The core tube106can be hollow or can be solid. The core tube106can be fluted, pleated or channeled axially to promote movement of product into and through the port114.

The core tube106can be composed of propylene-based polymer or ethylene-based polymer such as HDPE. Alternatively, the core tube106can be composed of amorphous polyester such as PETG or other suitable engineering thermoplastic.

In an embodiment, the core tube106is composed of a non-collapsing material.

The core tube106can have a uniform diameter along its length. Alternatively, the core tube106can be tapered. In an embodiment, the core tube106is tapered and the diameter of the core tube106gradually increases, moving from the proximate end (or top end) of the core tube to the distal end of the core tube. In another embodiment, the distal end of the core tube is rounded to reduce wear and/or prevent puncture of the bag108.

The core tube106can be integral to, or can be a separate component attached to, the valve housing102. In an embodiment, the core tube106is a component separate from the valve housing102and the core tube106is hollow. A hollow top end109of the core tube106extends through the opening of the bag108as shown inFIG. 1. The core tube106includes a port114and a port head118. The port114is below the hollow top end109and in fluid communication with the hollow top end109. The open end of the bag108is placed between a gasket116and the port head118. The hollow top end109attaches to a valve channel120on the underside of the valve housing102to place the port114in fluid communication with the valve112. The gasket116sandwiches the bag opening between the port head118and the valve housing102to hermetically close, or otherwise securely seal, the bag108to the valve housing102.

In a further embodiment, the secure attachment between the top end109and the valve channel120is by way of a fixed and secure snap fit. Materials of construction for the top end109can be different than for the core tube106. For example, INFUSE™ ethylene/alpha-olefin multi-block copolymer may be used. Also, in an embodiment, the bag108can be heat sealed to the top end109to provide hermetic seal and then secured into the valve channel120.

The sleeve110is a tube-like structure made of an elastomeric material. An “elastomeric material,” as used herein, is a material that can be stretched with the application of stress to at least twice its length and after release of the stress, returns to its approximate original dimensions and shape showing good recovery. The elastomeric material may, or may not, be a vulcanized or cross-linked or grafted material.

In an embodiment, the elastomeric material is vulcanized.

In an embodiment, the elastomeric material has a linear modulus vs elongation relationship. The elastomeric material exhibits a small amount of creep or stress relaxation sufficient to provide a shelf life from 3 months, or 6 months to 1 year for the fluid composition.

In an embodiment, the elastomeric material comprises nano-sized organoclays or nanoclays and as such in an elastomeric composite or elastomeric nanocomposite, for example.

The sleeve110can expand (and contract), or otherwise elongate, in a radial direction and an axial direction.

In an embodiment, the sleeve110expands and contracts in the radial direction.

The sleeve110is sized and shaped to contain the bag108and to exert pressure on bag108when the bag108is filled with fluid composition (or fluid product) to be dispensed. The sleeve110may or may not have a uniform thickness. The sleeve110may or may not impart uniform pressure during the discharge cycle of fluid composition from the bag108.

In an embodiment, the sleeve110provides even pressure during the entire dispensing cycle (bag filled with fluid composition to bag emptied of fluid composition). The sleeve110also provides positive pressure on the bag after dispensing ensuring complete discharge of all, or substantially all, fluid composition from the bag108. The sleeve110may or may not be open on top and bottom. The elastic sleeve110may be longer than the bag104to ensure emptying of all the contents in bag108.

The sleeve110is thick enough to apply a force that is sufficient to expel product from the bag108and through the valve112. When the valve112is actuated, the sleeve110uniformly contracts to push fluid composition from the bag108, through the port114and out through the valve112. In an embodiment, the sleeve110has a thickness when unexpanded, or otherwise unstretched, and denoted as “sleeve wall thickness.” The sleeve wall thickness is from about 1.5 mm, or 2.0 mm, or 3.0 mm, or 5.0 mm, or 7.0 mm to 10.0 mm, or 15.0 mm, or 20.0 mm.

In an embodiment, the sleeve110is made of an elastomeric material that has an elongation from greater than 200%, or 250%, or 300% to 400%, or 500%, or 550%, or 600%, or 700%.

In an embodiment, the elastomeric material has a tensile modulus at 200% elongation of at least 2 mega pascals (MPa), or 3 MPa, or 5 Mpa to 8 Mpa, or 10 Mpa, or 12 Mpa, or 14 MPa or higher.

In an embodiment, the sleeve110is extended (stretched) to from 300% elongation, or 400% elongation to 500% elongation. In an embodiment, the elastomeric material can have a modulus that is 20 MPa or higher at 400% elongation. The sleeve110may also exhibit a relaxation lower than 25% change in tensile modulus at 200% elongation within one year and/or an average creep rate lower than 4 mm/day.

In an embodiment, a clip122secures the sleeve110to the valve housing102as shown inFIG. 1.

In an embodiment, the minimum diameter of the core tube106encircled by the empty bag108combined (SBoV) is greater than the diameter of the unstretched sleeve110. With this configuration, the sleeve110provides constant positive pressure onto the bag108ensuring uniform distribution of the product from the bag until full and complete expulsion of all, or substantially all, product (fluid composition) from the bag108.

In an embodiment, the core tube106and empty bag108(the SBoV) have a combined minimum diameter that is from 10%, or 15%, or 20% to 25%, or 30%, or 40%, or even 50% greater than the diameter of the unexpanded sleeve110. In this way, the sleeve110applies constant positive pressure upon the bag108.

In an embodiment, the sleeve is longer than the bag on core/valve to ensure positive pressure is exerted on the bottom end of the bag sufficient to expel product at the bottom of the bag up and through the port114and through the valve112.

The fluid composition (for dispensing from the bag108) is a substance that is fluidly deliverable when dispensed under compressive pressure by the sleeve110, the fluid composition flowing out of the bag108under pressure when the valve112is opened. The fluid composition can be a liquid, a paste, a foam, a powder, or any combination thereof. Nonlimiting examples of suitable fluid compositions include:food products, such as mayonnaise, ketchup, mustard, sauces, desserts (whipped cream), spreads, oil, pastry components, grease, butter, margarine, sauces, baby food, salad dressing, condiments, beverages, syrup;personal care products such as cosmetics, creams, toothpaste, lotions, skin care products, hair gels, personal care gel, liquid soap, liquid shampoo, sun care products, shaving cream, deodorant;medicaments, pharmaceutical and medical products such as medications (including dosage packages) and ointments, oral and nasal sprays;household products such as polishes and glass, bathroom and furniture and other cleaners, insecticides, air fresheners; andindustrial products such as paints, lacquers, glues, grease and other lubricants, oil sealants, pastes, chemicals, insecticides, herbicides, and fire extinguishing components.
3. Blow Molding

The term “blow molding,” as used herein is a manufacturing process by which hollow parts composed of flowable polymeric material are formed. A description of the blow molding process may be found inBlow Molding Handbook, Rosato, Rosato and DiMattia, 2nded, Hanser, Munich, (2004). The blow molding process begins with heat, or otherwise melting, polymeric material into a flowable state and forming it into an annular structure of flowable polymeric material known as a parison. The annular parison (hereafter “parison”) is open at the end proximate to the die head. The parison is initially open at the end opposite of the die head. In one embodiment, compressed gas (such as compressed air) can pass from the die head into the interior of the parison to maintain the opening at the end of the parison opposite the die head. In another embodiment, the compressed gas (such as compressed air) is introduced in the interior volume of the parison at the open end of the parison opposite the die head and maintains the annular shape of the flowable polymeric material. InFIGS. 1-3, the die head12includes an annular flowpath18through which flowable polymeric material20flows. The flowable polymeric material20flows downward, or is otherwise drawn downward as shown by downward arrows A inFIG. 2. Those skilled in the art will recognize that the molten polymeric material may exhibit die swell, which may increase both the thickness and the diameter of the parison as the molten polymeric material travels away from the die head. Materials such as high density polyethylene commonly utilized in blow molding applications will exhibit considerable degree of die swell, while materials such as polycarbonate will exhibit a smaller degree of die swell.

In an embodiment, the polymeric material is an olefin-based polymer. Nonlimiting examples of suitable olefin-based polymer include propylene-based polymer and ethylene-based polymer. Nonlimiting examples of suitable propylene-based polymer include propylene-based polymer (including plastomer and elastomer), random propylene copolymer, propylene homopolymer, and propylene impact copolymer, blends of propylene-based polymer with other olefin-based polymer such as blends with ethylene-based polymer, polyethylene elastomer, and thermoplastic olefin (TPO).

Nonlimiting examples of suitable ethylene-based polymer include ethylene/C3-C10α-olefin copolymers (linear or branched), ethylene/C4-C10α-olefin copolymers (linear or branched), high density polyethylene (“HDPE”), low density polyethylene (“LDPE”), linear low density polyethylene (“LLDPE”), medium density polyethylene (“MDPE”), and blends of ethylene based polymers.

The polymeric material may include optional additives such as filler, pigment, stabilizer, antioxidant, and combinations thereof.

The polymeric material may be a single layer structure or a multilayer structure. The polymeric material may be biaxially oriented or monoaxially oriented. When the polymeric material is a multilayer structure, the multilayer structure may be coextruded or laminated.

As shown inFIG. 2, the process includes extending a parison22of the flowable polymeric material20around the SBoV100and between the opposing molds14,16. The parison22moves downward from the opening in the die head12. The downward movement continues such that the parison22extends beyond, or otherwise past, the bottom of the SBoV100. The extension and/or movement of the parison film can be by way of extrusion—(i) a pushing force of additional flowable polymeric material through the annular flowpath18, (ii) stretching the parison22by pulling a lower portion of the parison downward (i.e., stretch blow molding), and (iii) a combination of (i) and (ii).

FIG. 2is a sectional view showing the parison22of flowable polymeric material20completely surrounding the SBoV100. A pressurized gas (such as compressed air), shown by arrows B inFIG. 2may be optionally introduced into the mold chamber through inlets19and/or from below as shown inFIG. 2in order to maintain the annular shape and structure of the flowable polymeric film.

Once the parison22of the flowable polymeric material20has been extended around the SBoV100, between the opposing molds14,16and beyond, or otherwise past, the bottom of the SBoV100, the flow of the polymeric material is paused, halted, or otherwise interrupted such that flowable polymeric material20is no longer flowing from the die head12.

It is understood the present process is intermittent blow molding or reciprocating blow molding rather than continuous blow molding. In one embodiment, the flow of polymeric material is halted by stopping the screw rotation in the extruder. Alternatively, the flow of polymeric material is halted by allowing the extruder screw to reciprocate while continuing to rotate, known as reciprocating blow molding. In another embodiment, the flow of polymeric material may be halted by allowing the screw to continue to rotate while simultaneously filling a cylinder or accumulator positioned between the extruder and the die head, known as accumulator blow molding.

The process includes moving the opposing molds14,16toward each other to press an upstream portion23of the parison22against the valve seat104. In an embodiment, the opposing molds14,16move to a closed position, as shown by arrows D inFIG. 3, to impart pressure (and optional heat) onto the upstream portion23of the parison22adjacent to the valve seat104.FIG. 3shows the molds14,16in the closed position. Parison22is in the melt state (or is in a flowable state) and is malleable. The force of the closed molds14,16push the upstream portion23into intimate contact with the valve seat104, shaping and forming the malleable flowable polymeric material20onto and around the valve seat104.

In an embodiment, the closed and opposing molds14,16press the parison22of flowable polymeric material20(i) against, (ii) around, and (iii) against and around the lip portion105as shown inFIG. 3. In this way, the radial inward force imparted by the molds14,16onto the lip portion105overmold the flowable polymeric material20onto and around the lip portion105.FIG. 4shows flowable polymeric material20pressed and shaped around the lip portion105. Upon solidification of the flowable polymeric material20, the lip portion105is immobilized in the solid polymeric material, forming a melt bond24between the polymeric material and the lip portion105and/or the valve seat104.

The term “melt bonded,” as used herein, refers to a polymeric material that is overmolded, in the melt state, onto (and/or around) a structure, and the resultant adhesion between the structure and solid state polymeric material. As shown inFIG. 4, the flowable polymeric material20solidifies and adheres to the lip portion105. In an embodiment, the pressing and blow molding procedure surrounds the lip portion105, immobilizing the lip portion105in solid polymeric material20for firm and rigid adhesion.

In an embodiment, the upstream portion of the parison22has a thickness that is greater than the thickness of the downstream portion. Additional polymeric material in the upstream portion ensures sufficient polymeric material is available to secure valve seat104and/or lip portion105firmly in place and/or provide greater rigidity and strength to the container near the valve. Parison thickness can be controlled by controlling die gap flow.

The process includes moving the opposing molds14,16toward each other to a closed position to press the downstream portions20of the parison against each other. At point E (FIG. 3), the closed molds14,16seal together opposing sides of the parison22, closing the bottom portion to create a closed tube inside the mold halves.

In an embodiment, the process includes blow molding a downstream portion of the parison into a container-shape within the closed molds14,16. A needle is utilized to pierce the closed parison and a pressurized gas (such as compressed air), shown by arrows C inFIG. 3, is introduced into the mold chamber as shown inFIGS. 2-3. A downstream portion26of the parison22is blow molded against the inner surfaces of the molds14,16. The parison22is malleable and shapeable because the polymeric material20is flowable. The pressurized gas forces, or otherwise moves, the parison22radially outward to impinge against the interior surfaces of each mold14,16. The parison22takes the shape that is cast upon the interior surfaces of molds12,14. The mold surface temperature may be controlled by circulating a fluid, such as air, water, glycol or mixtures of water and glycol through cooling channels installed in the molds. The gas inflation pressure is maintained such that the polymer in contact with the mold surface is provided sufficient time to cool to such temperature that the polymer becomes sufficiently rigid to maintain the shape of the formed article. Once the polymer has sufficiently cooled, the gas inflation pressure is removed and the needle retracted from the bottle. The mold is opened, valve112is released from the die head and the container with SBoV is removed.

In an embodiment, the pressing procedure (of the upstream portion23) and the blow molding procedure (of the downstream portion26) are performed simultaneously, or substantially simultaneously (i.e., within 0.1 seconds, or 0.5 seconds, or 1.0 second, or 1.5 seconds, or 2.0 seconds) with respect to each other.

The process includes forming a container30with the valve seat104of the SBoV100melt bonded to a neck portion32of the container. The opposing molds12,14move from the closed position to the open position as shown by arrows F inFIG. 5. The formed blow molded container30is removed from the blow mold apparatus10. The excess polymeric material28is removed from the formed container30in a subsequent operation.

5. Blow Molded Container

The process produces container30as shown inFIGS. 5-8. In an embodiment, a container30includes a neck portion32, a body portion34, and a bottom portion36. The container30is closed and defines an interior chamber38. The container30is composed of a polymeric material. The container includes the SBoV100extending into the interior chamber. The valve seat104and/or the lip portion105, is melt-bonded to the neck of the container.

The blow molding process forms a single-piece container30. The neck portion32, the body portion34, and the bottom portion36form a single unitary and integral component. The container30that is an integral component is composed of the previously flowable polymer material that was the parison and is cooled and solidified to a non-flowable solid state polymeric material in the container30.

In an embodiment, a lip portion105of the valve seat104is melt bonded to the neck portion32. The polymeric material of the neck portion32immobilizes the valve seat104and/or the lip portion105and permanently seals, or otherwise permanently bonds, the SBoV100to the container30.

The bag on valve portion of the SBoV extends freely into the interior chamber38as shown inFIGS. 6-7.

FIGS. 6 and 7demonstrate how the bag108of the SBoV100is filled with fluid composition through the valve112. Fluid composition is introduced with positive pressure through the valve112and into the bag108.FIG. 7shows sleeve110stretched with the bag108holding a fluid composition and sleeve110applying the pressure.

The present container30maintains its shape, not collapsing or changing dimensions or appearance as the fluid composition is expelled from the bag (creating internal vacuum). In an embodiment, the average wall thickness, T, for the container30is from 0.075 mm, or 0.1 mm, or 0.15 mm, or 0.2 mm to 1.0 mm, or 1.5 mm, or 2 mm, or 3 mm.

In an embodiment, a valve cap40is attached to the valve112as shown inFIG. 8. Valve cap40enables a user of the container30to direct the spray (as well as determine the spray pattern and/or determine the spray flow rate) of the fluid composition42in a desired direction.

In an embodiment, the interior chamber38(shown inFIG. 7) has a volume from 0.050 L, or 0.1 L, or 0.2 L, or 0.3 L, or 0.4 L, or 0.5 L, or 0.6 L, or 0.75 L, or 1.0 L, or 1.5 L, or 2.5 L, or 3.0 L, or 3.5 L, or 4.0 L, or 5.0 L, or 10.0 L to 20.0 L, or 25 L, or 28.5 L. In a further embodiment, the volume of the filled bag108is from 5%, or 10%, or 15% to 20%, or 25%, or 30% less than the volume of the container30.

FIG. 8shows bottom portion36supporting the container30during discharge of a fluid composition42. The container30provides sufficient strength and rigidity to maintain, or otherwise hold, SBoV100and container30, in a vertical position, or in a substantially vertical position. Therefore, in an embodiment, the container30is “a stand-up container.”

After complete, or substantially complete discharge of the fluid composition, the bag108can be re-filled with fluid composition through the valve112. In an embodiment, the SBoV100of dispenser30can be refilled one time, or two times, or three times, to four times, or five times or more.

The valve112can also have various types of actuators or spray caps fastened to it in order to deliver product in the desired manner including but not limited to fluid stream, gel, lotion, cream, foam, fluid spray, or mist.

6. Injection Mold Apparatus

The present disclosure provides another process. In an embodiment, a process includes placing a sleeve bag on valve assembly (SBoV) in an injection mold apparatus. The injection mold apparatus has two opposing and movable molds. The SBoV has a valve seat. The process includes moving the opposing molds toward each other to a closed position. In the closed position, the two opposing molds define a flowpath. A portion of the valve seat is located in the flowpath. The process includes injecting flowable polymeric material into the flowpath and overmolding a portion of the valve seat with the injected flowable polymeric material. The process includes forming a container part, wherein the valve seat is melt bonded to the container part.

The term “injection molding,” and like terms, refers to a process for producing parts by injecting material into a mold. Polymeric material is fed into a heated extruder, the polymeric material heated to a flowable state, and forced into a mold cavity. The flowable polymeric material cools and hardens to a solid and to the configuration of the cavity.

InFIGS. 9-11, SBoV100is placed in an injection mold apparatus200. The injection mold apparatus200includes two opposing molds212and214. Molds212and214are movable with respect to one another. Alternatively, mold212is stationary with mold214movable with respect to mold212or vice versa. The cavity of mold212is configured to receive the valve seat104of the SBoV100.

The process includes moving the two opposing molds toward each other to a closed position. Arrows G inFIG. 9show mold214moving toward mold212. Mold214is moved to a closed position as shown inFIG. 10. In the closed position, the two opposing molds212,214define a flowpath216. In the closed position, the housing102, bag108, and sleeve110are not in contact with the mold.

A portion of the valve seat104is located in the flowpath216as shown inFIG. 10.FIG. 11shows injection of flowable polymeric material218into the flowpath216. The flowable polymeric material may be any polymeric material as previously disclosed herein. In an embodiment, the polymeric material is HDPE.

The process includes injecting flowable polymeric material into the flowpath. For example, flowable polymeric material218may be injected under pressure at entry point H. Under positive injection pressure, the flowable polymeric material218travels through and fills the flowpath216. The moving flowable polymeric material218contacts the valve seat104and continues flowing to endpoint I. At endpoint I, the flowpath216ends, with the opposing molds212,214in direct contact with the valve seat104. At endpoint I, the opposing molds212,214sandwich the valve seat104ending the flowpath216. Endpoint I prevents further inward flow of the flowable polymeric material218, preventing flow of the flowable polymeric material toward the housing102.

The process includes overmolding a portion of the valve seat with the injected flowable polymeric material. The flowable polymeric material218comes in direct and intimate contact with the lip portion105and optionally the valve seat104. In an embodiment, the injected flowable polymeric material218comes into direct and intimate contact with the lip portion105and the a portion of the valve seat104. As best seen inFIGS. 11 and 12, the flowable polymeric material218flows around both sides of the lip portion105and around both sides of the valve seat104. The flowable polymeric material surrounds the lip portion105and surrounds a portion of the valve seat104, the flowable polymeric material218melt bonding to the value seat104and lip portion105as it cools and solidifies.

The process includes forming a container part, wherein the valve seat is melt bonded to the container part. The flowable polymeric material218is allowed to cool and solidify. Upon cooling, the polymeric material218adheres to the valve seat104and adheres to the lip portion105. In the solid state, the polymeric material218solidifies, or otherwise hardens, and melt bonds to the lip portion105and melt bonds to a portion of the valve seat104. InFIG. 13, the valve seat104and the lip portion105are melt bonded to the solid polymeric material, the valve seat104and the lip portion105immobilized in the solidified polymeric material that was previously the flowable polymeric material218that is formed into a container part220.

In an embodiment, the container part220is attached to a container body222shown inFIGS. 13-16to form a closed container224. Container224defines an interior chamber226in which the bag108and sleeve110are located. Exposed edge228of container part220has a closure member that matingly engages with a reciprocal closure member on a reciprocal exposed edge230of the container body222. Nonlimiting examples of suitable closure member/reciprocal closure member include snap fit closure, tongue and groove closure, male-female closure, friction fit, face seal, and combinations thereof. In addition, the closure member can be secured to the reciprocal closure by way of adhesive, stir weld, spin weld, hot plate (melting and fusing together, and ultrasonic welding.

FIG. 14shows the bag108and sleeve110of the SBoV100extending freely into the interior chamber226. The SBoV inFIG. 14is empty and can be filled through valve112(arrow inFIG. 15).FIG. 15shows container224having sleeve110stretched with the bag108holding a fluid composition and sleeve110applying the pressure.

The present container224(FIG. 14) maintains its shape, not collapsing or changing dimensions or appearance as the fluid composition is expelled from the bag (creating internal vacuum). In an embodiment, the average wall thickness, TT, for the container224is from average wall thickness is 0.075 mm, or 0.1 mm, or 0.15 mm, or 0.2 mm to 1.0 mm, or 1.5 mm, or 2 mm, or 3 mm.

The SBoV100can be filled with a fluid composition as previously disclosed herein.FIG. 15shows filled SBoV100in the interior chamber of container224.

In an embodiment, a valve cap240is attached to the valve112as shown inFIG. 16. Valve cap240enables a user of the container224to direct the spray (and/or direct flow pattern and/or direct flow rate) of the fluid composition242in a desired direction.

The injection mold apparatus can be modified to produce injection-molded container part with melt bonded SBoV and having various shapes and sizes. For example, the two opposing molds can be modified to produce container part (with melt bonded SBoV) having shorter or longer lengths, as desired.

In an embodiment, container300includes injection-molded container shoulder302as shown inFIG. 17. The SBoV100is melt bonded to the container shoulder302as previously disclosed. A body part304is attached (as previously disclosed) to the container shoulder302to form container300and define and interior and closed chamber therein.

In an embodiment container400includes injection-molded container half402as shown inFIG. 18. The SBoV100is melt bonded to the container half402as previously disclosed. A body part404is attached to the container shoulder402to form container400and define an interior chamber therein.

In an embodiment, container500includes injection-molded container body502as shown inFIG. 19. The SBoV100is melt bonded to the container body502as previously disclosed. A molded bottom portion lid to enclose container500can be attached to the open end of the container body502as desired. Alternatively, the bottom of container body502can remain open.

The presence of the valve112extending from each of container300,400and500indicates that SBoV100(i) is disposed in the interior chamber of each container and (ii) the valve seat104and/or the lip portion105is melt bonded to the proximate end of each respective container part302,402, and502.

Applicant discovered the ability to plastic mold a support container for SBoV provides the ability to produce specimens with tailored configurations heretofore not available.

Definitions and Test Methods

The numerical ranges disclosed herein include all values from, and including, the lower value and the upper value. For ranges containing explicit values (e.g., 1, or 2, or 3 to 5, or 6, or 7) any subrange between any two explicit values is included (e.g., 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.).

The term “composition,” as used herein, refers to a mixture of materials which comprise the composition, as cup as reaction products and decomposition products formed from the materials of the composition.

The term “creep” or “creep rate” is a relaxation characteristic of an elastomeric material. As used herein, “creep” represents the time dependent change in strain while maintaining a constant stress.

Density is measured in accordance with ASTM D 792.

The phrase “elastomeric composite” encompasses also elastomeric nanocomposites, nanocomposites, and nanocomposite compositions. The term “nanofiller” is used in the art collectively to describe nanoparticles useful for making nanocomposites. Such particles can comprise layers or platelet particles (platelets) obtained from particles comprising layers and can be in a stacked, intercalated, or exfoliated state. In some cases, the nanofillers comprise particles of a clay material known in the art as nanoclays (or NCs).

Elongation is determined in accordance with ASTM D 412. Elongation is the extension of a uniform section of a specimen (i.e., an elastomeric composite) expressed as percent of the original length as follows:

An “ethylene-based polymer,” as used herein is a polymer that contains more than 50 mole percent polymerized ethylene monomer (based on the total amount of polymerizable monomers) and, optionally, may contain at least one comonomer.

The term “flowable polymeric material” is a polymeric material heated above its melting point (for crystalline and semi-crystalline polymers) or above its glass transition point (for amorphous polymers) such that the polymeric material can be extruded and molded.

The term “heat seal initiation temperature,” is minimum sealing temperature required to form a seal of significant strength, in this case, 2 lb/in (8.8N/25.4 mm). The seal is performed in a Topwave HT tester with 0.5 seconds dcup time at 2.7 bar (40 psi) seal bar pressure. The sealed specimen is tested in an Instron Tensioner at 10 in/min (4.2 mm/sec or 250 mm/min).

Melt flow rate (MFR) is measured in accordance with ASTM D 1238, Condition 280° C./2.16 kg (g/10 minutes).

Melt index (MI) is measured in accordance with ASTM D 1238, Condition 190° C./2.16 kg (g/10 minutes).

An “olefin-based polymer,” as used herein is a polymer that contains more than 50 mole percent polymerized olefin monomer (based on total amount of polymerizable monomers), and optionally, may contain at least one comonomer. Nonlimiting examples of olefin-based polymer include ethylene-based polymer and propylene-based polymer.

A “polymer” is a compound prepared by polymerizing monomers, whether of the same or a different type, that in polymerized form provide the multiple and/or repeating “units” or “mer units” that make up a polymer. The generic term polymer thus embraces the term homopolymer, usually employed to refer to polymers prepared from only one type of monomer, and the term copolymer, usually employed to refer to polymers prepared from at least two types of monomers. It also embraces all forms of copolymer, e.g., random, block, etc. The terms “ethylene/α-olefin polymer” and “propylene/α-olefin polymer” are indicative of copolymer as described above prepared from polymerizing ethylene or propylene respectively and one or more additional, polymerizable α-olefin monomer. It is noted that although a polymer is often referred to as being “made of” one or more specified monomers, “based on” a specified monomer or monomer type, “containing” a specified monomer content, or the like, in this context the term “monomer” is understood to be referring to the polymerized remnant of the specified monomer and not to the unpolymerized species. In general, polymers herein are referred to has being based on “units” that are the polymerized form of a corresponding monomer.

A “propylene-based polymer” is a polymer that contains more than 50 mole percent polymerized propylene monomer (based on the total amount of polymerizable monomers) and, optionally, may contain at least one comonomer.

As used herein, the term “stress relaxation”, which is also used herein simply as “relaxation”, describes time dependent change in stress while maintaining a constant strain. Stress of strained elastomeric material decreases with time due to molecular relaxation processes that take place within the elastomer.

Tensile strength and modulus,—“Tensile strength” is a measure of the stiffness of an elastic material, defined as the linear slope of a stress-versus-strain curve in uniaxial tension at low strains in which Hooke's Law is valid. The value represents the maximum tensile stress, in MPa, applied during stretching of an elastomeric composite before its rupture. “Modulus” is a tensile stress of an elastomeric material at a given elongation, namely, the stress required to stretch a uniform section of an elastomeric material to a given elongation. This value represents the functional strength of the composite. M100 is the tensile stress at 100% elongation, M200 is the tensile stress at 200% elongation, etc. Tensile strength and modulus are measured in accordance with ASTM D 412.

Tm or “melting point” as used herein (also referred to as a melting peak in reference to the shape of the plotted DSC curve) is typically measured by the DSC (Differential Scanning Calorimetry) technique for measuring the melting points or peaks of polyolefins as described in U.S. Pat. No. 5,783,638. It should be noted that many blends comprising two or more polyolefins will have more than one melting point or peak, many individual polyolefins will comprise only one melting point or peak.