Dispenser assembly for a fluid dispensing receptacle and method of assembling same

A dispensing assembly has a ferrule and collar for maintaining a coupling of a dispensing module to a receptacle neck. The ferrule has an annular plastic skirt open on one end, and plastic nibs extending radially inwardly from the skirt inner surface. The skirt outer surface is a regular polygon with flat surfaces between corners. The collar has a Nomar edge defining an annular recess adjacent the open end with an annular face facing the collar other end. At least the corners of the skirt open end extend radially outwardly into the annular recess of the collar inner surface when the dispensing assembly is secured to the receptacle to retain the collar on the ferrule while the dispensing assembly is secured to the receptacle by the ferrule nibs beneath the flange of the receptacle neck. Installation involves pushing the collar and ferrule onto the receptacle neck with the collar in a raised position on the ferrule, and then pushing the collar down relative to the ferrule.

CROSS REFERENCE TO RELATED APPLICATION(S)

Not applicable.

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

TECHNICAL FIELD

The present invention relates generally to dispensers or dispensing assemblies for receptacles containing fluid products to be dispensed, and the invention is especially suitable for use with bottles containing fragrance fluids or other personal care products.

BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE PRIOR ART

Generally speaking, prior art fragrance dispensers and other personal care product dispensers include a pump or aerosol module with a finger actuator for operating the module. Pump dispensers typically also include at least the following additional components: (1) a ferrule that contains the pump module and crimps onto or otherwise engages the receptacle (e.g., glass bottle, plastic container, or metal can), (2) a gasket that seals the ferrule to the top of the flange on the receptacle's neck (although some dispenser designs do not require a gasket if the ferrule material is soft enough to provide a good seal), and (3) a decorative collar around the ferrule. A cap may also be provided over the finger actuator and collar, either in a slip-fit or a snap-fit arrangement.

Typically, a pump module held in a ferrule is retained on a glass bottle by one of two methods:(a) the lower edge of the ferrule, typically comprised of aluminum, is collapsed inwardly under the neck flange of the bottle by a crimping tool. Then, the collar is pushed over the ferrule as a separate operation; or(b) the ferrule, made of either plastic or metal, has one or more retention portions that are moved, or retained, under the neck flange of the bottle by sliding the collar down the ferrule. With some designs, the collar and ferrule are initially “preassembled” by the module manufacturer so that the collar is in an “up” shipping position on the upper end of the ferrule, and subsequently the assembly is shipped to the customer (e.g., a fluid product manufacturer) who mounts the assembly on the bottle flange, and then pushes the collar all the way down on the ferrule to move and/or retain the retention portions under the bottle flange.

In either case, the collar can be metal or plastic. Usually, retention of a plastic collar on the ferrule is not a major concern because designs incorporate either snap fits or high force press fits (i.e., “heavy press fits”) that do not compromise the outer aesthetics of the collar. However, metal collars are usually fabricated in aluminum and then anodized to produce a lustrous surface. In order to accommodate physical tolerances in the ferrule and collar diameters, the internal surface of the collar may contain multiple, elongated, vertical ribs that project radially inwardly several thousandths of an inch off the inner surface thereof. When the collar is pushed over the ferrule with a heavy press fit, the collar slightly deforms, distorts, or “breathes,” into the shape of a polygon, with a resiliency that accommodates the tolerances. Another function of the ribs is to concentrate the “hoop” stress at multiple points, causing the ribs to dig into the ferrule and thus increase the resistance to removal.

However, finding the optimal parameters that provide the best retention and sealing of the module to the receptacle is difficult and heretofore has been elusive. For example, although the press fit over the ferrule must be strong enough to assure that the collar cannot be accidentally pulled off the ferrule, the fit must not be so strong as to damage the outer surface of the collar. The outer surface of the collar is especially susceptible to damage because the anodized surface of the collar is typically a very thin film of aluminum oxide that contains a colorant dye. When stressed in tension, the oxide film can crack, creating a diffraction grating that produces a rainbow effect that detracts from the aesthetics. As a result, the rib locations become evident on the outer surface of the collar, a condition known as “crazing.”

Similarly, while the press fit force must be high enough to compress the gasket sufficiently to ensure sealing to the bottle neck so as to avoid leaking, the press fit force should not be so high as to over-compress the gasket, causing it to extrude out from under the ferrule, or create such stresses that the bottle collapses or breaks.

Accordingly, it can be seen that improvements in the art are still desired. Specifically, it is desired to improve the state of the art collars to be able to increase the collar retention force (i.e., the force required to pull a collar off) while also not requiring so much force in initially applying the collar that crazing, bottle leaking, or breaking occurs.

Another proposal that has been used is shown in U.S. Pat. No. 6,253,941, which discloses a ferrule with a continuous skirt having an outwardly projecting lower edge which is deformed inwardly under the rim or flange of the container neck by the bottom portion of the rigid outer collar when the collar is forced down over the ferrule during the assembly process. However, it should be appreciated that the ferrule disclosed in that patent can therefore generally rest loosely on the container rim prior to the collar being pushed down over the ferrule during the assembly process. As a result, the ferrule may undesirably be dislodged or otherwise mis-positioned on the container rim during automated machine assembly.

Still another proposal which has been suggested is shown in U.S. Pat. No. 6,935,540, which describes a collar having angled ribs which facilitate securing of the collar to a ferrule of a dispensing assembly. While the collar such as disclosed therein may be advantageously used with a variety of ferrules, such ferrules may be subjected to some of the same drawbacks as referenced above.

Another improvement that has been suggested is to provide spiraling ribs in the inner surface of the collar, such as described in U.S. Pat. No. 5,799,810. In that structure, the bottom of the ferrule skirt has circumferentially spaced legs or tabs with catches or feet so that the ferrule may be pushed down over the container rim for initial assembly whereby the tabs will flex out to allow the feet to pass the rim and then snap back in when the feet pass the rim, whereby the feet will grip under the rim. The collar is then pushed down over the ferrule so as to trap the tabs and prevent the tabs from being pulled, or flexing, back out—the lowered collar thereby securing the dispensing assembly on the container rim. The spiral ribs on the collar assist in securing the collar on the ferrule, while also permitting the collar to be subsequently twisted off of the ferrule in order to then permit the tabs to flex out as would be necessary to remove the assembly, such as may be desired for recycling the components of a used assembly.

In a typical method of assembling a dispensing package employing the types of collars and ferrules disclosed in the above-discussed U.S. Pat. No. 5,799,810, the pump module is initially snap-fitted into the ferrule. If the ferrule is not itself capable of providing a seal (e.g., if the ferrule material is not soft enough to compress against and seal against the end of the bottle neck), a gasket is disposed inside the ferrule and around the module in a friction fit. Then the metal collar is mounted partially on the ferrule (i.e., the collar is pushed only partway down on the ferrule) in an “up” shipping position or configuration. The dispensing assembly is then shipped to the customer (e.g., a product manufacturer) for mounting to the bottle containing the fluid product. During such shipping and subsequent handling of the dispensing assembly, care must be exercised to avoid knocking the collar into a crooked orientation or off of the ferrule altogether. Thus, it would be desirable to provide an improved dispensing assembly facilitating initial mounting of the collar on the ferrule so that the collar can be initially positioned in the “up,” shipping position with an increased retention force while also accommodating subsequent lowering of the collar completely over the ferrule.

It would be beneficial if an improved dispensing assembly for a dispensing package could optionally accommodate incorporation of various aesthetically pleasing designs.

The improved dispensing assembly should preferably also accommodate designs for use with standard or conventional containers, especially glass bottles.

It would also be desirable if the constituent components of such an improved assembly could be relatively easily and economically manufactured with high production quality, and could provide consistent operating parameters unit-to-unit with high reliability.

The present invention is directed toward overcoming one or more of the problems set forth above, and provides an improved system which can accommodate designs having one or more the above-discussed benefits and features.

SUMMARY OF THE INVENTION

The present invention provides components for securing a container of a fluent material product to a dispenser that may include a dispenser cartridge (e.g., a dispensing pump cartridge or an aerosol dispensing valve) having an upwardly projecting, reciprocatable, product-dispensing stem and an attached actuator (e.g., button) through which the product can be discharged.

In a first aspect of the present invention, a set of components is provided for use in a dispensing assembly for dispensing a substance from a receptacle having a neck and a flange. The dispenser assembly includes a ferrule for maintaining a coupling of a dispensing module to the receptacle and a substantially rigid collar. The ferrule includes a shoulder member securable to the dispensing module, a plastic skirt which is generally annular about an axis and defines an axial aperture open on one end (wherein the dispensing module extends through the aperture when secured to the shoulder member), and plastic nibs extending from the inner surface of the skirt toward the axis. The collar has a generally annular inner surface adapted to be positioned over the ferrule skirt outer surface when the ferrule is mounted on the receptacle, and is open on one end with an inwardly extending annular flange on the other end, with the collar inner surface including an annular recess adjacent the open end defining an annular face facing the collar other end. The open one end of the ferrule skirt extends radially outwardly into the annular recess of the collar inner surface when the dispensing assembly is secured to the receptacle.

In one form of this aspect of the present invention, the skirt is continuous.

In a further form of this aspect of the present invention, the annular recess is conically tapered outwardly toward the collar open end, and at least portions of the ferrule skirt outer surface are tapered conically outwardly, wherein the ferrule skirt outer surface portions extend into the collar annular recess when the dispensing assembly is secured to the receptacle.

In a further form of this aspect of the present invention, the dispensing assembly components include a dispensing module secured to the ferrule.

In another form of this aspect of the present invention, the collar has a Nomar edge that is located at the open end and defines the recess and the annular face.

In still another form of this aspect of the present invention, a gasket is adjacent the ferrule shoulder member.

In yet another form of this aspect of the present invention, elongated ribs project inwardly from the collar inner surface and, in a further form, the ribs are angled along the inner surface of the collar. In a still further form, each rib forms an angle of approximately 5 to 15 degrees on the inner surface of the collar relative to the axis.

In another form of this aspect of the present invention, the skirt has an outer surface which, in a plane perpendicular to the axis, is substantially shaped as a regular polygon with flat surfaces between corners. In one further form, the corners are rounded. In another further form, the corners of the ferrule skirt outer surface extend into the collar annular recess when the dispensing assembly is secured to the receptacle. In still another further form, the radius of the ferrule corners from the axis is X, and the radius of the collar inner surface is Z, wherein X>Z prior to assembly of the collar on the ferrule, and in a still further form, the radius at the center of the ferrule flat surfaces from the axis is Y, wherein Y<Z. In yet another further form, the radius at the center of the flat surfaces from the axis is Y, and the radius of the collar inner surface is Z, wherein Y<Z.

In still another form of this aspect of the present invention, the dispensing module comprises a pump cartridge.

In yet another form of this aspect of the present invention, the collar is made of aluminum.

In still another form of this aspect of the present invention, a lip is on the ferrule outer surface adjacent the other end of the ferrule skirt and a recess is beneath the lip, wherein the lip extends to a diameter greater than the diameter of the collar one end.

In a further form, an assembly is provided of the receptacle and the dispensing assembly as described above.

In a second aspect of the present invention, components are provided for use in a dispensing assembly for dispensing a substance from a receptacle having a neck and a flange. The dispenser assembly includes a ferrule for maintaining a coupling of a dispensing module to the receptacle, and a substantially rigid collar. The ferrule includes a shoulder member securable to the dispensing module, and a skirt which is generally annular about an axis and defines an axial aperture. The dispensing module when secured to the shoulder extends through the aperture, and the skirt has an outer surface with a lower annular lip, wherein the skirt outer surface in a plane perpendicular to the axis is substantially shaped as a regular polygon with flat surfaces between corners. Nibs extend from the inner surface of the skirt toward the axis. The collar has a generally annular inner surface open on one end with an inwardly extending annular flange on the other end, with the collar inner surface including an annular recess adjacent the open end defining an annular face facing the collar other end, wherein the end of the ferrule skirt is in the annular recess when the dispensing assembly is secured to the receptacle. Further, the radius of the ferrule corners from the axis is X, the radius at the center of the ferrule flat surfaces from the axis is Y, the radius of the collar inner surface is Z, and X>Z>Y prior to assembly of the collar on the ferrule.

In one form of this aspect of the present invention, the skirt is continuous.

In a further form of this aspect of the present invention, the annular recess is conically tapered outwardly toward the collar open end, the ferrule skirt outer surface is tapered conically outwardly at the corners, and the ferrule skirt outer surface outwardly tapered corners extend into the collar annular recess when the dispensing assembly is secured to the receptacle.

In another form of this aspect of the present invention, the dispensing assembly components include a dispensing module secured to the ferrule.

In still another form of this aspect of the present invention, a gasket is adjacent the ferrule shoulder member.

In yet another form of this aspect of the present invention, the corners are rounded.

In another form of this aspect of the present invention, the skirt and nibs are plastic.

In still another form of this aspect of the present invention, elongated ribs project inwardly from the collar inner surface. In a further form, the ribs are angled along the inner surface of the collar and in a still further form, each rib forms an angle of approximately 10 degrees on the inner surface of the collar relative to the axis.

In yet another form of this aspect of the present invention, the dispensing module is a pump cartridge.

In still another form of this aspect of the present invention, the collar is made of aluminum.

In a further form, an assembly is provided of the receptacle and the dispensing assembly as described above.

In a third aspect of the present invention, a method is provided for securing the dispensing assembly of the above described first aspect of the invention to a receptacle having a neck and a flange, including (a) locating the ferrule on the receptacle flange with the dispensing module extending into the receptacle, (b) pushing the ferrule over the receptacle flange to locate the ferrule nibs beneath the receptacle flange, and (c) pushing the collar over the ferrule skirt to trap the nibs beneath the flange.

In a further form of this aspect of the present invention, a lip is on the ferrule with a recess beneath the lip, and (a1) the locating step includes supporting the collar on the ferrule lip, (b1) the ferrule pushing step includes pushing the collar while the collar is located on the ferrule lip to move both the collar and the ferrule relative to the receptacle flange, and (c1) the collar pushing step includes pushing the collar relative to the ferrule to push the material of the ferrule lip into the recess beneath the lip.

In another aspect of the present invention, a method is provided for securing the dispensing assembly of the above described second aspect of the invention to a receptacle having a neck and a flange, including (a) locating the ferrule on the receptacle flange with the dispensing module extending into the receptacle, (b) pushing the ferrule over the receptacle flange to locate the ferrule nibs beneath the receptacle flange, (c) pushing the collar over the ferrule skirt to compress the corners of the skirt and trap the nibs beneath the flange, wherein the collar is pushed sufficiently to position the collar annular face beneath the ferrule collar skirt, and (d) terminating the pushing of the collar.

In a further form of this aspect of the present invention, a lip is on the ferrule with a recess beneath the lip, and (a1) the locating step includes supporting the collar on the ferrule lip, (b1) the ferrule pushing step includes pushing the collar while the collar is located on the ferrule lip to move both the collar and the ferrule relative to the receptacle flange, and (c1) the collar pushing step includes pushing the collar relative to the ferrule to push the material of the ferrule lip into the recess beneath the lip.

In a still further form of this aspect of the present invention, a gasket is positioned between the ferrule shoulder member and the receptacle flange in the ferrule locating step, and the collar is pushed sufficiently to compress the gasket in the collar pushing step.

Numerous other advantages and features of the present invention will become readily apparent from the following detailed description of the invention, from the claims, and from the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiment in many different forms, this specification and the accompanying drawings disclose only some specific forms as examples of the invention. The invention is not intended to be limited to the embodiments so described, however. The scope of the invention is pointed out in the appended claims.

For ease of description, the components of this invention and the container employed with the components of this invention are described in the normal (upright) operating position, and terms such as upper, lower, horizontal, etc., are used with reference to this position. It will be understood, however, that the components embodying this invention may be manufactured, stored, transported, used and sold in an orientation other than the position described.

Figures illustrating the components of this invention and the container show some conventional mechanical elements that are known and that will be recognized by one skilled in the art. The detailed descriptions of such elements are not necessary to an understanding of the invention, and accordingly, are herein presented only to the degree necessary to facilitate an understanding of the novel features of the present invention.

The present invention provides an improved system for mounting a fluid dispensing module to a container. One presently preferred form of the invention is especially adapted for mounting a dispensing module in the form of a finger-operable, spray pump cartridge to a glass bottle that is particularly suitable for perfumes. However, the broad aspects of the invention are not limited to a particular dispensing module. Further, although the detailed design of the dispensing module forms no part of the broad aspects of the present invention, a brief discussion of some common types of dispensing modules is next presented below.

Finger-operable dispensing modules or dispensers (which can include, for example, both dispensing pumps and aerosol dispensing valves) are typically adapted to be mounted on hand-held containers that are commonly used for liquid products. Typically, some pumps and valves operate with a suitable discharge structure, such as a mechanical break-up unit, to produce a fine mist or atomized spray of the liquid product (e.g., perfume). Some pumps also operate to dispense a quantity of product in a liquid, cream, or paste form.

Some finger-operable pumps conventionally employ a dispensing module in the form of a pump cartridge having a chamber in which is disposed a pressurizing piston that can be actuated by the user's finger pressing down on an external actuator (e.g., button) which has a dispensing passage and which is connected to the piston with a hollow discharge tube or stem (which may typically be molded as a unitary part, or extensions of, the piston). The hollow stem establishes communication between the pump chamber and actuator from which the product is discharged. A spring acts against the piston or actuator to return the piston and actuator upwardly to the elevated, rest position when the finger pressing force is released.

Like the above-discussed pump type dispensers, aerosol valve dispensers are typically mounted at the top of a container, such as a metal can containing a pressurized product. Conventional aerosol valve dispensing systems for a container have a dispensing module that includes a hollow body which is open at the top and bottom ends and which is mounted in the top of the container. The bottom end of the hollow body is open to the pressurized contents in the container (usually through a dip tube connected to the bottom end opening in the aerosol valve body). A compression spring in the body biases a stem upwardly to project partly out of a body top end opening through an annular gasket at the top of the body. The upper part of the stem includes an internal, vertical discharge hole that is open at the upper end of the stem and that is connected to an external actuator button which has a dispensing passage from which the aerosol spray can be dispensed. Below the upper end of the stem, the stem has one or more lateral orifices which communicate with the vertical discharge hole inside the stem. Until the actuator button is pressed, the lateral orifices in the stem are located adjacent the inner cylindrical vertical surface of the annular gasket at the top of the valve body, and fluid inside the valve body is blocked by the gasket from flowing into the stem lateral orifices. When the actuator button is depressed, the stem is forced downwardly against the spring so as to locate the lateral orifices in the body below the gasket to permit the pressurized fluid in the valve body to flow through the stem lateral orifices, up the stem vertical hole, and through the actuator button.

Reference will now be had to the Figures and preferred embodiments incorporating the present invention providing an improved system for mounting a fluid dispensing module to a container. Some presently preferred forms of the present invention are described hereinafter as incorporated in a dispensing assembly that employs a dispensing module in the form of a finger-operable spray pump cartridge mounted on a glass bottle.

FIGS. 1-3illustrate a first embodiment of the present invention which consists of a dispensing assembly90for mounting to a container or receptacle100. The illustrated receptacle100is shown in one preferred form as a conventional, transparent, glass bottle suitable for containing a liquid perfume. As best illustrated in the exploded view ofFIG. 3, the container100includes a neck102with an outwardly projecting rim, lip or flange104at its upper end. The top of the bottle flange104has an upwardly projecting, annular sealing bead105(seeFIGS. 3 and 19).

A suitable dispensing module106, such as previously discussed, includes a pump cartridge108, a dip tube110, and an upwardly biased stem112on which an external actuator button114is disposed. (The dip tube110is illustrated inFIGS. 1 and 2as visible as would be the case with a transparent or translucent container100). It will be appreciated by those skilled in the art that a user may press down on the button114in order to operate the pump cartridge108whereby fluid in the container100is pumped up through the dip tube110and stem112and dispensed as a fine mist spray out the opening in the actuator button114.

In one preferred form, a gasket120(preferably molded from a plastic rubber), ferrule122and collar124function to secure the assembly to the container100as described in greater detail below. A removable dust cap or overcap126(seeFIGS. 2 and 3) is also provided for decorative design as well as to protect the actuator button114and prevent inadvertent dispensing of the product.

The ferrule122of the first embodiment is illustrated in detail inFIGS. 4-10, and may be advantageously molded of a durable but somewhat resilient, plastic material (e.g., polypropylene).

The ferrule122includes a lower skirt130having an outer surface which is generally a regular polygon in cross-section, and in the illustrated embodiment is generally octagonal with eight generally flat surfaces132connected at eight outwardly projecting, somewhat cut-off corners134(see, e.g.,FIGS. 7 and 8). The skirt130may advantageously be continuous, although it should be appreciated that a ferrule122in which the skirt130is slit, particularly in the flat surfaces132, could also be used with the present invention.

As best illustrated inFIG. 9, the outer surface of the skirt130at each of the corners134has, at the upper end, a lip136having an outer diameter ODC1with recessed area138beneath the lip136. A generally flat and axially extending surface140extends below the recessed area138(where the outer diameters at the top and bottom are the same: ODC2=ODC3). The bottom portion142of the skirt corners134are tapered outwardly at an angle A (seeFIG. 9) whereby the outer diameter at the bottom ODC4is slightly greater than the outer diameter ODC3of the axially extending surface140thereabove. As illustrated inFIG. 10, the flat surfaces132of the ferrule122between the corners134may be slightly tapered inwardly from top to bottom (e.g., by the angle B as illustrated inFIG. 10, where the outer diameter at the top of the skirt ODF1is greater than the outer diameter at the bottom of the skirt ODF2owing to the taper angle B).

The inner surface150of the skirt130is, by contrast, generally cylindrical (seeFIG. 7) with elongated ribs or nibs152projecting inwardly therefrom. Specifically, as best seen inFIGS. 7,9and10, sets of three nibs152are provided at each corner134, where each nib152includes a lower face156which tapers in toward the axial center of the ferrule122from the bottom at a point spaced above the bottom of the skirt130, and includes a less tapered upper shoulder158.

The internal diameter of the ferrule122, the distance each nib152projects inwardly, and the heights of the nib surfaces156and158are determined by the size and type of bottle flange104on which the ferrule122is to be mounted. For example, in the perfume pump spray bottle industry, different bottle flange sizes are provided according to industry standards such as GPI and FEA.

The exterior configuration and size of the ferrule122can be constant regardless of the interior size and configuration of the ferrule122. Thus, the design of the exterior of the ferrule122and the design of the collar124can remain the same regardless of the type and size of the bottle on which the dispensing assembly is to be installed.

The ferrule122includes a deck or downwardly facing shoulder160extending inwardly from the upper end of the skirt130, which shoulder160is adapted for seating against the gasket120on the top of the container neck102(seeFIGS. 3 and 19) when assembled as further described below.

In many instances, the hardness of the material of the ferrule122desired to ensure that the ferrule122will be properly retained on the container neck102as described in detail herein will be such that a softer gasket120may be advantageously used as described and shown to ensure a proper seal. However, if the ferrule deck160is capable of forming an adequate seal on top of the container neck102, the gasket120may be omitted. Therefore, it should be recognized that it would be within the scope of the present invention to provide a ferrule122which itself has sufficient softness to provide a desired seal without inclusion of a separate gasket.

A generally cylindrical turret or cap portion170(FIG. 10) with a central opening172extends up from the ferrule shoulder160and includes a reduced diameter portion174on its inner surface. It should be appreciated that the pump cartridge108may be secured in the cap portion170with the flange176(seeFIGS. 3 and 19) of the cartridge108trapped above the reduced diameter portion174with the stem112extending through the central opening172. A concentric outer lip178also extends up from the shoulder160and surrounds the cap portion170to define an annular space180therebetween, and a lower skirt on the actuator button114may be guided within the space180, and protected, during reciprocating pumping movement of the actuator button114(seeFIG. 19).

An outer shoulder or lip184defining outwardly extending lips at the corners above the ferrule skirt130is also provided to facilitate assembly as described hereinafter.

A notch188(FIG. 4) may also be provided in the upper end of the outer lip178to accommodate the mold gate for the injection of the thermoplastic resin during molding of the ferrule122.

The metal collar124of the embodiment ofFIGS. 1-3is illustrated inFIGS. 11-14wherein, as best seen inFIG. 14, the collar consists of two parts: an inner mounting collar200and an outer decorative collar202which is secured thereon. Both collars200,202may be made from aluminum or other suitable materials. Once the present invention is understood, it will be appreciated by those skilled in this art that the collar124may in one form be a single annular metal piece, and in another form may be a subassembly, such as illustrated, of two separate pieces (200,202) which are mechanically staked together to form a single, integral subassembly for mounting on the ferrule122in a process described in detail hereafter.

As can be seen inFIG. 14, the mounting collar200is generally cylindrical with an inwardly extending lip206at its upper end and a Nomar edge210at its lower end. A pair of spaced annular ridges214,216extend around the mounting collar200above the decorative collar202to define a groove within which the cap126(seeFIGS. 2 and 3) may be snapped in order to be secured thereon (seeFIG. 15). Also provided around the lower portion of the mounting collar200are a plurality of discrete ribs220which project inwardly from the inner surface of the collar200and extend generally axially but at an angle of, for example, about 15° (±5°) from the axial direction.

As indicated inFIG. 14, the inner diameter of the mounting collar200between the annular ridges214,216is ID1. Further, the general inner diameter of the lower portion of the mounting collar200is ID3, with the ribs220projecting inwardly to an effective inner diameter (between two diametrically opposite ribs) of ID2. As will be understood by those skilled in the art, the Nomar edge210at the lower end of the mounting collar200consists of a thinned annular portion above a thickened bottom annular portion (formed by bending up the bottom edge of the thinner, lower portion of the collar). Above the thickened bottom annular portion on the inside of the collar200there is a recess which, accordingly, has an increased inner diameter so that the thickened bottom annular portion has a smaller inner diameter ID4so as to define an upwardly facing shoulder224that presents an annular face facing toward the top end of the collar200.

Reference will now be had toFIGS. 15-18, in which the above described components are illustrated as assembled but prior to mounting on a container100. In this condition, it should be appreciated that the components are in substantially the same relative orientation to one another that they will be when finally assembled on a container100except that the mounting collar200is snap fit in a raised position relative to the ferrule122. In this raised (shipping) position, the collar124is only partially pushed onto the ferrule122with the bottom (Nomar) edge, at the corners134, secured to the ferrule122between the lip136and the outer lip184(seeFIG. 9) as seen inFIGS. 15 and 16. At the flat surfaces132between the corners134, the lower end of the mounting collar200may be spaced from the outer surface of the ferrule122as shown inFIGS. 17 and 18. (The gasket120may be stretched to fit over the pump cartridge108whereby it is frictionally held thereon as illustrated.) These Figures illustrate a shipping position in which the components are secured together in an assembled condition and can be handled by a customer to securely mount the assembly to the customer's filled container100as further described hereafter.

Mounting of the dispensing assembly90to a container100will now be described, such mounting being illustrated inFIGS. 19-24.

Specifically, advantageously according to the present invention, the ferrule122is pushed down over the bottle neck102during initial assembly, at which time the nibs152are first forced outwardly (by compression of the nibs152and stretching of the skirt130) in order to pass over the bottle flange104at the upper end of the bottle neck102. While the size of the bottle flange104may vary for different bottles100and may also vary due to manufacturing tolerances, the compression of the gasket120, and the elasticity of the ferrule skirt130and nibs152cause the nibs152to move radially inwardly under the bottle flange104at the end of the initial phase of the mounting process. This occurs generally when the lower faces156of the nibs152pass below the bottle flange104, at which point the upper shoulder158of the nibs152will either move under the bottle flange104or move under by compressing somewhat to provide some gripping or holding force preventing the ferrule122from being removed from the bottle neck102.

The mounting process may be effected entirely by automated equipment or partly manually. In either case, the process begins with the assembled components (as inFIGS. 15-18) provided to a bottler (typically, however, without the cap126thereon during mounting). If a partially manual process is employed to mount the dispensing assembly90on the container100, then the ferrule122(with gasket120, dispensing module106, and initially positioned collar124) are manually pushed onto the neck of a filled container100(such as a bottle) at a first work station. During this step, the collar124does not move relative to the ferrule122so that the collar124remains in the “up” position between the ferrule lips184and136as shown inFIG. 15. The ferrule122and collar124thus move downwardly together on the bottle flange104. The snap-fit engagement of the ferrule122with the bottle neck flange104maintains the assembly90in position on the bottle100while the bottle100is moved to a second work station at which a mechanical plunger device is operated to hold the bottle100and push the metal collar124all the way down on the ferrule122. Because the outside diameters of portions of the ferrule122are greater than some inner diameters of portions of the collar124as described above, portions of the ferrule122are compressed and deformed inwardly (and, to a small extent, the collar124may stretch radially outwardly) as a tight, interference fit is established.

In a fully automatic mounting process, the assembly of the gasket120, dispensing module106, ferrule122, and collar124may be pushed down on the bottle100in one continuous motion by a spindle. The spindle exerts an initial force (e.g., 30 to 40 pounds) on the top of the collar124so that the collar124and ferrule122move together until the bottom of the ferrule122initially snaps down over the bottle flange104and can be pushed down no further as previously described. The spindle then exerts a greater force (e.g., 40 to 80 pounds) in the final phase of mounting so that the collar124is then moved all the way down relative to the ferrule122so as to completely surround the exterior side of the ferrule122as shown inFIGS. 19-24and further described below.

Specifically, when the collar124is pushed over the ferrule122during the final phase of the mounting on a bottle neck102, the bottom of the Nomar edge210of the collar124initially pushes down on the lip136at the corners134of the skirt130, distorting the lip136and pushing its material down around the outside of the skirt. The recessed area138beneath the lip136provides a space into which the lip material can be deformed so that, once a sufficient force is applied to the collar124during mounting to distort the lip136and begin moving the collar124down over the ferrule122as desired, the deformed material of the lip136will thereafter provide little hindrance to the collar124as the collar124continues to be pushed over the ferrule122. As a result, the collar124can be pushed down with a sufficient, but not excessive, vertical installation force (e.g., less than 100 pounds, such as 80 pounds in one proposed commercial design) which will not risk damaging the collar124or container100in the process.

As the collar124continues to be pushed down over the ferrule122during the final mounting phase, it squeezes the outer surface of the ferrule122inwardly against the radial outward surface of the bottle flange104. While this will involve some squeezing inwardly of the nibs152to a position which is further under the bottle flange104compared to the initial phase of the mounting, the nibs152are already generally under the bottle flange104after the initial mounting phase as previously described.

In the fully mounted configuration as shown inFIGS. 19-24, the collar124has been pushed all the way down over the ferrule122so that the Nomar edge210is beneath the bottom edge of the ferrule skirt130, with the skirt elastically expanded outwardly so that it is above the upwardly facing shoulder224of the Nomar edge210. In this position, the nibs152are secured by the surrounding substantially rigid collar124underneath the bottle flange104whereby the mounted dispensing assembly90is securely retained on the bottle neck102. While some buckling of the flat surfaces132of the ferrule skirt130may result in portions of the skirt130being positioned below the bottle flange104, it is the nibs152which substantially retain the assembly90on the bottle neck102.

Further, in addition to the interference between the Nomar edge shoulder224and the bottom of the ferrule122(particularly at the skirt corners where the bottom portions142are tapered outwardly) which secures the collar124from being slid back up off the ferrule122after mounting, it should be appreciated that the ribs220on the inner surface of the collar124will also secure the collar124on the ferrule122, as the ribs220press into the outer surface of the ferrule skirt130(at least at the corners134), providing not only a friction connection but also, due to their slight angle relative to the axial direction, an interference against the collar124being pulled axially off the ferrule122. Moreover, such angled orientation of the ribs220enables the ribs220to be slid down relatively easily (and possibly slightly “screwed on”) during the final phase of the mounting process without requiring that an undesirably excessive mounting force be applied to the collar124. Once fully mounted, cold flow or creep of the plastic material of the ferrule122around the ribs220will further facilitate long term holding of the collar124on the ferrule122.

By way of example, the following previously discussed dimensions have been found to be suitable for a ferrule122and collar124combination such as described above for mounting on a conventional glass bottle100(e.g., FEA design) having a flange104with a nominal outside diameter which is (a) greater than an effective inner diameter between two diametrically opposite ferrule nibs152of 14.70 mm±0.20 and (b) no greater than an inside diameter of the ferrule skirt 150 of 15.60 mm±0.13, for example, a bottle neck104having a nominal outside diameter of 15 mm:

FIG. 14(collar124):ID1:=16.08 mmID2=16.08 mm±0.03ID3=16.33 mm±0.03ID4=16.13 mm
Of course, still other dimensions could be used within the scope of the present invention depending upon the size of the bottle neck with which the dispensing assembly is used, and the above dimensions are stated merely for illustration purposes and to provide an indication of one set of relative sizes which have been found suitable to provide the advantageous mounting features as described herein.

FIGS. 25-39illustrate an alternate embodiment of a dispensing module90A also incorporating aspects of the present invention. In this embodiment, the components may be the same as in the first described embodiment except that a different collar300is used, without an overcap. Accordingly, the same reference numerals are used in theFIGS. 25-39as used to describe the same components inFIGS. 1-24and repetition of the details of those same components will not be made here. With respect to the different collar300, comparable elements will be identified by comparable reference numbers as used inFIGS. 1-24but with100added (e.g., the ribs220inFIG. 14are identified as ribs320where appropriate inFIGS. 25-39).

Specifically, the modified metal collar300is shown in particular inFIGS. 26-29, and is essentially simplified from the collar124of the first embodiment by providing a substantially cylindrical outer surface without annular ridges for mounting an overcap. This simpler configuration (with a longer straight cylindrical portion) provides a smooth aesthetic appearance to the entire collar300(which is not covered by an overcap), and also permits the internal ribs320to be longer as well (seeFIG. 29). As a result, the friction between the ribs320and the ferrule122may be increased, as may the interference against axially pulling the fully mounted collar300off the ferrule122, even though the ribs320extend up above the engaged outer surface of the ferrule122and therefore at their upper end are not enclosed by creep of the ferrule122. Moreover, while this design may permit the collar300to be more readily twisted and pulled off if necessary for some unusual reason, such removal would still not be easy given the interference between the bottom of the ferrule skirt and the collar Nomar edge310. Further, given the slight angle of the ribs320, while this configuration would facilitate appropriate removal if necessary by a manufacturer with knowledge of the rib configuration, it would be unlikely to be accomplished by an individual who would be unlikely to apply the correct combined degrees of pulling and twisting which would be required to accomplish such removal.

Accordingly, should be appreciated that the present invention permits easy and reliable assembly of a dispenser assembly90, and further permits easy and reliable mounting of the assembly90on a container100. Moreover, the present invention significantly reduces the likelihood that the dispenser assembly90will inadvertently or undesirably become decoupled from the container100. In particular, the assembly90can be properly installed without requiring an excessive installation force—yet the installed configuration provides a greatly increased resistance to removal (owing significantly to the interference between the bottom of the ferrule corners134and the Nomar edge shoulders224,324(FIGS. 20 and 35)).

Still other aspects, objects, and advantages of the present invention can be obtained from a study of the specification, the drawings, and the appended claims. It should be understood, however, that the present invention could be used in alternate forms where less than all of the objects and advantages of the present invention and preferred embodiment as described above would be obtained.