Screw cap construction

A multi-part screw cap construction for a container, comprising a thin-walled cup-like shell, an insert member having an annular side wall receivable in the shell, and a one-piece weight member constituted essentially as a single wire coil disposed completely within the shell at a location between its closed end and the end of the insert member, so as to provide a "weighted feel" to the cap. The coil is secured against looseness or vibration by suitable adhesive or cement, and the insert member can be pressed into the shell and adhered thereto by the adhesive while the latter is still tacky. The insert member is cup-like, and internally threaded for cooperation with the external threads on the neck of the container. The advantage is that an improved ornamental appearance can be imparted to the exterior surface of the shell, such as by metallizing or lacquering processes, while at the same time there can be employed relatively inexpensive components, such as economically molded plastic parts, drawn metal shells, and simple wire stock, for economy.

BACKGROUND 
This invention relates generally to screw cap constructions for bottles, 
jars or other containers, and more particularly to caps of the type 
employed with consumer oriented products, such as cosmetics, colognes, 
perfumes, or other items where decorative caps are desired for purposes of 
ornamentation. 
In the past, ornamental caps were generally molded of one-piece plastic and 
their exterior surfaces suitably decorated with distinctive designs of the 
type including small ornamental pieces or stampings of one form or 
another. One popular arrangement was to employ a phenolic substance for 
the body of the cap, and to apply a metallizing coating to the exterior 
surface, giving the appearance of solid metal. This construction had the 
advantage of relative economy, while at the same time there was little 
sacrifice in attractive appearance. A shine or luster could be imparted to 
the surface by suitable lacquering, yielding a cap which was aesthetically 
pleasing and eye-catching to the consumer. In addition, the phenolic 
substance had a characteristic "body" or weighted feel, which tended to 
remove the cap from the domain of the less expensive or cheaper-appearing 
molded parts. 
Frequently, where economical plastic substances were employed, the density 
of the material was such that the finished part was extremely light in 
weight. While such a characteristic might be considered desirable from the 
standpoint of storage or shipping, a light-weight "feel" gave to the 
consumer the impression of cheapness, and it has been found that such an 
initial impression had an adverse affect on the successful marketing of 
certain products, especially in the cosmetic field where a premium is 
placed on product quality and effective or attractive packaging. 
SUMMARY 
The above drawbacks and disadvantages of prior screw cap constructions are 
largely obviated by the present invention, which has for one object the 
provision of a novel and improved screw cap which is extremely simple in 
construction and economical to manufacture, while at the same time 
providing an unusually attractive part which presents an aesthetically 
pleasing impression to the consumer. 
A related object of the invention is to provide an improved screw cap as 
above set forth, wherein overall manufacturing economy is realizeable 
through the use of simple and economical molded components, drawn metal 
parts, and readily available metal wire stock. 
Still another object of the invention is to provide an improved screw cap 
as above characterized, wherein the time required for assembly is minimal, 
and wherein neither special fixtures or tools are required, nor unusual 
skills on the part of assembly personnel. 
Yet another object of the invention is to provide an improved screw cap of 
the kind indicated, wherein a significantly improved product appearance is 
obtained, comprising exceptionally smooth surfaces, without incurring 
excessive manufacturing expense, either in time, equipment, or materials. 
A still further object of the invention is to provide an improved screw cap 
in accordance with the foregoing, which has the relatively high quality, 
ornamental appearance and weighted feel of a metallized phenolic cap but 
which employs less expensive metal and cheaper molded plastic parts. 
Yet another object of the invention is to provide a novel method of 
manufacturing an improved screw cap, the steps being especially simple and 
straightforward to carry out, and involving neither special tools nor 
equipment, nor requiring the services of specially trained personnel. The 
various steps lend themselves readily to mass production techniques and 
procedures, which reduce the overall manufacturing cost to an absolute 
minimum without sacrificing product quality. 
The above objects are accomplished by the provision of a multi-part screw 
cap for a container comprising a thin-walled cup-like shell closed at one 
end, said shell presenting the exterior surface of the cap and having an 
annular side wall, comprising an insert member also having an annular side 
wall which is adapted to engage and fit generally within the inner surface 
of the wall of the shell, and comprising a one-piece weight member 
constituted as a single inexpensive wire coil disposed completely within 
the shell at a location between the closed end thereof and the insert 
member so as to provide a "weighted" feel to the cap. Means are provided 
for fixedly securing the insert member within the wall of the shell, and 
for securing the weight member against inadvertent loosening or rattling 
during subsequent use of the cap. The insert member is cup-like and has 
internal threads which are adapted to mate with the external threads on 
the neck of the container. 
The objects are further accomplished by a novel and improved method of 
producing a multi-part screw cap of the type having an outer cup-like 
shell closed at one end and presenting the exterior surface of the cap, 
and having an annular side wall, an insert member with an annular side 
wall adapted to engage and fit generally within the inner surface of the 
annular wall of the shell and wherein the insert member is cup-like and 
has internal threads adapted to mate with the external threads on the neck 
of the container, and a one-piece weight member constituted as a single 
wire coil. The method further comprises the steps of applying a quantity 
of adhesive to the inner surface of the shell, inserting the coil into the 
shell such that at least some surfaces thereof come into contact with the 
adhesive prior to solidifying or curing of the latter, and pressing the 
insert member into the shell until it is fully seated and a transverse 
wall of the insert member comes into contact with the adhesive, such it 
will be held in position in the shell following sufficient curing of the 
same. 
The arrangement is such that the finalized cap has an especially smooth and 
pleasing ornamental appearance while at the same time being characterized 
by a desirable, "weighted feel". Through suitable metallizing and 
lacquering procedures performed on the exterior of the shell, the 
impression of a "solid" highly polished metal component can be created. 
The expense of a phenolic plastic is thus eliminated, without sacrificing 
a high quality or rich appearance of the article. 
Other features and advantages will hereinafter appear.

Referring first to FIGS. 1-3, the improved cap construction shown therein 
comprises an outer, cup-shaped shell or member 20 having a cylindrical 
side wall 22 and a circular top wall 24. The member 20 can be constituted 
of drawn sheet metal, or of molded or otherwise shaped plastic substance, 
with the top and side wall integral with each other. 
Disposed within the outer member 20 is an inner, cup-shaped insert member 
26 having a transverse wall 28 and a cylindrical side wall 30, the latter 
being provided with internal screw threads 32 adapted to mate with the 
external threads on the neck of a container (not shown) such as a bottle, 
for example. The inner member 26 is illustrated as being formed of plastic 
substance, molded in the usual manner well known in the art, and according 
to the invention it occupies only a portion of the interior space in the 
outer member 20, being preferably flush with the latter at the respective 
lip portions or open ends of both members. 
In accordance with this invention there is provided for the purpose of 
imparting a solid, massive or "weighty" feel to the cap construction, a 
novel, inexpensive and economical-to-fabricate weight member in the 
unoccupied space between the top transverse walls 24 and 28 respectively 
of the outer and inner members, such weight member comprising a metal coil 
or spring of significant weight and mass, designated 34. The coil 34 is of 
helical configuration, with spaced-apart convolutions and random end 
terminations, and is characterized by a lack of critical dimensions or 
tolerances. It is merely required that the weight member 34 be loosely 
received in the outer cap member or shell 20 and have an axial length not 
exceeding the space between the top portions 24 and 28 of the outer and 
inner cap members. 
Further, in accordance with the present invention, the insert or inner 
member 26 and the weight member 34 are fixedly secured in place within the 
outer cap member 20. Such securement can be effected by various means, 
that at present preferred being an economical application of multiple 
quantities of adhesive, designated 36. Such application can be done by 
squirting the adhesive in a single shot from multiple orifices of a 
nozzle, against four circumferentially-spaced inner wall surfaces of the 
outer member 22. Thus, in the assembly of the cap construction, after the 
individual formation of the three separate components comprising the 
members 20, 26 and 34, the outer member 20 can have the adhesive 
conveniently applied to it, after which the coil member 34 is put in place 
and then the insert or inner member 26 inserted to the required depth. 
Preferably the center of gravity of the weight member lies between 20% and 
80% of the distance from the closed end (wall 24) of the shell to the open 
end thereof, typically being on the order of 40% of this distance, as an 
example, to provide for a desired, optimum "feel". 
Also, the adhesive is preferably of the quick-setting kind, and can be 
applied in a heated condition and characterized by a tacky state whereby 
the assembly is most easily and quickly effected with the least amount of 
possible malfunction. The resultant product has distinct advantages, in 
that the cap when being handled, has a heavy or solid feel to it which 
makes a favorable impression on the user or consumer, while at the same 
time not requiring costly substances or thick-walled structures in the 
fabrication, involving slow setting times or cycles. The outer member, 
when formed of metal, can have various desired finishes imparted to it 
which would not be acceptable to a plastic material. The inner member 26 
can be economically fabricated in volume by known molding procedures, and 
the weight or coil can be run off in large quantities from plated or 
unplated wire stock, at low cost and without requiring any finishing 
operations whatsoever. The setting of the adhesive effects a reliable 
securement of the components, without the likelihood of looseness or 
rattle developing at a later date or in usage. Light-weight materials such 
as plastics and aluminum can be used for the inner and outer members, and 
the total weight of the two components can be very small while at the same 
time the "feel" of the cap construction is solid, or massive and 
substantial when held in the hand. 
Another embodiment of the invention is illustrated in FIG. 4, wherein the 
insert or inner member and the weight member can be the same as those 
designated 26 and 34 above whereby they are similarly indicated by these 
same numerals. In the embodiment of FIG. 4 the outer member is constituted 
of molded plastic substance, and is indicated by the designation 20a. In 
other respects, such as by the provision of the adhesive 36 (FIG. 2) at 
four intervals around the inner circumference of the outer member 20a, the 
cap of FIG. 4 is similar to that of FIGS. 1-3, having the advantage of a 
solid or massive "feel", and giving a favorable impression to the user. 
Still another embodiment of the invention is illustrated in FIGS. 5-7, 
depicting a larger-diameter cap such as a jar cap. In these figures the 
outer cup-like member is shown as being of metal, designated 38, having a 
circular top wall 40 and a cylindrical side wall 42. By suitable metal 
stamping operations such shapes can be produced in large quantities and at 
low cost. Disposed within the outer member 38 is an insert or inner member 
44, formed of molded plastic substance, having a transverse top wall 46 
and a cylindrical side wall 48. The side wall 48 has the usual screw 
thread 50 adapted to mate with the external screw thread of a jar (not 
shown) such as a cosmetic container, for example. As provided by the 
invention, a weight member 52 in the form of a wire coil is located in the 
space between the transverse walls 40 and 46 respectively of the outer and 
inner members. The coil 52 is shown as formed to lie in a flat plane 
whereby it occupies little axial space, and is actually a planar metal 
ring, with unconnected, abutting ends. Portions of adhesive, designated 
54, can be applied to the outer member 38 as previously explained, and the 
assembly of the coil 52 and insert member 44 thereafter easily effected. 
The adhesive 54 not only secures the coil 52 against dislodgement but also 
cements the insert member 44, as with the previous embodiments of the 
invention. 
FIGS. 8 and 9 illustrate another embodiment of the invention, wherein the 
weight member is in the form of a flat spiral 56, constituted of heavy 
metal wire. The spiral 56 could be used to replace the coil 52 in the 
embodiment of FIGS. 5-7, for example, whereby the resultant cap 
construction would have still more added weight. Adhesive as previously 
explained would be used to secure the weight member 56 in the cap, as can 
be understood. The diameters of the coils 52 or 56 are somewhat less than 
the inner diameter of the shell 38 such that the coil can be readily 
loosely inserted or dropped into the latter, during assembly. 
Yet another embodiment of the invention is shown in FIGS. 10-12, wherein a 
jar cover is constituted of inner and outer cup-shaped members both of 
which are of plastic substance. The outer member 58 has a plain shallow 
cup shape without screw threads, whereas the inner member 60 has an 
internal screw thread 62 for cooperation with the screw thread of the jar. 
The members 58 and 60 have transverse walls 64 and 66 respectively, and 
cylindrical side walls 68 and 70 which telescope with each other. As 
provided by the invention, in the space between the transverse walls 64 
and 66 there is secured a weight member 72 in the form of a wire coil. 
Ridges of cement or glue 74 are applied to the inner surface of the outer 
member 58, and hold the coil 72 fixedly in place, as well as securing the 
inner member 60 to the outer member 58. 
FIG. 13 illustrates a further embodiment of the invention wherein both the 
outer and the inner members 76 and 78 are of metal, stamped and drawn in a 
well-known manner and sized to telescope one in the other. The bottom edge 
of the inner member 78 is curled outward to act as a stop, engaging the 
bottom edge of the outer member 76. The members 76 and 78 have transverse 
walls 80 and 82 respectively, and cylindrical side walls 84 and 86. The 
weight member in FIG. 13 can be the same as the member 72 in FIG. 10, and 
has been given the same numeral. Glue or cement 74 secures in place the 
weight member 72, and also fixes the inner member 78 to the outer member 
76. The inner member 78 has an internal rolled screw thread formation 88 
for engagement with the external thread of a jar, as is understood. The 
edge or lip of the member 78 has an annular curl of circular 
cross-sectional configuration, which provides a seat for the edge or lip 
of the shell 80, and mostly conceals the latter. A smooth undersurface or 
edge is thus provided. 
Another embodiment of the invention is illustrated in FIG. 14, wherein an 
outer member 90 is constituted of metal, and an inner or insert member 92 
is of plastic substance. The member 90 has a transverse, top wall 94 and a 
cylindrical side wall 96, whereas the member 92 has a transverse wall 98 
and a cylindrical side wall 100, the latter being provided with a screw 
thread 102. The weight member 72 is disposed between the transverse walls 
94 and 98 and held in place by the adhesive ridges 104, such adhesive also 
securing the members 90 and 92 fixedly to each other. 
In each of the embodiments of the invention, separate inner and outer cap 
members are telescoped with each other and separated at their top portions 
by a wire coil weight member which gives the cap assemblage a substantial 
"feel" of weight or solidity, greatly improving its attractiveness to the 
trade and consumer. Various finishes are possible by the use of the 
desired materials for the cap components, and the assembly is quick and 
convenient by employing glue or tacky cement, preferably squirted into the 
outer member against the side walls thereof. The components can be 
mass-produced economically, whereby the overall cost is kept to a minimum. 
Referring again to FIGS. 1-3, the novel method of the invention involves 
producing a multi-part screw cap of the type having an outer cup-like 
shell or member 20 closed at one end by a transverse wall 24, and having 
an annular side wall 22, an insert member 26 with an annular side wall 
engaging and fitting within the inner surface of the wall 22 of the shell 
20, and a one-piece weight member 34 constituted as a single wire coil, 
the method further comprising the steps of applying a quantity of adhesive 
substance 36 to one or several locations of the inner surface of the shell 
20, inserting the coil into the shell 20 such that at least some surfaces 
of the coil come into contact with the adhesive prior to solidifying of 
the same, and pressing the insert member 26 into the shell 20 until the 
transverse wall 28 of the insert member comes into contact with the 
adhesive, such that it can be held in position in the shell following 
sufficient curing of the same. As shown, various configurations can be 
employed as far as placement of the adhesive is concerned. It has been 
found that four locations circumferentially spaced by roughly 90.degree. 
around the inner surface of the shell 20 provides satisfactory results. 
The adhesive is preferably applied to the shell in a liquid state, and is 
in a heated condition. Upon contact with the relatively cool surface of 
the shell, the adhesive becomes somewhat tacky, and at this point, 
typically within a few seconds of the application of the adhesive, the 
coil can be inserted or dropped into the inverted shell and into contact 
with the adhesive substance. Preferably the adhesive solidifies within a 
minute or so, and prior to this time the insert member can be pressed in 
to the desired position, wherein the edges or lips of the outer and inner 
members coincide, so as to provide a relatively smooth, finished 
appearance. 
Referring to the embodiment of FIG. 13, wherein metal members are employed, 
the method of the invention involves imparting a bead or curl to the edge 
portion of the insert member 78, such that its lower surface presents a 
relatively smooth lip of curvilinear cross sectional configuration, with 
the sharp edge of the shell 80 resting upon the upper part of the bead or 
curl. This latter edge is mostly concealed by the bead, again so as to 
constitute a neat, finished appearance. 
From the above it can be seen that there has been provided a novel and 
improved cap oonstruction which is extremely simple in its structure while 
at the same time being inexpensive to manufacture and exhibiting an 
especially high quality appearance and "feel" which is not normally 
characteristic of components constituted of sheet metal or thin molded 
plastic. The weight member, being constituted of round wire metal stock, 
can be mass-produced in large quantities and very economically, since no 
critical dimensions or tolerances are required, nor special finishes. The 
ends of the weight member can abut or come close to each other if the 
member lies in a single flat plane. Where the weight member is in the form 
of a helix, the ends will be separated an appreciable amount which again 
is not critical. This same is true of the spiral configuration 
illustrated. By the use of wire stock, no scrap results from the formation 
of the coil, whatsoever, whereby the basic material is used with the 
greatest economy. As can be readily understood, coil wire stock in all 
different sizes and materials is available commercially, in large 
quantities at extremely low cost. The assembly is seen to be readily 
accomplished without the need for special tools or skilled personnel. The 
time required is minimal, thus representing a distinct manufacturing 
economy. 
The product and method of the invention thus constitute a distinct advance 
and improvement in the field of closure caps for bottles and jars. 
Each and every one of the appended claims defines an aspect of the 
invention which is distinct from all others, and accordingly each claim is 
to be treated in this manner when examined in the light of the prior art 
devices in any determination of novelty or validity. 
Variations and modifications are possible without departing from the spirit 
of the invention.