Process for filling a regulated pressurised dispenser

Abstract: A flexible closed plastic pouch 27 disposable within a container holding a product for supplying dispensing pressure therein. A plurality of pocket members (34) disposed at spaced positions within said pouch with their openings facing the interior of the pouch. Each pocket member having an extension of a predetermined length attached at its end to the interior of first of two facing wall members of the pouch. Each pocket member enclosing a predetermined quantity of first component of a two-component gas generation system and being releasably closed by one of a plurality of closure members, each of said closure members having an extension of a predetermined length attached at its end to the interior of the second of the two facing walls of the pouch. The pouch contains a second component 37 of said two-component gas generation system and a starting means (38) encapsulated within delay means or device to initially generate a predetermined quantity of pressurizing gas after a delay of a predetermined period of time. The pressurizing gas inflates and expands the pouch within the container under pressure. Due to the dispensing of the product, the pouch expands further and causes sequential separation of the pocket member from their closure members and serial opening of each pocket member to add predetermined quantities of aliquot of the first component to the second component and further generate additional quantities of pressurizing gas. The internal pressure within the container is maintained substantially within a range of predetermined maximum and minimum pressure levels until dispensing the product from the container is completed.

Description: The invention relates to a process for filling an aerosol type dispenser in accordance with the preamble of claim 1, which dispenser, has internal expulsion means for developing and maintaining gaseous dispensing pressure ranging substantially between predetermined maximum and minimum pressure levels for a product within a container of the dispenser. A process and a dispenser of this kind are disclosed in US-A-4 646 946. This document describes an aerosol type dispenser with an expulsion device for generating a substantially constant gaseous pressure level to discharge the product when the aerosol valve is turned to an open position. Releasably closed pocket members arranged in staggered positions, each containing a predetermined quantity of a first chemical component of two chemical components of a gas generating system are disposed within a pouch of predetermined dimensions to form an expulsion assembly. The pouch contains the second chemical component of said two component gas generating system and a predetermined quantity of the first component encapsulated within a reaction delaying device, which eventually dissolves in the second component and exposes the first component to the second component for reacting and generating the initial quantity of pressurizing gas, which causes the product within the aerosol type container to be discharged out of the dispenser when the aerosol type valve is turned to an open position, then closed pocket members open up sequentially to generate more pressurizing gas as product is discharged. In the manufacturing process of such a dispenser a quantity of water must be poured from a narrow spout that can go through the narrow open lip of the pouch on the production line which requires the pouch to remain under the spout pouring the liquid for several seconds. The filling of the dispenser according to the prior art is therefore time consuming and expensive. It is the object of the present invention to provide an improved process for filling an aerosol type dispenser. This object is achieved according to a process as characterized in claim 1. Other objects and the precise nature of the present invention will become evident from the following description and accompanying drawings in which each of the various components has the same reference numeral in their different views. Description of the drawings Figure 1 is an elevation sectional view of an aerosol dispensing container including an expulsion means embodiment of the present invention shown in a fragmentary cutaway view; Figure 2 is a sectional plan view of the structure shown in Figure 1 showing the expulsion means in initial collapsed condition. Fig. 3 is a sectional plan view of the structure shown in Fig. 1, showing the expulsion means in intermediate expanded condition; Fig. 4 is an enlarged isometric view of the two envelope sheets of an embodiment of the invention prior to assembly; Fig. 5 is an enlarged isometric view of the two envelope sheets of Fig. 4 in assembled condition; Fig. 6 is a sectional view taken along lines 6-6 of Fig. 5; Fig. 7 is an enlarged schematic respresentation showing, the method of insertion of the envelope into the pouch; Fig. 8 is an enlarged schematic representation, showing heat sealing of the envelope sides to the inner walls of the pouch; Fig. 9 through 11 are reduced sectional elevations showing assembly of the pouch containing the envelope inside an aerosol type dispenser; Figs. 12 and 13 are enlarged fragmentary schematic views showing separation of the envelope sides during expansion of the pouch to open the pocket members; Fig. 14 is another cross section view of the structure shown in Fig. 1, showing the expulsion means in initial collapsed condition. Fig. 15 is another sectional plan view of the device shown in Fig. 1, showing the expulsion means in intermediate expanded condition. Also shown are the exterior surfaces of the extensions of the pocket and closure members attached to the interior of the facing walls of the pouch. Fig. 16 is a schematic respresentation of an arrangement of the closure members and the pattern of attachment of the exterior sides of their extensions to the interior of the facing wall of the pouch. Fig. 17 is a schematic respresentation of the arrangement of a plurality of envelopes, independent from each other disposed within the pouch and each having a single pocket member. Detailed Description Referring to the drawings, in which each of the various components has the same reference numeral in the different views, and in particular Figs. 1-3, a fluid impermeable dispensing container is shown and designated generally by reference 10. Container 10 has a cylindrical body or side wall 11, inwardly dished bottom 12 and bell-shaped top 13 in which is mounted a conventional spring valve assembly 14. Container 10 and its component parts just described can be fabricated from any suitable material such as thin gauge aluminum or other metal, or even plastics, depending on the product to be dispensed and any governing safety specifications that might be involved. Valve assembly 14 is also of conventional design having plunger and spray head 15 carrying spray orifice 16, suitable constructed of plastic material, and internal parts (not shown) such as a spring, ball valve and mounting ring 17 and bottom intake member 18 which may be of metal and/or plastic consistent with the previously mentioned requirements. Within container 10 is flowable product 19 and expulsion assembly 20 which is the subject of the present invention and as will be seen , generates and maintains gas pressure therein to enable product 19 to be dispensed on demand, substantially under a range of predetermined maximum and minimum pressure levels. At the upper end 21 of the interior of cylindrical body 11 is a perforated or foraminous barrier member 22 having a plurality of holes 23 distributed throughout its surface. Also located along inner surface 24 of sidewall 11 and extending longitudinally there along is a perforate tube member 25 having a plurality of holes 26 at spaced positions around and along said tube member 25. The function of barrier member 22 and tube member 25 is to insure trouble-free operation of the dispenser and prevent expulsion assembly 20, as it expands in the manner to be described, from blocking off or plugging the interior of the container either laterally/circumferentially or plugging off valve bottom intake member 18. Expulsion assembly as shown is disposed within container 10 without being attached or anchored to container 10, although it may, if desired be so connected. Assembly 20 is comprised of generally regular envelope, bag or pouch 27 which is constructed of a flexible, fluid impermeable plastic material, such as, for example, polyethylene or polypropylene and may be fabricated from a sheet of plastic by folding it into overlaid halves 27a, 27b which are then sealed or adhered by suitable means along their respective contacting side, bottom and top edges 28, 29, 30 respectively to form sealed enclosure as shown in Fig. 1 to 3 inclusive. Disposed within pouch 27 is fluid impermeable flexible plastic sandwich or enfoldment 31, having a pair of facing wall members 32 and 33 releasably adhered to one another - see also Figs. 2 through 6 - and permanently attached on their exterior surfaces by suitable means, such as heat sealed portions 35 to respective interior sides 27c and 27d respectively. Portions of one wall member 33 have plurality of cup-shaped depressions, cavities or pocket members 34 disposed inwardly from one surface thereof at spaced positions, and other portions of wall member 33 each forms an extension member (a) as in Fig. 15, to each pocket member. Each extension member extends from the edge of the opening of its respective pocket member to the edge of wall member 33. Each extension ends at a predetermined distance from the edge of the opening of its pocket member. Each extension is affixed permanently at its end by one of weld portions 35 to predetermined locations or spots on the interior wall 27d. These spots on interior wall 27d are located on the same locations as weld portions 35 shown in the drawing and are superimposed and concealed by them. They may be referred to in the drawings by the same numeral 35. The other wall member 32 is substantially flat and has lidding area members or closure members which close each of the respective facing member of pockets 34 and releasably adhered to it. Pocket members 34 are superimposed on these closure members in the drawings, see Fig. 17. Other areas of wall member 32, each forms an extension member b as in Fig. 15, to each closure member. Each closure extension member extends from the edge of each of closure member to the edge of wall member 32. Each extension ends at a predetermined distance from the edge of its closure member. Each extension is affixed permanently at its end by one of weld portions 35 to a predetermined location or spot on interior wall 27c. These spots on interior wall 27c are on the same locations and are superimposed by weld portions 35 in the drawings. They may be referred to in the drawing by the same numeral 35. Each of pocket members 34 is releasably closed by wall member 32 to encapsulate within each of pocket members 34 a predetermined quantity of aliquot of component 36, which may be either in the form of powder or a solution. Disposed within pouch 27 is component 37 including a solvent. Also disposed within pouch 27 and mixed with component 37 is starting delay means or device 38, which as shown is in the form of dissolvable capsule and contains an inital charge of component 36. Pouch 27 is then closed by sealing its open end. After the elapse of a predetermined period of time after assembling expulsion assembly 20 and disposing it within container 10, filling product 19 therein, and placing tubing 25 and barrier 22 in place and capping container 10 with top 13 and its associated parts, capsule 38 dissolves and causes component 36 contained therein to be exposed and to mix and react with component 37 and generate the initial quantity of pressuirzing gas, thereby inflating and expanding bag or pouch 27 and providing dispensing pressure within container 10. The solvent portion of component 37 which is in a liquid state during the useful life of the dispenser is added in a frozen state during manufacturing. It is to be understood that cavities or pocket members 34 and capsule 38 may carry component 36, e.g. citric acid in powder form or in solution, and component 37 may be sodium bicarbonate and water added in a frozen state during manufacturing, or the two carbon dioxide gas generating components can be switched the other way around. Pouch 27, in one preferred embodiment, is constructed of a three layer laminated film having a middle layer of saran, an external layer of Mylar about 0.5 mils thick, and the inside layer (the interior of the pouch) being low density polyethylene of about 1.5 mils thick, and the saran layer is only deposited from spray. The characteristics required or desired in said pouch is that it be non-toxic, has sufficient mechanical strength and chemical stability, and flexible but not appreciably stretchable, and the interior facing surfaces of the pouch be heat sealable. Pouch 27 can also be constructed from other films such as impervious or non-impervious, non-laminated or laminated with plastics, foil or treated fabrics or other suitable material which may be available. Wall member 32 is fabricated from the same material which contacts the interior of pouch 27 and is of compatible plastic material, e.g. low density polyethylene. In one preferred embodiment, it has an overall thickness of about 4.5 mils and is a three layer sandwich of about 0.5 mils mylar in the middle and about 2.0 mils of low density polyethylene on either sides. Wall member 32 may also be constructed from other films such as impervious or non-impervious, coated or non-coated, laminated with plastics, foil or treated fabrics or any other suitable material which may be available. Wall member 33, carrying the cup-shaped depressions or pocket members 34, adapted for deep drawing and is in one preferred embodiment a laminated plastic sheet having an exterior layer - (the layer in contact with the interior of pouch 27)- of low density polyethylene of about 0.5 mils to about 20 mils thick and an interior layer (the other side) of polypropylene of from about 0.1 mils to about 3.75 mils thick or higher. Wall member 33 may also be constructed from any other suitable material. While for most practical applications of the invention, components 36 and 37 as citric acid and sodium bicarbonate mixed with water respectively are normally preferred, it is possible that under particular circumstances other materials may be suitable such as, for example, dilute hydrochloric acid (e.g. 10 to 30%) may replace citric acid, and lithium carbonate or calcium carbonate my replace the sodium bicarbonate. It is to be understood that component 36 may be selected from any suitable material which can react with component 37 and generate a pressurizing gas, and the contents of each of pocket members 34 and capsule 38 may be the same material or different from each other. The radio-activity at the surface of the dispenser and its component parts and accessories as well as that of the product discharged therefrom is within human tolerence, an does not exceed 0.1 milliroentgen per hour at the time of manufacturing. This requirement may be obtained by blending materials of lower level radio-activity than the level required with materials of higher level radio-activity than the level required in order to produce blended materials of the required low level radio-activity. Capsule 38, which functions as the starting delay means or device, may be constructed from any suitable material, such as gelatin, or coating such as shellac, or any breachable or breakable barrier enclosure. The method of assembly requires the following data to be determined: 1. The Maximum and minimum pressure levels under which product 19 is to be discharged out of container 10. 2. The increases in the size of pouch 27 within container 10 at the time when its internal pressure drops sequentially from predetermined maximum to predetermined minimum pressure levels. 3. The number of the releasably closed pocket members 34 required to be disposed within pouch 27 and the order of their sequential opening within pouch 27 as the product is dispensed from container 10, the quantities of component 36 to be enclosed in each of these releasably closed pocket members 34 as well as in capsule 38, the quantity of component 37 including the solvent e.g., water in this case, to be deposited in a frozen state within pouch 27, and the lengths of each of the pocket and closure extension members of each of said closed pocket members according to the order of their sequential opening. For all practical purposes, the internal pressure within pouch 27 or expulsion means 20 is presumed to be equivalent to the internal pressure of container 10. As capsule 38 disintegrates, its content of component 36 is released and reacts with second component 37 within pouch 27, and generates the initial predetermined quantity of pressure generating gas which raises the internal pressure therein to the predetermined maximum pressure level, and pouch 27 inflates and expands within container 10. As product 19 is dispensed, and thereby pouch 27 expands and increases in size further and displaces the space vacated by product 19 within container 10, each quantity of component 36 encapsulated in each of closed pocket members 34 is released sequentially and reacts with component 37 within pouch 27 and generates sequentially additonal predetermined quantities of pressurizing gas therein each time the internal pressure within pouch 27 drops from predetermined maximum pressure level to predetermined minimum pressure level. These additional quantities of pressurizing gas raise the internal-pressure within pouch 27 from predetermined minimum pressure levels to predetermined maximum pressure levels. The increases in the size of pouch 27 cause its facing walls to push outwardly, and thereby the distance between interior wall members 27c and 27d as well as the distances between identifiable spots on these two walls increase. Eventually the pocket members of each of closed pocket members 34 separate from their respective closure members and said closed pocket members open sequentially and discharge their contents, which react with component 37 and generate sequentially additional predetermined quantities of pressurizing gas, which raise the pressure therein to predetermined maximum levels. The internal pressure within pouch 27 alternates between predetermined maximum and minimum pressure levels, until dispensing product 19 is completed. The method of assembly is depicted schematically in Figs. 4 to 8 and 9 to 11. By heating and drawing portions of sheet 33 in a mold, cavities or pockets are formed on portions of sheet 33, and extension members to each of pockets 34 are formed on other portions of sheet 33. Each of these extensions extends from the edge of the opening of each member of pockets 34 and ends at the edge of sheet 33. Each extension ends at a predetermined distance from the edge of the opening of its pocket member. Predetermined quantities of component 36 e.g. citric acid are deposited in each member of pockets 34. Each of these quantities and the length of the extension of each pocket member are predetermined according to the order of the sequential opening of each closed pocket member in the manner to be described. Then sheet 32 is overlayed on sheet 33 and they are releasably sealed together (Fig. 5) to close each of pockets 34, and thereby form enfoldment 31. Portions of sheet 32 become liddings or closures to each member of pockets 34. Other portions of sheet 32 become extensions to each of these closure members. Each extension member extends from the edge of each closure member to the edge of wall member 32. Each extension ends at a predetermined distance from the edge of its closure member. The length of the extension of each closure is predetermined according to the order of the sequential opening in the manner to be described. Enfoldment 31 is inserted into the open end 30 of pouch 27. The exterior walls of enfoldment 31 are heat sealed together permanently by weld portions 35 as follows: The end of each extension member of pocket members 34 is affixed permanently to predetermined identified location or spot on interior wall 27d by one of weld portions 35, and the end of each extension member of the closure members is affixed permanently to predetermined identified location or spot on interior wall 27c by one of weld portions 35, (Fig. 8.). Capsule 38 and a predetermined quantity of component 37, which includes water in a frozen state are deposited within pouch 27, and then upper edge 30 is closed and heat sealed permanently to completely enclose the contents in pouch 27 and thereby complete the assembly of expulsion means 20. This expulsion means assembly 20 is then inserted into container 10 and product 19 is added therein around it, barrier 22 and perforated tubing 25 are put into place, and top 13 is affixed to container (10 Fig.) 10. After elapse of a prescribed period of time, the frozen ingredient in component 37 melts, and capsule 38 has dissolved and generates a predetermined quantity of pressurizing gas, e.g. carbon dioxide gas, which inflates, pressurizes and causes pouch 27 to expand, and the dispenser is now ready for use (Fig. 11.) Figs. 3, 12, and 13 show schematically how interior walls 27c and 27d of pouch 27 are permanently affixed and welded at weld portions 35 to the exterior of wall members 32 and 33, and how the expansion of pouch 27 causes the closure members to sepaarate from their respective pocket members and open and expose their content of first component 36 to admix and react with the second component 37 and water within pouch 27 and thereby generate additional predetermined quantities of the pressurizing gas. Enfoldment 31 may also be sliced in suitable patterns to form smaller units of enfoldment 31, each comprised of a single closed pocket member 34 encapsulating a predetermined quantity of component 36. Each pocket and its closure has an extension extending to the edges of sheet 33 and 32 respectively as described above. Each of single closed pocket members 34 may be disposed within pouch 27 unattached to the other closed pocket members. Each extension of pocket members 34 ends at a predetermined distance from the edge of the opening of its respective pocket member, and each extension of the closure members ends at a predetermined distance from the edge of its respective closure member. Each of these ends defines a free end of their respective extensions. The delay device may be constructed from gelatinous material in the form of a gelatinous capsule or a pouch which disintegrates in its sourrounding within the expulsion assembly, and it may also be a container or an enclosure constructed from glass or any other suitable material, which is broken open within the expulsion assembly at any time before or after assembling the dispenser, whichever situation is suitable in the manufacturing process. The second component of the two-component gas generation system 37 includes an ingredient in a frozen state at the time when it is deposited within pouch 27 and subsequently it liquifies. In a dispesner of the following description, the method of determination of, a. The increases in the pouch size each time the pressure therein drops from the predetermined maximum to the predetermined minimum pressure levels, b. the number of closed pocket members 34 to be disposed within pouch 27. c. the quantity of first component 36 e.g. citric acid to be encapsulated in each of closed pocket members 34 and capsule 38, d. the length of each extension of the pocket and the closure members of each of closed pockets 34, e. the quantity of second component 37 e.g. sodium bicarbonate and solvent, e.g. water, to be introduced in a frozen state into pouch 27, The above mentioned items may be determined as follows: It is assumed that expulsion assembly 20 comprising a bag or pouch 27 enclosing: a gelatin capsule 38 encapsulating a predetermined quantity of citric acid, and a predetermined quantity of sodium bicarbonate and 5 cc of water and an insignificant quantity of atmospheric air, and having displacement capacity of 12 cc, is disposed within container 10 having displacement capacity of 140 cc. One hundred (100) cc of flowable product 19 is introduced into container 10 around expulsion means 20, and barrier member 22 and perforated tubing 25 are put in place, and top 13 is affixed on container 10 to close it. The aggregate head space above the liquid in container 10 and in expulsion assembly 20 is 28 cc, occupied by atmospheric air. The pressure under which product 19 is to be discharged from container 10 should be within the range of maximum pressure level of 144 psig. and minimum pressure level of 100 psig. It is assumed that one atmospheric pressure at normal temperature measures 14.4 psig., and 144 psig. is equivalent to ten (10) atmospheric pressures. It is assumed that the complete reaction of 1.45 gms. of citric acid with 1.9 gms. of sodium bicarbonate in aqueous medium generates 1 gm. of carbon dioxide gas, and that 1000 cc of carbon dioxide gas weigh 1,82 gms., and that 1 gm of carbon dioxide gas measures 549.45 cc at normal temperature and pressure. It is assumed that 0.02639 gms. of citric acid is required to completely react with enough quantity of sodium bicarbonate in aqueous medium in order to generate 1 cc of carbon dioxide gas compressed under 144 psig. (pound per square inch gauge), and 0.03458 gms. of sodium bicarbonate is required to completely react with enough quantity of citric acid in aqueous medium in order to generate 1 cc of carbon dioxide gas compressed under 144 psig. The air in the 28 cc of head space in this dispenser pressurized under 14.4 psig., that is the number of molecules contained therein, provides a quantity of pressurized gas under 144 psig. for only 2,8 cc. After the completion of discharging its contents of product 19, this dispenser will be capable of holding gas pressurized under 144 psig., the volume of which is calculated as follows: 100 + 28 - 2.8 = 125.2 cc. The quantity of sodium bicarbonate required to react with enough quantity of citric acid to generate carbon dioxide gas compressed under 144 psig. in a space of 125.2 cc is calculated according to the above mentioned mathematical formula as follows: 125.2 x 0.03458 = 4.32 gms., rounded to 4.4 gms. of sodium bicarbonate. (It is permitted to exceed the calculated quantity of component 37, which may help the chemical reaction). Following are the stages of the internal pressure in pouch 27 and the incremental expansion in the size of pouch 27 in the course of discharging product 19 out of container 10 from beginning to end: Under normal conditions, immediately after the dispenser is assembled and before the generation of the pressurizing gas begins therein, the internal pressure within the 28 cc of head space in container 10 should measure one atmospheric pressure or 14.4 psig. An additional quantity of pressurizing gas is required to provide another 25.2cc of pressurizing gas compressed under 144 psig. for raising the pressure in the total head space of 28cc within container 10 to 144 psig. This 25.2cc is the difference between 28 cc and 2.8 cc.This additional quantity of pressurizing gas is generated by reacting an additional quantity of citric acid with the sodium bicarbonate with pouch 27, which is calculated according to the above mentioned mathematical formula as follows: 25.2 x 0.02639 = 0.665 gms. citric acid. This quantity of citric acid is encapsulated in capsule 38, which is deposited within pouch 27 together with the sodium bicarbonate and water, which may be in a frozen state. After a predetermined period of time, this capsule disintegrates or dissolves and releases its content within pouch 27. Its 0.665 gms. content of citric acid reacts with the sodium bicarbonate within pouch 27 and generates the required quantity of additional pressurizing gas which raises the pressure within this space of 28 cc to 144 psig. Product 19 is discharged from container 10 at staggered intervals in small increments. Pouch 27 gradually expands therein and increases in size. When its internal pressure drops from 144 psig. to 100 psig. for the first time, the size of pouch 27 should expand to the size which is calculated as follows: (28 x 144) divided by 100 = 40.32 cc., that is an increase of 12.32 cc. This additional 12.32 cc requires an additonal quantity of pressurizing gas which can be generated by reacting the following quantity of citric acid with the sodium bicarbonate within pouch 27 in order to raise the internal pressure within this dispenser to 144 psig. from 100 psig., which is calculated as follows: 12.32 x 0.02639 = 0.325 gms. citric acid. This quantity of 0.325 gms of citric acid is encapsulated in one of closed pocket members 34 which is disposed within pouch 27 and is scheduled to open first among the plurality of closed pocket members 34 which are scheduled to open within pouch 27. By the same method of the calculation mentioned above, after the internal pressure within pouch 27 drops from 144 psig. to 100 psig. twice, its size increases further as follows: 40.32 x 1.44 = 58.06 cc, that is an increase of 17.74 cc. The closed pocket member disposed within pouch 27 and scheduled to open second in sequence, should encapsulate the following quantity of citric acid in order to raise the pressure within this dispenser to 144 psig. from 100 psig., which is calculated as follows: 17.74 x 0.02639 = 0.468 gms. citric acid. After the internal pressure within this dispenser drops from 144 psig. to 100 psig. three (3) times, the size of pouch 27 increases as follows: 58.,06 x 1.44 = 83.6 cc, that is an increase of 25.546 cc. The closed pocket member disposed within pouch 27 and scheduled to open third in sequence should encapsulate the following quantity of citric acid in order to raise the internal pressure within this dispenser to 144 psig. from 100 psig., which is calculated as follows: 25.546 x 0.02639 = 0.674 gms. After the internal pressure within this dispenser drops from 144 psig. to 100 psig. four (4 ) times, the size of pouch 27 increases as follows: 83.6 x 1.44 = 120.384 cc, that is an increase of 36.784cc. The closed pocket member disposed within pouch 27 and scheduled to open fourth in sequence, should encapsulate the following quantity of citric acid in order to raise the pressure within this dispenser to 144 psig. from 100 psig., which is calculated as follows: 36.784 x 0.02639 = 0.97 gms of citric acid. However, there is only 128 cc of space available within container 10, and pouch 27 can expand additionally only another 7.616 cc, which is the difference between 128 and 120.384 cc. Consequently, the internal pressure within this dispenser cannot drop to 100 psig. when dispensing product 19 from this dispenser is completed. On the other hand, in order to have the internal pressure within this dispenser drops to a minimum of 100 psig. at the time when dispensing product 19 from this dispenser is completed, this closed pocket member which is scheduled to open fourth in sequence must encapsulate the following minimum quantity of citric acid, which is calculated as follows: 7.616 x 0.02639 = 0.2 gms. citric acid. Accordingly, any quantity of citric acid ranging between 0.2 gms. and 0.97 gms. encapsulated within this closed pocket member which is disposed within pouch 27 and is scheduled to open fourth in sequence, will provide pressure within the range between 100 psig. and 144 psig. at the time when discharging product 19 from this dispenser is completed, and thus conform with the requirements specified for this dispenser. The four (4) closed pocket members mentioned above are required to be disposed within pouch 27 according to the order of their sequential opening. Items a), b), c), and e) mentioned above have been determined as mentioned above. Item d mentioned above may be determined as follows: The length of the extension of the pocket member and the length of the extension of its respective closure memer of each of closed pocket members (34) may be determined as follows: I. An experimental pouch 27 made of transparent plastic material having two (2) facing walls 27a and 27b. Walls 27a and 27b having interior walls 27c and 27d respectively. Each of interior walls 27c and 27d is marked at random with four identifiable markings or spots at suitably accessible locations forming four identifiable pairs of spots,each comprisin two (2) member spots, one member spot of which is suitably located on interior wall 27c and the other member spot is suitably located on interior wall 27d. II. An experimental container 10 having the shape and dimensions of the container intended to be utilized in the mass production of the dispenser, and is constructed from any suitable metal or transparent material. III. An experimental expulsion assembly 20 comprising pouch 27 described in step I, in which are deposited capsule 38 encapsulating 0.665 gms. of component 36 e.g., citric acid, and 4.4 gms. of component 37 e.g., sodium bicarbonate including 5 cc of water in a frozen state, in contact with each other. Then pouch 27 is closed by sealing its open end, top side 30. IV. An experimental apparatus is assembled by disposing experimental expulsion assembly 20 of step III within experimental container 10 of step II and adding therein around expulsion assembly 20 100 cc of product 19. Perforate tubing 25 and barrier 22 are put in place, and top 13 is affixed to container 10. Container 10 is immersed in water heated to about 60 degrees Centigrade. After elapse of a period of time of about four (4) minutes, capsule 38 has disintegrated and components 36 and 37 mix and react and produce a predetermined quantity of carbon dioxide pressurizing gas, which raises the pressure within pouch 27 to 144 psig., and this pressurized apparatus is ready to be sprayed. V. Product 19 is discharged from container 10 at intervals in small increments, and the internal pressure within container 10 is measured after each time product 19 is discharged. Container 10 is shaken periodically. Simultaneously when the internal pressure within this apparatus drops to 100 psig. for the first time, pouch 27 expands an additional 1232 cc within container 10 and the distances between the member spots of the identifiable pairs of spots also increase. VI. The image of the interior of experimental container 10 and that of the experimental expulsion assembly 20 and their component parts are reproduced by an imagery process or by photography or by any other suitable process at the time when the internal pressure in container 10 drops to 100 psig. for the first time. The distance between two members of an identifiable pair of spots which are suitably located on each of interior walls 27c and 27d, is measured. VII. Step IV is repeated using experimental container 10, experimental expulsion assembly 20 containing 4.4 gms. of sodium bicarbonate, 5 cc of water, capsule 38 encapsulating 0.665 gms. of citric acid, and adding the first closed pocket member encapsulating 0.325 gms. of citric acid disposed within pouch 27 as follows: the total length of its pocket extension member a plus the length of its closure extension member b is made equal to the distance between the two members of the pair of the identifiable spots measured in step VI, and the end of its pocket extension member a and the end of its closure extension member b are affixed by weld portions 35 to each member of the identifiable pair of spots on interior walls 27c and 27d identified in step VI. VIII. Step V is repeated, allowing the internal pressure in container 10 to drop twice to 100 psig., and thereby pouch 27 has expanded an additional 17.68 cc. IX. Step VI is repeated, and the distance between the two members of another identifiable pair of spots, one member spot on each of walls 27c and 27d, is measured. X. Step VII is repeated, and in addition the second closed pocket member encapsulating 0.47 gms. of citric acid is disposed within pouch 27 as follows: The total length of its pocket extension member a plus the length of its closure extension member b is made equal to the distance between the two members of the pair of the identifiable spots measured in step IX, and the end of its pocket extension member a and the end of its closure extension member b are affixed by weld portions 35 to each member of the identifiable pair of spots on interior walls 27c and 27d identified in step IX. XI. Step VIII is repeated, allowing the internal pressure in container 10 to drop three times to 100 psig., and thereby pouch 27 has expanded an additional 25.52 cc. XII. Step IX is repeated and the distance between members of the third pair of identifiable spots, one member spot on each of walls 27c and 27d, is measured. XIII. Step X is repeated, and in addition, the third closed pocket member encapsulating 0.674 gms. of citric acid is disposed within pouch 27 as follows: the total length of its pocket extension member a plus the length of its closure extension member b is made equal to the distance between the two members of the pair of the identifiable spots measured in step XII, and the end of its pocket extension member a and the end of its closure extension member b are affixed by weld portions 35 to each member of the identifiable pair of spots on interior walls 27c and 27d identified in step XII. XIV. Step XI is repeated, allowing the internal pressure within container 10 to drop four times to 100 psig., and thereby pouch 27 has expanded an additional 36.75 cc. XV. Step XII is repeated and the distance between members of the fourth pair of identifiable spots, one member spot on each of walls 27c and 27d, is measured. XVI. Step XIII is repeated and in addition the fourth pocket member encapsulating 0.97 gms. of citric acid is disposed within pouch 27 as follows: the total length of its pocket extension member a plus the length of its closure extension member b is made equal to the distance between the two members of the pair of the identifiable spots measured in step XV, and the end of its pocket extension member a and the end of its closure extension member b are affixed by weld portions 35 to each member of the identifiable pair of spots on interior walls 27c and 27d identified in step XV. For practical purposes, the internal pressure within pouch 27 is dealt with as synonymous to that of expulsion assembly means 20 and is equivalent to the internal pressure within container 10. All quantities, pressures, volumes and measurements given above are in approximate numbers and are presumed to be substantially accurate. The above is the data required to manufacture and assemble the aove mentioned dispenser. In mass production, expulsion assembly 20 in step XVI is duplicated, and the dispenser is assembled and completed on the production line. By following the above mentioned method, dispenser of other specifications can be processed as well. After dispensing the product from the container is completed, the pouch will line the interior of the container.

Claims: Process for filling an aerosol type dispenser, having internal expulsion means for developing and maintaining gaseous dispensing pressure ranging substantially between predetermined maximum and minimum pressure levels for a product within a container of the dispenser said expulsion means comprising an enclosed fluid impermeable, flexible closed pouch (27) disposed within said dispenser and having a pair of facing wall members (27a, 27b), a plurality of pocket members (34) disposed within said pouch in spaced relation to one another and affixed to the interior of a first of said pair of facing wall members (27a, 27b) of said pouch (27), a predetermined quantity of a first component (36) of a two-component gas generation system disposed within each of said pocket members (34), closure members associated with the interior of the second of said pair of said facing wall members of said pouch closing each of said pocket members and releasably adhering to their contacting surfaces, thereby forming a plurality of closed pocket members (34) each containing a predetermined quantity of said first component (36) of said two-component gas generation system, a predetermined quantity of a second component (37) of said two-component gas generation system disposed within said pouch and externally of said closed pocket members, starting delay device (38) carrying a predetermined quantity of said first component disposed within said pouch in contact with said predetermined quantity of said second component of said two-component gas generation system for causing the initial generation of gas after a prescribed period of time, said closed pocket members (34) being sequentially separable from their respective closure members to empty their contents into admixture with said second component and to react and generate more gas as said pouch (27) expands due to dispensing said product, said product being dispensed disposed externally of said pouch within said container, a plurality of identifiable pairs of spots (35), each comprising two identifiable member spots, and one member spot being located on said first and the other member spot being located on said second of said facing wall members of said pouch, each of said plurality of closed pocket members (34) having a first extension (a) of a predetermined length extending from the edge of its pocket member (34) and being affixed at its end to said first facing wall member of said pouch at one identifiable member spot (35) of an identifiable pair of spots of said plurality of identifiable pairs of spots, and a second extension member (b) of a predetermined length extending from the edge of each closure member closing a respective pocket member of said plurality of closed pocket members being affixed at its end to said second facing wall member of said pouch at the other identifiable member spot of said identifiable pair of spots, whereby as the product is dispensed, the pouch expands and its said first and second facing wall members move away from each other under pressure, thus causing the distance between said ends of said first and second extension members of each of said closed pocket members affixed to said first and second facing wall members of said pouch to exceed the total predetermined lengths of said first and second extension members of said closed pocket members (34), thereby, causing sequential separation of each of said pocket members from their respective closure members according to a predetermined sequence and serial opening of each of said closed pocket members (34), which discharge their contents sequentially and generate additional predetermined quantities of pressurizing gas each time the internal pressure within said dispenser drops to a predetermined minimum pressure level, whereby said pouch (27) increases in size to a predetermined capacity each time the internal pressure within said dispenser drops from predetermined maximum to predetermined minimum pressure levels, whereby dispensing said product from said dispenser causes the internal pressure therein to alternate continuously between said predetermined minimum and maximum pressure levels, whereby the coordination of said range of predetermined maximum and minimum pressure levels with the lengths of the extension members of each of said pocket and closure members of said plurality of closed pocket members, the quantity of said first component enclosed within each of said pocket members and in the starting delay device, the order of sequence of the opening of each of said closed pocket members, and the quantity of said second component deposited within said pouch is necessary for dispensing said product within the range of predetermined maximum and minimum pressure levels, said process comprising depositing said second component in said pouch characterized by depositing an ingredient of said second component (37) of said two-component gas generation system in said pouch in a frozen state which ingredient subsequently liquifies. Process for filling an aerosol type dispenser according to claim 1, wherein said pouch (27) is comprised of three-layer laminated plastic film, the external layer being Mylar polyester 0.5 to 3 mils thick, the inner layer being low density polyethylene 0.5 to 20 mils thick, and the middle layer being saran deposited by spraying at least one of the inner surfaces of said Mylar and polyethylene layers. Process for filling an aerosol type dispenser according to claim 2, wherein said sheet carrying said pocket members (34) is comprised of two-layer plastic lamination having an outer layer of low density polyethylene 0.5 to 20 mils thick, and an inner layer of polypropylene 0.1 to 10 mils thick, said closure members comprised of three-layer plastic sandwich lamination having an inner Mylar polyester layer of 0.3 to 3 mils in thickness, the outer layers of the sandwich being of low density polyethylene of 0.3 to 20 mils thick. Process for filling an aerosol type dispenser according to claim 3, wherein each of said pocket members (34) and said starting delay device encapsulating said predetermined quantity of said first component of said two-component gas generation system comprises at least one compound selected from the class consisting of a water soluble mineral acid, carboxylic acid and citric acid, and said second component is comprised of at least one compound selected from the class consisting of barium carbonate, calcium carbonate and sodium bicarbonate in an aqueous medium and said generated pressurizing gas being carbon dioxide gas. Process for filling an aerosol type dispenser according to claim 4, wherein each of said plurality of pocket members (34) is individually separated and independent from the others. Process for filling an aerosol type dispenser according to claim 5, wherein said delay device comprises at least one device selected from the class consisting of a gelatin capsule, disintegrating pouch and breakable enclosure which break open within said expulsion assembly prior to assembling the dispenser. Process for filling an aerosol type dispenser according to claim 5, wherein said delay device comprises at least one device selected from the class consisting of a gelatin capsule, disintegrating pouch and breakable enclosure which break open within said expulsion assembly after assembling the dispenser. Process for filling an aerosol type dispenser according to claim 6 or 7, wherein a foraminous barrier (22) is located under a valve intake and a perforated tubing (25) located alongside and internally of the container to facilitate the flow of the contents in said container to said valve intake. Process for filling an aerosol type dispenser according to claim 8, wherein the end of each of said extension members (a, b) of each of said closed pocket members of said plurality of pocket members is affixed by proportionately short heat sealed weld portions (35) to one of two facing walls (27a, 27b) of said pouch (27) at a predetermined spot (35), and each of said extension member (a, b) of each of said closure members respective to said pocket members is affixed by proportionately short heat sealed portion to the other of the two facing walls of said pouch (27) at a predetermined spot, said spots constitute two member identifiable spots of an identifiable pair of spots, one of which is located on each of said facing walls of said pouch (27). Process for filling an aerosol type dispenser according to claim 9, wherein said product to be dispensed is comprised of at least one component selected from the class consisting of bromo-chloro-difluoro-methane, chlor-penta-fluoro-ethane, chloro-trifluro-methane, and dibromo-tetra-fluoro-ethane. Process for filling an aerosol type dispenser according to anyone of the preceeding claims, wherein the radioactivity at the surface of said dispenser and its component parts and accessories as well as that of the product dispensed therefrom does not exceed 0.1 milliroengten per hour.

Inventors: REYNER ELLIS M, REYNER, ELLIS M.
Applicants: JOY RESEARCH INC, JOY RESEARCH INCORPORATED
Application year: 1990
Main classification: B65D83
IPC codes: B65D83