Abstract:
A method of producing a container, dispenser, and closure comprises blow molding a body comprising a container portion, a dispenser portion, and a closure portion joined together, and separating the closure portion from the container portion and the dispenser portion. A container, dispenser, and closure made according to the method are also disclosed, along with an intermediate product for producing a container, dispenser, and closure.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates generally to blow molded containers, dispensers, and closures. More specifically, the present invention relates to containers, dispensers, and closures that are simultaneously blow molded.  
         [0003]     2. Related Art  
         [0004]     Containers including a dispenser and a closure are known in the art. According to one type of known construction, the container includes a container body, a dispenser portion that snaps onto or otherwise permanently attaches to the upper portion of the container body, and a closure, such as a cap, that attaches to the assembled container body and dispenser. The container body is typically blow molded, while the dispenser portion and/or the closure are typically injection molded or compression molded. Molding the dispenser portion and/or the closure by injection molding or compression molding, however, can pose difficulties or make it impossible for the dispenser or closure to be of multi-layer construction, which may be desirable depending on the intended contents.  
         [0005]     In some instances, the dispenser portion and/or the closure are injection or compression molded in the same mold that the container body is blow molded in. In this situation, the cavities for the dispenser portion and/or the closure are located above the cavity for the container body, along the parting line of the mold halves. This arrangement usually requires the cavities for the dispenser portion and/or the closure to be oriented vertically with respect to the container body (e.g., tilted 90° with respect to their position when applied to the container), disadvantageously increasing the vertical dimension of the mold. This can place limitations on the possible depths and shapes of the closure. Further, injection or compression molding the closure in the same mold that the body is blown in can require undesirably large clamping forces to be applied the mold halves. In addition, dispensers and/or closures made by this type of injection or compression molding process can be very costly.  
         [0006]     Therefore, there remains a need in the art for a method of making a container, dispenser, and closure that overcomes the shortcomings of conventional solutions.  
       BRIEF SUMMARY OF THE INVENTION  
       [0007]     The present invention relates to a method of producing a container, dispenser, and closure, comprising blow molding a body comprising a container portion, a dispenser portion, and a closure portion joined together, and separating the closure portion from the container portion and the dispenser portion. The step of separating the closure portion from the container portion and the dispenser portion can comprise cutting the body with a trimmer. The method can further include the step of separating the dispenser portion from the container portion. The dispenser portion can include a spout for dispensing contents.  
         [0008]     According to one illustrative aspect of the invention, the closure portion can be adapted to snap onto the dispenser portion. Alternatively, the closure portion can be adapted to snap onto the container portion. Additionally or alternatively, the dispenser portion can be adapted to snap onto the container portion.  
         [0009]     According to another illustrative aspect of the invention, the body can further comprise a first moil portion disposed between the dispenser portion and the closure portion. Additionally or alternatively, the body can further comprises a second moil portion disposed between the container portion and the dispenser portion.  
         [0010]     According to yet another illustrative aspect of the invention, the body can comprise a single layer of material. Alternatively, the body can comprise multiple layers of material.  
         [0011]     The present invention also relates to a container, a closure, and a dispenser made by the above-described method.  
         [0012]     The present invention further relates to an intermediate product for producing a container, dispenser, and closure, comprising a blow molded plastic body comprising a container portion, a dispenser portion having a spout for dispensing contents, and a closure portion joined together.  
         [0013]     Further objectives and advantages, as well as the structure and function of preferred embodiments will become apparent from a consideration of the description, drawings, and examples. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     The foregoing and other features and advantages of the invention will be apparent from the following, more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.  
         [0015]      FIGS. 1-4  illustrate an exemplary method of producing a container, dispenser, and closure according to the present invention;  
         [0016]      FIG. 5  is a rear view of an exemplary embodiment of an intermediate product for producing a container, dispenser, and closure according to the present invention;  
         [0017]      FIG. 6  is a side view of an exemplary embodiment of an intermediate product for producing a container, dispenser, and closure according to the present invention;  
         [0018]      FIG. 7  is a side view of the intermediate product of  FIG. 5 , shown with first and second moil portions removed; and  
         [0019]      FIG. 8  is a perspective view of an exemplary embodiment of a container, dispenser, and closure according to the present invention, shown with the dispenser attached to the container and the closure detached from the container and dispenser. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0020]     Embodiments of the invention are discussed in detail below. In describing embodiments, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected. While specific exemplary embodiments are discussed, it should be understood that this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations can be used without parting from the spirit and scope of the invention. All references cited herein are incorporated by reference as if each had been individually incorporated.  
         [0021]     Referring to  FIGS. 1-4 , an exemplary method of producing a container, dispenser, and closure according to the present invention is shown. The method includes blow molding a body  10  which comprises a container portion  12 , a dispenser portion  14 , and a closure  16  joined together. The body  10  can also include one or more moil portions, such as a first moil portion  18  located between the container portion  12  and the dispenser portion  14 , and/or a second moil portion  20  located between the dispenser portion  14  and the closure portion  16 . The body  10  can be blow molded in a cavity defined by a pair of mold halves  22 ,  24  using one of several known blow molding techniques, such as, for example, extrusion blow molding, injection blow molding, or stretch blow molding. According to one exemplary embodiment, the body  10  can be extrusion blow molded by inserting the blow needle (not shown) into one or both of the moil portions  18 ,  20 .  
         [0022]     Body  10  can be blow molded from a monolayer plastic material, such as a polyamide, for example, nylon; a polyolefin such as polyethylene, for example, low density polyethylene (LDPE) or high density polyethylene (HDPE), or polypropylene; a polyester, for example polyethylene terephthalate (PET), polyethylene naphtalate (PEN); or others, which can also include additives to vary the physical or chemical properties of the material. For example, some plastic resins can be modified to improve the oxygen permeability. Alternatively, the container can be prepared from a multilayer plastic material. The layers can be any plastic material, including virgin, recycled and reground material, and can include plastics or other materials with additives to improve physical properties of the container. In addition to the above-mentioned materials, other materials often used in multilayer plastic containers include, for example, ethylvinyl alcohol (EVOH) and tie layers or binders to hold together materials that are subject to delamination when used in adjacent layers. A coating may be applied over the monolayer or multilayer material, for example to introduce oxygen barrier properties.  
         [0023]     Once the body  10  is blow molded, the mold halves  22 ,  24  separate to release the body  10  from the mold, as shown in  FIG. 2 . Next, as shown in  FIG. 3 , the different portions of body  10  are separated, where necessary. For example, the closure portion  16  can be separated from the container portion  12  and the dispenser portion  14 . According to one exemplary embodiment of the invention, the dispenser portion  14  and the container portion  12  can remain joined together, as molded, for final use of the container. Alternatively, the dispenser portion  14  can be separated from the container portion  12  and subsequently reconnected thereto, as will be discussed in more detail below.  
         [0024]     In order to separate the different portions of body  10 , it can be cut with one or more trimmers, such as a blades, hot knives, hot wires, or other devices, to separate the different portions from one another. In the exemplary embodiment of  FIG. 3 , a first blade  26  separates the closure portion  16  from the first moil portion  18 , a second blade  28  separates the first moil portion  18  from the dispenser portion  14 , a third blade  30  separates the dispenser portion  14  from the second moil portion  20 , and a fourth blade  32  separates the second moil portion  20  from the container portion  12 . The blades  26 - 32  can act on the body  10  simultaneously, as shown in  FIG. 3 , or alternatively, can act on the body  10  in separate steps. Alternatively, a single blade can act on body  10  in four different steps. In addition, one of ordinary skill in the art will appreciate that other techniques for separating the different portions of body  10  are possible, and are included within the present invention. For example, the different portions of body  10  can be separated using a laser.  
         [0025]     Referring to  FIG. 4 , once the container portion  12 , closure portion  16 , and optionally the dispenser portion  14  are separated, the container can be assembled. For example, the dispenser portion  14  can attach to the container portion  12 , for example, by mating threads, snap connectors, bonding, or some combination thereof. One of ordinary skill in the art will appreciate that other structures are possible for attaching the dispenser portion  14  to the container portion  12 . In the exemplary embodiment shown in  FIG. 4 , the dispenser portion  14  attaches to the container portion  12  by a snap connection, discussed below in more detail. As discussed above, dispenser portion  14  and container portion  12  may alternatively remain together as an integral unit (i.e., as molded) for use. The closure portion  16  can be removably attached to the assembled container portion  12  and dispenser portion  14 , for example, by mating threads or snap connectors. According to one exemplary embodiment shown, the closure portion  16  attaches to the container portion  12 . Alternatively, the closure portion  16  can attach to the dispenser portion  14 . The optional moil portions  18  and/or  20 , if provided, can be discarded or recycled.  
         [0026]     Referring to  FIGS. 5 and 6 , an exemplary embodiment of body  10  is shown in detail. Body  10  generally defines a central axis A. The container portion  12 , dispenser portion  14 , and/or closure portion  16  can have a substantially round cross-section in a plane perpendicular to the central axis A, as shown. Alternative cross-sections can include, for example, an oval transverse cross-section, a substantially square transverse cross-section, other substantially polygonal transverse cross-sectional shapes such as triangular, pentagonal, etc., or combinations of curved and arced shapes with linear shapes. As will be understood by one of ordinary skill in the art, when the container has a substantially polygonal transverse cross-section, the corners of the polygon are typically rounded or chamfered.  
         [0027]     Still referring to  FIGS. 5 and 6 , the dispenser portion  14  can include a spout  30  adapted to facilitate dispensing of the contents of the finished container. For example, spout  30  can be adapted to pour liquid, granular, powder, etc. contents from the finished container. Spout  30  may be offset from the central axis A toward the perimeter of the container, as illustrated in  FIG. 6 . First moil portion  18  may be attached to the dispenser portion  14  at the spout  30 , such that separating the first moil portion  18  from the dispenser portion  14  creates the opening in spout  30  for contents to pass through.  
         [0028]     Referring to  FIG. 5 , the container portion  12  can define its own central axis B, the dispenser portion  14  can define its own central axis C, and the closure portion  16  can define its own central axis D. In the exemplary embodiment shown, these axes are collinear with the body central axis A. When the container portion  12 , dispenser portion  14 , and closure portion  16  are still joined together (i.e., prior to separating them with the trimmer), two, and preferably all three of these axes are substantially parallel to one another (i.e., such that the dispenser portion  14  and/or closure portion  16  are oriented in the position in which they are attached to the container portion  12 ). This configuration can reduce the overall height of body  10  as compared to prior art configurations, thereby potentially saving valuable space in the molding machine.  
         [0029]     Referring to  FIG. 7 , the container portion  12 , dispenser portion  14 , and closure portion  16  are shown with the first and second moil portions  18 ,  20  removed. The dispenser portion  14  can be adapted to snap onto the container portion  12 . For example, the upper rim of container portion  12  can include a ridge  32  immediately above a groove  34 . The lower edge  36  of dispenser portion  14  can be slightly recessed inward, such that the lower edge  36  snaps over the ridge  32  and into the groove  34 , thereby retaining the dispenser portion  14  on the container portion  14 . Additionally or alternatively, the dispenser portion  14  can be bonded or thermowelded onto the container portion  12 . According to an alternative embodiment of the invention, the dispenser portion  14  can be attached to the container portion  12  by mating threads or other known structures. The container portion  12  can be filled with contents prior to attaching the dispenser portion  14 , or alternatively, after attaching the dispenser portion  14  (i.e., through the spout  30 ).  
         [0030]     Referring to  FIG. 8 , the assembled container portion  12  and dispenser portion  14  is shown, with the cover portion  16  detached. The cover portion  16  can snap onto the container portion and/or dispenser portion  14  in order to cover the spout  30 , for example, to prevent accidental spillage of contents from the container. Container portion  12  can include a recess  40  defined below a ridge  42 , and the lower edge  44  of closure portion  16  can recede inwardly, such that the lower edge  44  slides over the ridge  42  and snaps into the recess  40 , thereby retaining the closure portion  16  on the container portion  12 . The ridge  42  and recess  40  can alternatively be provided on the dispenser portion  14 . Alternatively, the closure portion  16  can be secured to the container portion  12  and/or dispenser portion  14  by mating threads or other types of connectors.  
         [0031]     Still referring to  FIG. 8 , the container according to the present invention can be used to package a wide variety of liquid, viscous or solid products including, for example, juices, other beverages, yogurt, sauces, pudding, lotions, soaps in liquid or gel form, and bead shaped objects such as candy.  
         [0032]     The container portion  12  can include various features that improve the appearance, ergonomics, and strength of the container. For example, the exemplary embodiment shown in  FIG. 8  includes a recessed panel  50  and a plurality of grips  52 . One of ordinary skill in the art will appreciate that numerous other features that improve the appearance, ergonomics, and strength can alternatively or additionally be provided.  
         [0033]     The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the present invention. All examples presented are representative and non-limiting. The above-described embodiments of the invention may be modified or varied, without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the invention may be practiced otherwise than as specifically described.