Abstract:
An aerosol dispenser is formed from a metal drawn container with an open bottom and a mounting cup structure integrally formed in its top. A bottom piece is attached to the open bottom with a double seam and a dispensing device held in the mounting cup structure. In one embodiment the dispensing device is an anti-clog valve designed to clear all dispensing passages after each operation.

Description:
[0001]     This application claims the priority of provisional application 60/726646 filed Oct. 17, 2005. 
     
    
       [0002]     The present invention relates to aerosol containers in general and more particularly to an aerosol container in which the mounting cup that supports an aerosol valve is formed integrally with drawn container and in which the valve is an anti-clog valve.  
         [0003]     The conventional container used for aerosol dispensers for many years includes a steel can with a standard 1 inch opening at the top as shown in  FIG. 1 . The bottom of the can is closed by means of a bottom piece that is attached by double seaming, a method that has been proven to be satisfactory over the years. Although generally made with a seam on the side, such cans or containers may also be integrally formed in one piece (other than the bottom) using a drawing process to avoid the additional seam on the side of the container. The can is formed with a neck terminating in a bead with a one inch opening.  
         [0004]     A valve for dispensing, either a standard continuous aerosol spray valve or a metering valve (or hand operated pump) which controls the amount of product to be dispensed is mounted in the 1 inch opening using a mounting cup as shown in  FIG. 2 . This is accomplished by crimping the mounting cup to the bead at the opening, the valve or pump, in turn, being crimped into the mounting cup.  
         [0005]     The empty container normally is printed on the outside with label specified by customer, usually the marketer. Most containers have a protective coating on the internal wall to resist corrosion and meet F.D.A. approval standards. The metal mounting cup for the one inch valve should have a protective coating similar to the internal coating on the container. The empty container is typically shipped to the facility that formulates the product. There the product is filled into the container through the one inch opening, after which the valve in its mounting cup is crimped into position to result in the structure of  FIG. 2 . Current practice is for the marketing company which has specified the particular aerosol valve or hand operated pump to also specify the empty container. The marketer or the company that does the filling of product buys the valve from the valve supplier. The valve and container have to be received and inventoried by the company responsible for the filling. After the filling operation the filled unit is shipper to a distribution center.  
         [0006]     Containers and valves are shipped from separate facilities with essential information to be inventoried and so as to be available to be scheduled for the filling operation. After the filled container is passed through a hot water bath to test for leaks, an actuator and a protective closure are put in place on the dispenser. The product is put in cartons and shipped to a marketer or distribution center.  
         [0007]     Although a drawn container in an improvement over seamed containers, this construction still requires both crimping a valve so as to be sealed within the mounting cup and also crimping and sealing the mounting cup to the opening in the can. In addition to the number of steps involved, problems can arise because of dissimilar metals in the can and mounting cup. This can lead to corrosion unless additional coatings are applied. As a way to avoid these problems, there have been proposals in the past to effectively form structure equivalent to the mounting cup in the top of the drawn can. However, previous designs have not taken full advantage of cost savings that can be achieved with such a construction.  
         [0008]     Another problem in the art is that of dispensing materials containing powders or other ingredients that tend to clog at the valve seat. Propellants used to expel the product from the closed container have a liquid phase and a vapor phase that forces the product out of the container via a valve supplied by a dip tube, when the valve opens. Most valves utilize a rubber sealing disc to seal the valve outlet when not in use. When the valve is operated, the product passes through an orifice to a passageway in the stem bypassing the sealing disk. When the valve is closed some of the product settles around the valve orifice and can dry over a period of time. If not at the valve orifice, then these deposits sometimes accumulate in the passages of the valve stem and actuator. Drying within the valve body can also occur.  
         [0009]     To overcome this problem current valves have vapor taps to open clogs by turning the package upside down and actuating the valve causing the gas in the vapor phase to clear it out.  
         [0010]     My previous U.S. Pat. No. 6,247,613 provides an anti-clog actuator and prevents product residue from clogging in the actuator orifice but does not prevent clogging at the value seat.  
         [0011]     Thus, there a need for an improved container with a simplified method of construction and method of filling such a container that is more economical. Further there is a need of an improved valve that does not clog and a container containing such a valve 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]      FIG. 1  is a perspective view of a drawn steel can with a 1 inch opening.  
         [0013]      FIG. 2  is a cross-sectional view of the can of  FIG. 1  with an attached mounting cup and aerosol valve.  
         [0014]      FIG. 3  shows an exploded cross section of a first embodiment of an aerosol container according to the present invention.  
         [0015]      FIG. 4A  is a cross-sectional view of the assembled first embodiment of the aerosol container according to the present invention.  
         [0016]      FIG. 4B  a is a cross-section of a conventional valve that may be used in the embodiment of  FIG. 4A .  
         [0017]      FIG. 5  is a perspective cross sectional view of a first embodiment of an anti-clog dispensing valve according to the present invention mounted in a mounting cup.  
         [0018]      FIG. 6  is a cross sectional view of the first embodiment of the anti-clog dispensing valve according to the present invention mounted directly in an embodiment of a container according to the present invention.  
         [0019]      FIG. 7  is a cross-section of a second embodiment of the anti-clog valve of the present invention.  
         [0020]      FIG. 8  is a cross-sectional view of a second embodiment of an aerosol container according to the present invention.  
         [0021]      FIG. 9  is a cross-sectional view of the embodiment of  FIG. 8  before crimping the outer part of the cylindrical portion into which the valve is inserted.  
         [0022]      FIG. 10  is a cross-sectional view of the embodiment of  FIG. 8  after crimping the outer part of the cylindrical portion into which the valve is inserted.  
         [0023]      FIG. 11  is a cross-sectional view of the embodiment of  FIG. 8  after crimping the outer part of the cylindrical portion into which the valve is inserted in which a gasket is disposed at the top of the valve body.  
         [0024]      FIG. 12  is a flow chart for a method for efficiently making a container according to the present invention, filling it and assembling it. 
     
    
     DETAILED DESCRIPTION  
       [0025]     A conventional metal can or container  11  with standard 1 inching opening  13  is shown in  FIG. 1 . The can is made, for example of drawn aluminum or steel and is sealed at the bottom by a double seal  15  attaching a bottom piece  17 . The one inch opening  14  at the top contains a bead  19  to receive a mounting cup with a valve, which is crimped to the opening with a sealant between the bead  19  and the mounting cup.  
         [0026]      FIG. 2  is cross-sectional view of the can  11  of  FIG. 1  with an attached mounting cup  21  and aerosol valve  23 . The can  11  is drawn in one piece with an open bottom to accept a conventional bottom piece  17 , shown separated from the bottom. The mounting cup  21  containing valve  23 , around which the mounting cup  21  is crimped in a sealed manner, is itself crimped to the bead  19  at the opening  13  in the can with a sealant between the bead  19  and mounting cup  21  to form a finished container, once the bottom  17  is attached. The finished container is shown with an actuator  43  mounted to the stem  40  of the valve  23 , which projects through a sealing washer or gasket  41 . The valve is shown in the operated position. A dip tube extends from the bottom of valve  23  to the bottom of the container to supply product to the inlet of the valve.  
         [0027]     Such containers are well known and are used for dispensing various products after the container has been filled, and assuming dispensing is via an aerosol valve, pressurized. The can may be coated on the inside to avoid reaction with the product and decorated on the outside to identify the product it contains. One problem with such a container is the need to both crimp the valve into the mounting cup and to crimp the mounting cup to the container. In addition, the container and mounting cup are often of dissimilar metal, which can lead to corrosion unless further steps are taken, such as applying a coating to the inside of the mounting cup.  
         [0028]      FIG. 3  is an exploded cross section of an embodiment of an aerosol dispenser according the present invention. The metal drawn can or container  11 ′, can be fabricated from any available metal that can be drawn, for example, be means of a plunger press typically used in multiple stages for forming a container or receptacle out of aluminum. In the first step, a dome is formed, followed by formation of the mounting cup structure  21 ′. A series of drawing steps follow to form the cylindrical container. The final step is that of trimming the bottom. Such processes are known in the art and, thus are not described in detail. If steel is used, it may be tin plated or coated on the inside with a protective coating to resist corrosion or any reaction with the product to be dispensed. Thus, the container  11 ′ after it is fabricated, as is known in the art, can be internally coated with a protective lining and also decorated externally. Typical the material contained in such dispensers will be dispensed under pressure of a gas which under pressure is liqufied. However, it is also possible to carry out dispensing with pressure developed by other means such as pumps. Shown separated from the can  11 ′ is the bottom  17 ′ which can be attached with a conventional double seal as in the embodiment of  FIGS. 1 and 2 . The bottom  17 ′, in this embodiment has an opening into which a one-way check valve  27  is inserted.  
         [0029]     The top of the can  11 ′, instead of having the 1 inch opening is shaped to accept an aerosol valve  23 ′ (or a pump). Thus, at the diameter  19 ′, at about the spot where the prior art had a bead, there is provided a cylindrical axially inwardly extending portion  31 . Extending radially inward from portion  31  is a portion  33 , from which a portion  35  extends axially outwardly to a radially inwardly extending portion  37 . This structure formed when fabricating the can provides a special opening or built-in mounting cup  21 ′, for accepting the aerosol valve  23 ′ shown alongside the can  11 ′, along with its attached dip tube  25 .′ Valve  23 ′ may be a conventional valve, metered or continuous that can be crimped into the special opening  21 ′ either by the container supplier or the marketer of the product. In particular, a valve such as that shown in FIGS.  6  or  7  may be used. Alternatively, valve  23 ′ may be a finger operated pump. Typically, such valves or pumps are made of plastic, as with the embodiment of  FIG. 7  and there is no need to be concerned about their reacting with the metal of the container  11 ′.  
         [0030]      FIG. 4A  shows the valve  23 ′ crimped in place in the special opening  21 ′. It is inserted until the top of the valve abuts against portion  37 , with the valve stem  40  extending through the opening  39 . A gasket  41  seals against the stem  40  and also seals against portion  37 . The portions  31 ,  33 , and  35  are deformed by crimping so that portion  35 , in particular, conforms to the shape of the valve  23 ′ to hold it in place, pressing gasket  41  against portion  37 . An actuator  43  of conventional design is attached to the valve stem  40  to press it axially inwardly to dispense material in the form of a spray from the finished dispenser. In this view, a conventional valve is shown in the operated position.  
         [0031]     The valve  23 ′ is shown in the unoperated position in  FIG. 4B . In this position, a radial inlet port  44  leading to a passageway  46  formed in the valve stem  40  is above the gasket  41 , which seals around the valve stem  40 . The pump body or tank  42  is filled with material to be dispensed, since it is in communication with the container via the dip tube  25 ′. The stem is biased outwardly by a spring  48  acting between the bottom of the tank  42  and an annular flange  50  on the valve stem  40 . The inner end of passageway  46  in stem  40  is sealed from the tank.  
         [0032]     On operation, the stem  40  is pressed inwardly by an actuator (not shown) causing the inlet port  44  to pass through the gasket  41  into the tank  42  allowing material under pressure to flow out through the passageway  46 . Upon release of the stem it returns to the position shown to cut off the flow.  
         [0033]     Many existing products can benefit from the advantage of eliminating the problem of corrosion which occurs when using the standard 1 inch valve in which a metal mounting cup must be protective coat to be compatible with the metal container. This advantage results in further cost reduction beyond that of eliminating a part and the additional crimping step. The valve, which, as noted above, is typically made of plastic and includes a body and dip tube, can be supplied to the marketer of the product being dispensed who can then crimp it in place.  
         [0034]     In one method of use, after filling the container, the bottom  17 ′ is doubled seamed to the open bottom of the can  11 ′. The product can be cold filled with propellant mixture before attaching the bottom, or the bottom can be fitted with the one way valve  27  through which gas may admitted to pressurize the container at a later date, any time, anywhere.  
         [0035]     If the type of valve shown in  FIG. 4B  is used with a powder, for example, clogging in the passageway  46 , at the inlet port  44 , and for that matter in the tank  42  which remains filled with material is possible. Thus, an embodiment of the present invention provides an embodiment of a continuous flow valve with an orifice outside the seal, which eliminates clogging by insuring that no residue remains in the valve stem.  
         [0036]     The valve and actuator of  FIG. 4A  are shown is a depressed position. In this position, an orifice  44  is below the gasket or seal  41  so that material supplied by the dip tube  25  reaches a passageway  46  in the valve stem  40  to allow it to flow to the actuator  43  and be dispensed. If a powdery material such as starch is being dispensed, after operation, the orifice  44  or passageway  46  may become clogged. As noted above, in this valve, shown in the unoperated position in  FIG. 4B , the valve body or tank is always open to the container contents via the dip tube  25 ′. When operated, the inlet orifice  44  enters the tank  42  and material under pressure can flow through the outlet passage  46 . However, when it is released, the stem returns to the position shown in  FIG. 4A  and material can remain in the passage  46  and or orifice  41 .  
         [0037]     The anti-clog valve of the present invention avoids this problem. In this arrangement, the residue is cleared by vapor after product is expelled. A first embodiment of such a valve is shown in  FIGS. 5 and 6 .  FIG. 5  shows the valve in a mounting cup and  FIG. 6  shows it crimped in a container such as that of  FIG. 3 . The valve has a housing  101  with an attached dip tube  103 . Housing  101  had an enlarged annular portion  105  at its outer end. Gasket or seal  141  forming a valve seat is disposed between the portion  105  and portion  107  of the top of the can. The valve has a two piece stem. Upper stem  109  is a hollow cylindrical member with an orifice or port  111  leading to a discharge passage  113 . Its inner end  115  is of a smaller diameter and is inserted into lower stem part  117 . Lower stem part  117 , closed at its inner end, extends through a seal  119  at the bottom on the housing or tank  101 . This prevents the liquid from entering the hollow space in the lower stem part  117 . Liquid from the dip tube  103  is prevented from filling the housing  101 , because the lower stem part  117  seals against inlet seal  119 . The two piece stem is biased outwardly by a spring  118 .  
         [0038]     When the stem  109  is depressed by an actuator (not shown) a bottom stem orifice  121  bypasses inlet housing seal  119  and product passes through hollow stem part  117  and then through an orifice  122  to the housing. From the housing it reaches the orifice  111 , which is now below the seal  107  and passes into the passage  113  to be dispensed through the actuator. When the actuator is released the stem is returned to its rest position, the position shown in the Figures. The orifice  121  is closed before the orifice  111  passes through the seal  107 . As a result, the vapor phase remaining in the tank will clean out any powder or residue remaining in the valve orifices before the orifice  111  passes through the seal  107  to reach its rest position outside the seal  107 . Furthermore, the housing  101  remains will be empty.  
         [0039]     The two piece valve stem in  FIGS. 5 and 6  is typically made of metal. The housing in this embodiment may also be of metal. However, for the reasons noted above, i.e., to avoid problems with dissimilar metals, a plastic valve is preferred. Thus, the present invention provides another embodiment of anti-clog dispensing valve for dispensing material from a container, which can be made with a plastic stem, so the whole valve (except for the spring) is made of plastic as shown in  FIG. 7 . It includes a valve housing  101 ′ having an enlarged annular portion  102  at its outer end and adapted to accept a dip tube  103 ′ at its inner end. A gasket  107 ′ forming a valve seat is disposed at the outer end of annular portion  102  and adapted to be held between the outer end of annular portion  102  and an annular portion of the container to which the valve is attached.  
         [0040]     The valve has a plastic stem  125  with an upper cylindrical stem portion  127  with a bore  129  forming a discharge passage and a discharge orifice  131  in its wall leading to discharge passage  129 . The upper stem portion  127  extends through gasket  107 ′ with the orifice  131  above the gasket  107 ′ in the unoperated position of the valve. A lower cylindrical stem portion  133  closed at its inner end extends through an inlet seal  135  at the inner end of the housing  101 ′. An annular flange  137  is provided between the inner end of the upper cylindrical stem portion  127  and the outer end of the lower cylindrical stem portion  133 . A spring  139  extends between the inner end of the housing  101 ′ and the annular flange  137 , biasing said stem outwardly. In the lower cylindrical stem portion, a bypass passage  241  is formed. The ends of said passage are located so that upon actuation of the valve by pressing inwardly on stem  125 , after a first movement, an inner end  243  of the bypass  241  passes through the seal  135  to permit material to flow into the housing  101 ′ via the inner end  143  and out an outer end  245  of the passage. After further movement, the discharge orifice  131  passes through the gasket  107 ′ into the housing to allow material to be dispensed.  
         [0041]     This type of valve, in which the tank is sealed off when not dispensing, can also be constructed as a metering valve. If the outer end  245  of passage  241  is locate to close off before orifice  131  is opened to the housing  101 ′ this will be the case. As inner end  243  is moved past the seal  135 , the housing  101 ′ will fill with material. Then, outer end will close off so the only the material in the housing is available to dispense. Finally, orifice  131  moves past gasket  107  so that only the dose in the housing is dispensed.  
         [0042]     Upon release of the stem and return to a rest position by the spring, the bypass  241  closes before the orifice  131  is closed by gasket  107 ′. As a result, the remaining vapor phase propellant in the pump housing  101 ′ drives out material remaining in the housing  101 ′. This clears orifice  131  and passageway  129 . Subsequently, the orifice passes behind said gasket to terminate dispensing and the housing remains isolated from material in the container until the valve is again operated. Because the remaining pressure in the tank blew out the material in the tank before the outlet orifice was closed, the tank is essentially empty, and the outlet orifice and passageway free of material. As a result, clogging that would otherwise result in a conventional valve is avoided.  
         [0043]      FIG. 8  is a cross section of a second embodiment of an aerosol dispenser according the present invention. The metal drawn can or container  11 ,″ like can  11 ′ of  FIG. 3  can be fabricated from any available metal that can be drawn, for example, be means of a plunger press typically used in multiple stages for forming a container or receptacle out of aluminum. In the first step, a dome is formed, followed by formation of the mounting cup structure  21 ,″ which allows a valve or pump  23 ″ to be inserted from above. The following drawing steps, coating and decorating are as described in connection with  FIG. 3 . Again, shown separated from the can  11 ′ is the bottom  17 ″ which can be attached with a conventional double seal as in the embodiment of  FIGS. 1 and 2 .  
         [0044]     The top of the can  11 ″, in this case is shaped to accept an aerosol valve  23 ″ (or a pump) inserted from above with a press fit. Thus, at the diameter  19 ″, at about the spot where the prior art had a bead, the dome has a radially inwardly extending portion  310 . Extending axially outward from portion  310  is a cylindrical portion  312 . Just above the junction between portions  310  and  312 , the cylindrical portion is crimped inwardly to form a shoulder  314 , better seen in  FIG. 9 . This structure formed when fabricating the can provides a special opening or built-in mounting cup  21 ″, for allowing aerosol valve  23 ″ to be press fit into the cylindrical portion  312  from above. Valve  23 ″ may be a conventional valve, metered or continuous that can be press fit into the cylindrical portion  312  either by the container supplier or the marketer of the product. In particular, a valve such as that shown in FIGS.  6  or  7  may be used. Alternatively, valve  23 ″ may be a finger operated pump. Typically, such valves or pumps are made of plastic, as with the embodiment of  FIG. 7  and there is no need to be concerned about their reacting with the metal of the container  11 ″.  
         [0045]      FIG. 10  shows the valve  23 ″ press fit into the cylindrical portion  312 . It is inserted until the enlarged outer portion  316  of the valve abuts against shoulder  314 . The valve  23 ″ is held in place by crimping the outer part  318  of portion  312  both radially and axially inwardly so that it abuts the top of the outer portion of the valve  23 ″, with the valve stem  40  extending through the opening  320  remaining.  
         [0046]     As shown, for example, in  FIG. 11 , a gasket  41  may be provided to seal against the stem  40  and also seal against the enlarged outer portion  316  of the valve. In that case the tip of the outer portion will press against the gasket  41 . The enlarged outer portion  316  of the valve  23 ″ can be formed with a recess  322  to receive the gasket  41 . In addition, a sealant  324  may be provided in the location where the enlarged outer portion  316  of the valve abuts the shoulder  314  to insure no leakage at that point. An actuator of conventional design may be attached to the valve stem  40  to press it axially inwardly to dispense material in the form of a spray from the finished dispenser.  
         [0047]     With the construction of the embodiments of  FIGS. 8-11 , it becomes possible for the container, with bottom attached to be made by the container manufacturer. The container can be filled from the top before insertion of the valve. This is preferable done at the same location, but is also very amenable to filling by a contract filler who need only obtain the container and valve. After filling the container, he need only insert the valve and crimp the end  318  to hold it in place. This would be followed by pressurizing and testing in conventional fashion.  
       Method of Constructing and Filling  
       [0048]     Substantial savings can be achieved if the container manufacture who fabricates the container body and the bottom closure can assemble the valve in the top of the container that is formed to accept the modular valve, such as the anti-clog valve of  FIGS. 5 and 6  or  7 . Directly mounting the valve to the container avoids potential leakage due to improper crimping or problems caused by a dissimilar protective coating of the metal mounting cup that occur when using containers with the one inch opening.  
         [0049]     The container manufacturer can also perform the filling operation and put the actuator on the valve stem, check for leakage, and pack the finished product into shipping container to meet customer&#39;s specifications. The entire dispensing product can be produced under one roof with one manufacturer thereby reducing multiple responsibilities. Substantial savings are achieved by having to issue only one purchase order covering all the elements necessary to meet the customer&#39;s needs.  
         [0050]     Thus, as shown in  FIG. 12 , at one location, under one roof, first in step  201  the can or container is formed with a structure to accept a valve or pump as shown in  FIG. 3 . Then in step  203 , the inside of the can is coated and the outside decorated by painting, for example. In step  205  a valve or pump is inserted either by snapping in place or crimping into the top of the container  11 ′ of  FIG. 3 . The can is filled with the material to be dispensed in step  207  and the bottom  17 ′ is then attached in step  208 . The can is pressurized in step  209 . This can be done by cold filling the propellant in the liquid phase before attaching the bottom or by supplying it via the one way valve  27  of  FIG. 3 . In step  211 , the container is checked for leaks and in step  213  the actuator and any cover is put on the can. Finally the containers are packaged, temporarily stored in inventory and then shipped to buyers.  
         [0051]     Although it is most advantageous to do all operations at one location, there is still an advantage to doing all but container manufacture at the same location, e.g., by a contract filler. In that case steps  201  and  203  would be done by the container manufacturer and the remaining steps of  FIG. 12  at another location. The embodiment of  FIGS. 8-11  is particularly amenable to contract filling. In the past, with the prior art embodiments of  FIGS. 1 and 2 , the contract filler needed to crimp the mounting cup in place after filling the container from the top. In the present case, with the embodiment of  FIG. 8  he must only insert the valve and crimp it into place after filling from the top. Thus, in terms of the process shown in  FIG. 12  the steps  205  and  208  would be interchanged. That is the bottom would be attached before filling and the valve inserted after filling.  
         [0052]     These and other modifications can be made without departing from the spirit of the invention, which is intended to be limited solely by the appended claims.