Abstract:
A toggle-action dispensing closure is provided for manipulation between a closed, non-dispensing orientation and an open, dispensing orientation that is easily assembled, resists inadvertent opening and has an improved aesthetic appearance for variously shaped closures. The closure includes an actuator rotationally mounted on a housing whereby the housing may be secured to a container. The axis of rotation of the actuator is asymmetrically disposed in the housing. The actuator has a rear flange with an articulatable hinge that is longer than its front flange. When the closure is securely mounted to a container, the portion of the rear flange below the hinge resiliently contacts the container assisting in preventing inadvertently opening the closure.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    This invention relates to a toggle-action dispensing closure which can be manipulated between a closed orientation and an open, dispensing orientation. 
         [0003]    2. The Related Art 
         [0004]    Dispensing closures deliver consumer convenience and allow for product dispensing using simple mechanical action. Several versions of dispensing closures have been employed. See, for example, U.S. Pat. Nos. 5,341,950; 5,058,775; 4,952,869; 4,776,501; 4,545,086 and 3,516,581. One common version of the dispensing closure is commonly referenced as a “disk top” or “two piece pivot closure”. Prior art closures that require a separate housing and actuator and that rely on a centralized, symmetrically disposed pivot point to function are disadvantageous because the closure requires a secondary assembly step after molding to marry the actuator and housing parts together making a closable cap. This requires precision alignment under tight clearances in order to properly assemble the two pieces. The pivot point of the movable actuator must have a centered fulcrum point to have equal movement in the housing to create an unbroken seal between the two pieces during actuation. The captive actuator is held in the housing only by the two pivot points. This makes the closure more sensitive to premature opening or dislodging during handling. 
         [0005]    Surprisingly the problems of precision assembly and inadvertent opening were found to be solved by an actuator with an articulatable rear flange that is pivotally and asymmetrically mounted (off-centered) in the closure housing. The articulated actuator flange can be deflected inward to create a smaller foot print which eases the alignment of the actuator and housing during assembly improving quality, speed of assembly, expand design possibilities, be more tolerant of part variation due to tolerances and shrinkage, and potentially reduce part weight. This same feature also helps eliminate inadvertent opening due to housing deformation during shipment or due to rough handling. The articulatable hinge in the actuator was surprisingly seen to absorb energy transferred from housing deflection, thereby reducing the moment generated about the pivot point which prevents unintended opening. The force to actuate the articulation is less than what is required to open the closure. 
         [0006]    Prior art toggle closures with a long actuator flange or “tail” require sufficient clearance under the location (or “button”) that the user applies manual pressure to in order to open the toggle. The size and shape of the actuator will determine the amount of clearance required. The present invention allows for reduced or zero clearance beneath the button side of the actuator. Downward movement on the button of the actuator will articulate the rear flange of the actuator allowing the nozzle orifice to advance and open for dispensing. 
         [0007]    A further unexpected improvement was seen with respect to the elimination of a rear gap created between the housing and actuator with specific shaped actuators when the toggle is opened. This improves aesthetics and eliminates negative issues created by such a gap (e.g. cleanliness and sharp edges). 
       SUMMARY OF THE INVENTION 
       [0008]    In one aspect of the invention is a toggle-acting dispensing closure for use with an optional container, the closure includes but is not limited to: 
         [0000]    a. a housing having a transverse floor and outer wall;
 
b. an actuator having a top wall including a top rear wall overlying the transverse floor and defining a nozzle opening with a floor, the actuator being asymmetrically and pivotally mounted inside the housing for movement between a closed, non-dispensing position and an open, dispensing position;
 
c. a rear actuator flange extending below the top rear wall at a first location and extending within the housing;
 
d. the rear flange having a hinge with a major axis that divides the rear flange into an upper rear flange adjacent to the top rear wall and a lower rear flange adjacent to a rear flange rim; and
 
e. whereby the hinge major axis is oriented substantially parallel to the transverse floor.
 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The foregoing features, advantages, and objects of this invention are now described in more detail with reference to the drawings in which like numerals are employed to designate like parts throughout the same: 
           [0010]      FIG. 1  is a perspective view of the closure of the present invention shown in a non-dispensing, closed orientation; 
           [0011]      FIG. 2  is a perspective view of the closure shown in an open, dispensing orientation; 
           [0012]      FIG. 3  is a top plan view of the closure with the actuator removed to reveal interior details of the housing; 
           [0013]      FIG. 4  is a cross-sectional view taken generally along the plane  3 - 3  in  FIG. 3 ; 
           [0014]      FIG. 5  is an enlarged, cross-sectional view of the actuator taken generally along the plane  1 - 1  in  FIG. 1  with the housing omitted for clarity. 
           [0015]      FIG. 6  is a bottom plan view of the actuator taken generally along the plane  5 - 5  in  FIG. 5 ; 
           [0016]      FIG. 7  is a perspective view of the actuator depicted in  FIGS. 1 ,  2 ,  5  and  6 ; 
           [0017]      FIG. 8  is an enlarged, cross-sectional view taken generally along the plane  1 - 1  in  FIG. 1  showing the closure attached to a bottle; 
           [0018]      FIG. 9  is an enlarged, cross-sectional view taken generally along the plane  2 - 2  in  FIG. 2  showing the closure attached to a bottle; 
           [0019]      FIG. 10  is a cross-sectional view taken generally along the plane  4 - 4  in  FIG. 3 ; and 
           [0020]      FIG. 11  a bottom perspective view of the closure depicted in  FIG. 1   
       
    
    
     DETAILED DESCRIPTION 
       [0021]    For ease of description, the closure of this invention is described in an upright position, and terms such as upper, lower, horizontal, etc., are used with reference to this position. It will be understood, however, that the closure of this invention may be manufactured, stored, transported, used, and sold in an orientation other than the position described. 
         [0022]      FIG. 1  shows a preferred embodiment of the dispensing closure  10  of the present invention in the closed, non-dispensing position. The closure  10  is adapted to be mounted on a container  200  (see  FIGS. 8 and 9 ) which may have a conventional open mouth defined by a neck  210  (see  FIGS. 8 and 9 ) or other suitable structure. The container most typically is of the type having a generally flexible wall portion which can be squeezed by a user to assist in dispensing the contents from the container but is not limited thereto. 
         [0023]    The closure  10  includes a housing  14  ( FIGS. 1-4 ,  8 - 11 ) for attachment to the container  200 . The housing  14  includes a generally ovoid cylindrical, outer wall  16 . A generally transverse closure wall or floor  18  having upper surface  180  ( FIGS. 3 ,  4 ,  8 - 11 ) extends across actuator receptacle  15  molded into the housing  14 . Actuator receptacle  15  is further defined by diametrically opposed receptacle walls  11  and front wall  13 . Diametrically opposed roof segments  19  and shipping posts  87  flank aperture receptacle  15 . In a second preferred embodiment receptacle  15  and floor  18  extend to the periphery of the housing defined by outer wall  16  where walls  11  are coincident with portions of outer wall  16  (not shown). Actuator  50  replaces roof segments  19  in this second embodiment. 
         [0024]    Inner cylindrical wall  21  of housing  14  is adapted by way of snap-fit bead  190  to engage the outer periphery of the top of the container neck  210  around the container mouth  220 , as with complementary container snap-fit bead  230  (FIGS.  4  and  8 - 11 ). Other suitable engaging means (e.g. threads or any suitable equivalent) may be provided to secure the housing  14  on the container  200 . Alternatively, in some applications the housing  14  could be non-releasably attached to, or formed unitary with, the container  200 . 
         [0025]    An annular sealing ring  20  may be provided as shown in FIGS.  4  and  8 - 11  for engaging an interior edge of the container neck  210  at the container mouth to effect a tight seal. 
         [0026]    The housing  14  includes a discharge aperture or passage  30  through the floor  18  as illustrated in  FIGS. 3 ,  4 , and  8  to  10 . In a preferred embodiment, housing  14  includes a discharge tube  32  projecting upwardly from the floor  18 , and the discharge aperture  30  fluidly communicates with tube  32 . The discharge aperture  30  in the tube  32  communicates through the floor  18  with the optional container  200  interior at the lower end of the tube  32 . 
         [0027]    As shown in  FIGS. 3 ,  4 , and  8 - 11 , the ovoid cylindrical, outer wall  16  of housing  14  extends around the floor  18 . A rear portion of the wall  16  adjacent to floor  18  partially defines a finger recess area  34  in the form of a cutout or notch in the top edge of the rear portion of wall  16  opposite wall  13 . 
         [0028]    The housing  14  receives actuator  50 . The actuator  50  includes a transverse top wall  52  having a top rear wall  80 , a front peripheral flange  54  and diametrically opposed side flanges  59 . Adjacent to top rear wall  80  is a rear flange  55  having an articulatable hinge  57  dividing rear flange  55  into an upper rear flange  91  and a lower rear flange  93  with lower rim  101  ( FIGS. 1 ,  2 ,  5 - 9  and  11 ). At each of two opposed side flanges  59  there is a projecting, hemispherical protuberance or pivot member  56 , preferably with a flattened face ( FIGS. 6 and 7 ). 
         [0029]    In a preferred embodiment the pivot members  56  cooperate with the receptacle walls  11  by way of recesses  58  to asymmetrically mount the actuator  50  for pivoting movement within the housing  14 . To this end receptacle walls  11  each define recess  58  ( FIG. 3 ) for each mating with one of the pivot members  56  to provide a snap-action engagement of the pivot member  56 . This accommodates the pivoting movement of the actuator  50  about a pivot axis defined by a line joining the pivot members  56  wherein the pivot axis is parallel to transverse floor  18  and asymmetrically positioned within housing  14 . 
         [0030]    The top edge of the wall  11 , above each recess  58 , may be provided with a chamfer (not shown) for facilitating assembly. When the housing  14  and actuator  50  are assembled, the actuator pivot members  56  and housing recesses  58  function as part of the mounting structure so that the actuator  50  can be pivoted (by a user pushing downwardly on the rear portion of the actuator  50 ) until the nozzle  60  is exposed above the walls  11  and  13  as illustrated in  FIG. 2 . In the second preferred embodiment referred to above where the aperture recesses extend to housing outer wall  16 , the pivot members  56  cooperate with wall  16  by way of complementary recesses defined by wall  16  where receptacle  15  and wall  11  extend to the periphery of the housing  14  coincident with wall  16 . 
         [0031]    The actuator  50  includes a conduit structure  61  communicating with nozzle  60 , with a floor  105  connected to the bottom surface of the top wall  52 . The actuator functions, depending upon its orientation, to either permit dispensing of flowable material from the discharge tube  32  and nozzle  60  or occlude tube  32  so as to prevent flow out of nozzle  60 . In particular, as shown in  FIGS. 5 ,  6 ,  8  and  9 , conduit structure  61  fluidly communicates with stepped, cylindrical sealing walls  69 . 
         [0032]    The walls  69  surround and seal the upper periphery of the discharge tube  32  when the actuator  50  is in the closed position as illustrated in  FIGS. 1 and 8 . Preferably, a sealing plug  76  projects downwardly from the bottom of the actuator top wall  52 . The sealing plug  76  has a generally cylindrical or annular configuration and is adapted to sealingly engage the opening at the top of the discharge tube  32  to occlude the discharge aperture  30  and tube  32  when the actuator is in the closed position as illustrated in  FIGS. 1 and 8 . Tube  32  and walls  69  cooperate to provide sliding resistance to help prevent premature opening of the closure. 
         [0033]    On the other hand, when the top rear wall of the actuator  50  is pushed down to tilt the actuator to the dispensing position as illustrated in  FIGS. 2 and 9 , then the front portion of the sealing plug  76  is tilted away from the top of the discharge tube  32  to permit flow of the material out of the discharge aperture  30  in tube  32  through conduit  61  and dispensing nozzle  60 . When the actuator  50  is tilted to the dispensing position as illustrated in  FIGS. 2 and 9 , walls  69  ( FIGS. 5 and 9 ) continue to seal the outer periphery of the upper end of the discharge tube  32  so that the container contents, while being dispensed into conduit  61 , cannot leak out around the top of the discharge tube  32 . 
         [0034]    The actuator  50  can be pivoted to the open position by applying a downwardly directed force at the top rear wall  80  of the actuator  50 . To this end, the top rear wall  80  is preferably recessed within a well ( FIGS. 1 ,  2 ,  5  and  7 - 9 ) for receiving the end of a thumb or finger. In a preferred embodiment, actuator  50  has axles  81  rigidly connected to the bottom surface of top wall  52  that rotationally engage bearings  83  rigidly mounted on floor  18  ( FIGS. 3 and 6 ). Preferably actuator  50  is further supported by pivot support  85  rigidly connected to the bottom surface of top wall  52  and in pressing engagement with floor  18  while the actuator  50  pivots. 
         [0035]    In accordance with the present invention, a deformable integral hinge  57  is provided to prevent both accidental movement of the actuator  50  to the open, dispensing orientation and to allow easy assembly of the actuator into the closure housing  14 . This provides a closure which is resistant to inadvertent actuation during shipping and rough handling prior to use by a consumer. 
         [0036]    In operation when closure  10  sealingly engages optional container  200 , lower rear flange  93  pressingly engages an adjacent portion of container  200  which serves to provide a portion of the resistance to such inadvertent activation until a sufficiently large force is purposely applied to the top rear portion of actuator  50  ( FIG. 8 ). Additional optional forces preventing inadvertent activation of actuator  50  in this preferred embodiment include the sliding resistance shipping posts  87  provide against actuator  50  and the sliding resistance walls  69  provide against discharge tube  32 . When a sufficient level of force is applied to the top, rear portion of the actuator  50 , the lower rear flange  93  is deflected towards finger recess area  34  (away from the nozzle) ( FIG. 9 ). Simultaneously actuator  50  is pushed below shipping posts  87  and walls  69  are urged over tube  32 . The forces to which the actuator may be subjected during shipping and handling are typically insufficient to deflect or deform lower rear flange  93  as well as to overcome the other sources of resistance to tilt the actuator. Thus, the actuator  50  cannot be tilted to any significant extent away from the closed, non-dispensing position. 
         [0037]    However, when a consumer subsequently wishes to use the closure, the consumer initially applies a substantially greater force to the top rear wall  80  of actuator  50 . A force equal to or greater than, a predetermined force will simultaneously drive actuator  50  passed shipping posts  87 , walls  69  passed tube  32  and the lower rear flange  93  against container  200  with a force sufficient to deflect lower rear flange  93  along hinge  57  towards finger access area  34  causing the opening of the actuator  50  ( FIG. 9 ) as described above. 
         [0038]    The above-described rear flange retention structure can be readily molded in the closure actuator. Conventional molds can be relatively easily retrofitted to include this feature. 
         [0039]    In one aspect of the invention is a toggle-acting dispensing closure  10  for use with an optional container  200 , the closure includes but is not limited to: 
         [0000]    a. a housing  14  having a transverse floor  18  and outer wall  16 ;
 
b. an actuator  50  having a top wall  52  including a top rear wall  80  overlying the transverse floor  18  and defining a nozzle opening  60  with a nozzle floor  105 , the actuator  50  being asymmetrically and pivotally mounted inside the housing  14  for movement between a closed, non-dispensing position and an open, dispensing position;
 
c. a rear actuator flange  55  extending below the top rear wall  80  at a first location within the housing  14 ;
 
d. the rear flange  55  having a hinge  57  with a major axis that divides the rear flange  55  into an upper rear flange  91  adjacent to the top rear wall  80  and a lower rear flange  93  adjacent to a rear flange rim  101 ; and
 
e. whereby the major axis of the hinge is oriented substantially parallel to the transverse floor  18 .
 
         [0040]    Substantially parallel is defined as parallel or nearly so where the orientation of the hinge functions to both prevent inadvertent opening of the closure and facilitate assembly of the actuator into the housing as described above. 
         [0041]    Advantageously the closure further includes but is not limited to: 
         [0000]    a. a front actuator flange  54  extending below the nozzle floor  105  within the housing  14  having a length L 1  normal to the nozzle floor  105  and extending to a front flange rim  103  opposite the nozzle floor;
 
b. wherein the rear flange  55  has a length L 2  normal to the top rear wall  80  and extending to a rear flange rim  101  opposite the top wall  52 ;
 
c. wherein the ratio of L 1  to L 2  is in the range of about 0.1 to 0.33.
 
         [0042]    L 1  preferably has a maximum length of about 6 mm, more preferably in the range of about 1 to 6 mm, most preferably about 3 mm. L 2  preferably has a maximum length of about 18 mm, more preferably in the range of about 8 to 18 mm, and most preferably about 15 mm. The ratio of L 1  to L 2  is preferably about 0.2. 
         [0043]    Preferably the hinge  57  is spaced apart from the outer housing wall  16  and has a length L 3  wherein the hinge  57  is positioned at a distance of L 4  along a line normal to the upper surface  180  of the transverse floor  18  when the hinge is not flexed. Preferably L 3  has a minimum length of about 7 mm, more preferably in the range of about 7 to 40 mm, and most preferably about 25 mm. Preferably L 4  has a minimum value of 0.1 mm, more preferably L 4  is about 1 mm or less, most preferably L 4  is less than about 1 mm. The hinge  57  is positioned at a distance of L 5  along a line normal to the hinge and extending to the lower rear flange rim when the hinge is not flexed. Preferably the ratio of L 4  to L 5  is in the range of about 0.01 to 0.20 (advantageously about 0.03). In a preferred embodiment L 5  is about 12 mm. 
         [0044]    Advantageously the lower rear flange  93  is adapted to resiliently contact an optional container  200  the closure  10  is sealingly engaged to whereby the lower rear flange  93  prevents movement of the actuator  50  on said container  200  in response to the application of a first force at the rear top wall  80  of the actuator opposite the Nozzle (“the first location”), but permits movement of said actuator  50  in response to a substantially higher second force downwardly applied at said first location. 
         [0045]    In a preferred embodiment, the hinge is a thin region of plastic of less than or equal to 1 mm in thickness that is integrally molded in the actuator. Preferably the actuator includes but is not limited to a thermoplastic material and the rear lower flange is resilient at 25 C allowing it to flex when a user applies moderate force to the rear of the actuator to open the closure. Preferably this opening force is in the range of about 25 to 50 Newtons (5.6 to 11 lb ft.) and optimally at a minimum of about 30 or 35 Newtons and a maximum of about 40 or 45 Newtons. The actuator thermoplastic flexural modulus range is preferably about 600 to 2000 MPa (mega pascals) at 25 C. 
         [0046]    Preferably the axis of rotation of the actuator with respect to the housing is offset from the center line of the housing by at least 80% where 0% allows symmetric rotation and 100% allows no rotation within the housing. 
         [0047]    The closure of the present invention can be readily molded from thermoplastic materials and easily assembled to provide a stream-lined product. Thermoplastic resins such as polypropylene and polyethylene are preferably used, since tight engagement must be established between the actuator and the housing and between the housing and the container. Suitable containers that can be employed with the inventive closure are preferably made of such material that enables the vessel to be squeezed by hand and rapidly restored to its original form upon recovery. Examples of suitable materials include thermoplastic resins such as polypropylene, polyethylene, polyethylene terephthalate, polyvinyl chloride, nylon, or laminates thereof, and the like. 
         [0048]    While this invention has been described with respect to particular embodiments thereof, it is apparent that numerous other forms and modifications of the invention will be obvious to those skilled in the art. The appended claims and this invention generally should be construed to cover all such obvious forms and modifications which are within the true spirit and scope of the present invention.