Abstract:
A method of pressurizing a container usable for an aerosol dispenser. The method comprises providing a pressurizeable outer container and complementary valve cup, at least one having a channel into the container. A manifold is brought into sealing relationship with the channel of the container. Propellant is supplied from the manifold, goes through the channel and into the container. While the manifold is still sealed to the container, the channel is sealed shut to maintain the pressure. Sealing may be accomplished by sonic or ultrasonic welding.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention relates to aerosol dispensers and the manufacture of components thereof. 
       BACKGROUND OF THE INVENTION 
       [0002]    Aerosol dispensers are well known in the art. Aerosol dispensers typically comprise an outer container which acts as a frame for the remaining components and as a pressure vessel for propellant and product contained therein. Outer containers made of metal are well known in the art. However, metal containers can be undesirable due to high cost and limited recyclability. 
         [0003]    The outer containers are typically, but not necessarily, cylindrical. The outer container may comprise a bottom for resting on horizontal surfaces such as shelves, countertops, tables etc. The bottom of the outer container may comprise a re-entrant portion as shown in U.S. Pat. No. 3,403,804. Sidewalls defining the shape of the outer container extend upwardly from the bottom to an open top. 
         [0004]    The open top defines a neck for receiving additional components of the aerosol dispenser. The industry has generally settled upon a neck diameter of 2.54 cm, for standardization of components among various manufacturers, although smaller diameters, such as 20 mm, are also used. Various neck shapes are shown in US 2007/02782531 A1; U.S. Pat. Nos. 7,303,087; 7,028,866; and commonly assigned U.S. Pat. No. 6,019,252. 
         [0005]    Typically a valve cup is inserted into the neck. The valve cup is sealed against the neck to prevent the escape of the propellant and loss of pressurization. The valve cup holds the valve components which are movable in relationship to the balance of the aerosol dispenser. 
         [0006]    Aerosol dispensers, having a valve cup and movable valve components, may comprise different embodiments for holding, storing, and dispensing product used by the consumer. In one embodiment, the product and propellant are intermixed. When the user actuates the valve, the product and propellant are dispensed together. This embodiment may utilize a dip tube. The dip tube takes the product and propellant mixture from the bottom of the outer container. By dispensing from the bottom of the outer container, the user is more likely to achieve dispensing of the product/propellant mixture and not dispense pure propellant from the headspace. This embodiment may be used, for example, to dispense shaving cream foams. 
         [0007]    The dip tube embodiment of an aerosol dispenser has the disadvantage that when the user tips the aerosol dispenser from a vertical orientation, dispensing of gas from the headspace, rather than dispensing of product/propellant mixture, may occur. This disadvantage may occur when the aerosol dispenser contains a product such as a body spray, which the user dispenses all over his/her body, often from inverted positions. 
         [0008]    To overcome this disadvantage, other embodiments could be utilized. For example, a collapsible, flexible bag may be sealed to the opening on the underside of the valve cup or may be placed between the valve cup and the container. This bag limits or even prevents intermixing of the contents of the bag and the components outside of the bag. Thus, product may be contained in the bag. Propellant may be disposed between the outside of the bag and the inside of the outer container. Upon actuation of the valve, a flow path out of the bag is created. Gage pressure from the propellant disposed between the bag and the outer container causes pressurization of the product, forcing the product to flow into ambient pressure. This embodiment is commonly called a bag on valve and may be used, for example, in dispensing shaving cream gels. In either embodiment, flow to the ambient may comprise droplets, as used for air fresheners or may comprise deposition on a target surface, as may occur with cleansers. 
         [0009]    The process for manufacturing a bag on valve type aerosol dispenser is complicated. One the filling operation is used to pressurize the outer container with propellant. This filling operation may utilize hydrocarbon propellant and/or inert gas propellant, such as Tetrafluoroprop-1-ene commercially available from Honeywell Company of Morristown, N.J. 
         [0010]    Specialized equipment is typically used for pressurizing the outer container with the various propellant gases. If a hydrocarbon propellant is selected, the manufacturing process becomes more complex and costly due to safety concerns, environmental regulations and other industry regulations. 
         [0011]    Propellant filling of aerosol dispensers presents its own challenges. Propellant must be added to the outer container, without contaminating the inside of the bag, if present. Further, leakage to the ambient must be minimized. And the relevant portions of the aerosol container must be sealed in a manner to prevent later leakage and depressurization after shipment, handling and storage. 
         [0012]    Yet different equipment must be utilized for disposing the desired product into the bag. Often, the outer container pressurization and disposing of product inside the bag occur in two separate operations at the same location. This manufacturing process is influenced by industry regulations governing transport, storage and shipping of pressure vessels, such as an aerosol dispenser. Thus, to avoid extra shipping operations, the pressurization step and product filling step often occur at the same site. 
         [0013]    However, utilizing a common site for pressurization and filling of the aerosol dispenser presents certain problems and inherent fixed costs. For example, each manufacturing site must have the complex and highly regulated propellant pressurizing equipment and safety systems. Yet, multiple manufacturing sites may be desirable if the product is to be shipped to several geographies. 
         [0014]    Conversely, if a single manufacturing site is used to source multiple geographies, that site must be knowledgeable in specific products and consumer preferences for each geography. Some of the geographies may be remote. A single manufacturing site may not be able to quickly respond to changes in consumer preference or to tailor the product to the unique consumer preferences in different geographies. Different geographies may further have different labeling requirements and languages. Additionally, import duties and taxes for finished products are typically higher than the duties and taxes for intermediates exported to that same country. 
         [0015]    Thus, limiting complex manufacturing to fewer sites/first regions, then exporting a product to a second region for completing the manufacturing process may be viable. Such manufacturing may provide cost benefits for the product and convenient customization of the product for the second region. 
       SUMMARY OF THE INVENTION 
       [0016]    The invention comprises a method of pressurizing a container usable for an aerosol dispenser, by providing a pressurizeable outer container having a neck with a neck periphery and a hole therethrough, optionally providing a valve cup sealable to the hole of the outer container, at least one of the outer container and valve cup having at least one channel forming a flow path from the outside of said outer container to the inside of said outer container, optionally disposing the valve cup onto the neck of the outer container, applying a manifold over the at least one channel, the manifold being in fluid communication with the channel and with a supply of propellant, dispensing propellant from the supply, into the outer container to internally pressurize the container; sealing the channel, to keep said propellant therein at a pressure at least as great as atmospheric pressure; and removing the manifold from said at least one channel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1  is a perspective view of an aerosol dispenser according to the present invention having a plastic outer container and a bag. 
           [0018]      FIG. 2A  is an exploded perspective view of the aerosol dispenser of  FIG. 1  having a collapsible bag. 
           [0019]      FIG. 2B  is an exploded perspective view of the aerosol dispenser of  FIG. 1  having a dip tube. 
           [0020]      FIG. 3A  is a perspective view of the pressurizable container of the aerosol dispenser of  FIG. 1  having a plastic outer container. 
           [0021]      FIG. 3B  is a perspective view of a perspective view of a pressurizable container according to the present invention having a metal outer container and a clinched valve cup. 
           [0022]      FIG. 4  is an exploded perspective view of the pressurizable container of  FIG. 3A  and having an outer container, bag, valve cup and valve assembly. 
           [0023]      FIG. 5  is a vertical sectional view of the pressurizable container of  FIG. 3A . 
           [0024]      FIG. 6  is a perspective view of a representative valve assembly usable with the aerosol dispenser of the present invention. 
           [0025]      FIG. 7  is a vertical sectional view of the valve assembly of  FIG. 6 , as inserted into a sleeve. 
           [0026]      FIG. 8  is a fragmentary exploded perspective view of the valve cup and neck of the outer container of  FIGS. 3A ,  4  and  5 . 
           [0027]      FIG. 9  is a schematic sectional view of a representative manifold engaging a pressurizable outer container for filling with propellant. 
           [0028]      FIG. 10  is a vertical sectional view an aerosol dispenser having a bag and plural valve assemblies in a single outer container. 
           [0029]      FIG. 11A  is a schematic block diagram of a divided manufacturing process according to the present invention having the container pressurized at the point of manufacture. 
           [0030]      FIG. 11B  is a schematic block diagram of a divided manufacturing process according to the present invention having the container pressurized at a second location, with product added at this location or a successive location. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0031]    Referring to  FIGS. 1 ,  2 A and  2 B, an aerosol dispenser  20  is shown. The aerosol dispenser  20  comprises a pressurizeable outer container  22  usable for such a dispenser. The outer container  22  may comprise plastic or metal, as are known in the art. The outer container  22  may have an opening. The opening is typically at the top of the pressurizeable container when the pressurizeable container is in its-in use position. The opening defines a neck  24 , to which other components may be sealed. 
         [0032]    A valve cup  26  may be sealed to the opening of the outer container  22 , as described in further detail below. A valve assembly  28 , in turn, may be disposed within the valve cup  26 . The valve assembly  28  provides for retention of product  42  within the aerosol dispenser  20  until the product  42  is selectively dispensed by a user. The valve assembly  28  may be selectively actuated by an actuator  30 . Neither the valve assembly  28  nor the actuator  30  form any part of the claimed invention. 
         [0033]    Selective actuation of the valve assembly  28  allows the user to dispense a desired quantity of the product  42  on demand. Illustrative and nonlimiting products  42  for use with the present invention may include shave cream, shave foam, body sprays, body washes, perfumes, cleansers, air fresheners, astringents, foods, paints, etc. 
         [0034]    Inside the outer container  22  may be a product delivery device. The product delivery device may comprise a collapsible bag  32  as shown in  FIG. 2A . The collapsible bag  32  may be mounted in sealing relationship to the neck  24  of the container and/or to the valve assembly  28 . This arrangement is known in the art as a bag-on-valve. The collapsible bag  32  may hold product  42  therein, and prevent intermixing of such product  42  with propellant  40 . The propellant  40  may be stored outside the collapsible bag  32 , and inside the outer container  22 . 
         [0035]    The collapsible bag  32  may expand upon being charged with product  42 . Such expansion decreases the available volume inside the outer container  22 . Decreasing the available volume increases the pressure of any propellant  40  therein according to Charles law. 
         [0036]    The product delivery device may alternatively or additionally comprise a dip tube  34  as shown in  FIG. 2B . The dip tube  34  extends from a proximal end sealed to the valve assembly  28 . The dip tube  34  may terminate at a distal end juxtaposed with the bottom of the outer container  22 . This embodiment provides for intermixing of the product  42  and propellant  40 . Both are co-dispensed in response to selective actuation of the valve assembly  28  by a user. Again, insertion of product  42  and/or propellant  40  into the outer container  22  increases pressure therein according to Charles law. 
         [0037]    Referring to  FIGS. 3A ,  3 B,  4  and  5 , the aerosol dispensers  20 , and components thereof, may have a longitudinal axis, and may optionally be axi-symmetric with a round cross section. Alternatively, the outer container  22 , product delivery device, valve assembly  28 , etc., may be eccentric and have a square, elliptical or other cross section. 
         [0038]    Referring particularly to  FIGS. 3A ,  4  and  5  the outer container  22  may comprise a plastic pressurizeable container. The plastic may be polymeric, and particularly comprise PET. The valve assembly  28 , and optional valve cup  26  may be welded to the neck  24  of the outer container  22 , as discussed below. Referring to particularly to  FIG. 3B , the outer container  22  may be made of metal, such as steel and/or aluminum. If so, the valve cup  26  may be clinched to the neck  24  in known fashion. 
         [0039]    Referring to  FIGS. 6-7 , any number of known valve assemblies may be usable with the present invention. One suitable and non-limiting example, is shown. In this example, a rigid sleeve  54  may be attached to the top of the bag with an impermeable seal. An elastically deformable plug may be tightly inserted into the sleeve  54 . Longitudinal movement of the plug, in the downward direction and within the sleeve  54  may allow product  42  to be selectively dispensed. The sleeve  54  may be impermeably joined to an optional valve cup  26 . The valve cup  26 , in turn, may be joined to the neck  24  of the outer container  22 . A suitable plug and sleeve  54  type valve assembly  28  may be made according to the teachings of commonly assigned publications 2010/0133301 A1 and/or 2010/0133295 A1. 
         [0040]    The pressurizeable container may further include a propellant  40 . The propellant  40  may be disposed between the outer container  22  and the product delivery device. Alternatively propellant  40  may be disposed in the outer container  22  and/or the collapsible bag  32 . Typically the pressure in the outer container  22  is greater than the pressure in the collapsible bag  32 , so that product  42  may be dispensed from within the bag. If a dip tube  34  is selected for the product delivery device, the propellant  40  and product  42  may be intermixed, and thus co-dispensed. The pressure of the propellant  40  within the outer container  22  provides for dispensing of the product  42 /co-dispensing of product  42 /propellant  40  to ambient, and optionally to a target surface. The target surface may include a surface to be cleaned or otherwise treated by the product  42 , skin, etc. Such dispensing occurs in response to the user actuating the valve assembly  28 . 
         [0041]    Referring generally to  FIGS. 3A ,  3 B,  4  and  5 , and examining the components in more detail, the pressurizeable container may comprise an outer container  22  having a hole with a valve cup  26  therein or disposable therein. A user activated valve assembly  28  may be disposed in the valve cup  26 . A product delivery device may be joined to the valve cup  26 . Propellant  40  may be disposed between the outer container  22  and the product delivery device. The product  42  and propellant  40  may be separately dispensed or may be dispensed together. 
         [0042]    If the product delivery device comprises a flexible, collapsible bag  32 , the pressure boundary for the propellant  40  is formed, in part, by the collapsible bag  32 . If the product delivery device comprises a dip tube  34 , the pressure boundary for the propellant  40  is formed, in part by the underside of the valve assembly  28  when the valve is closed. 
         [0043]    If desired, the outer container  22 , valve cup  26 , valve assembly  28 , dip tube  34  and/or collapsible bag  32  may be polymeric. By polymeric it is meant that the component is formed of a material which is plastic, comprises polymers, and/or particularly polyolefin, polyester or nylons. Thus, the entire aerosol dispenser  20  or, specific components thereof, may be free of metal, allowing exposure to microwave energy. 
         [0044]    Thus, an aerosol dispenser  20 , or pressurizable container therefor, according to the present invention may be microwavable. Microwave heating of the aerosol dispenser  20  or pressurizable container therefor provides for heating of the product  42  prior to dispensing. Heating of the product  42  prior to dispensing may be desirable if the product  42  is applied to the skin, becomes more efficacious at lower viscosities, or is to be eaten. 
         [0045]    If desired, the outer container  22 , collapsible bag  32 , and/or dip tube  34 , may be transparent or substantially transparent. If both the outer container  22  and a collapsible bag  32  used as the product delivery device are transparent, this arrangement provides the benefit that the consumer knows when product  42  is nearing depletion and allows improved communication of product  42  attributes, such as color, viscosity, etc. Also, labeling or other decoration of the container may be more apparent if the background to which such decoration is applied is clear. Alternatively or additionally, the outer container  22 , collapsible bag  32 , etc. may be transparent and colored with like or different colors. 
         [0046]    The outer container  22  may define a longitudinal axis of the aerosol dispenser  20 . The outer container  22  may be axisymmetric as shown, or, may be eccentric. While a round cross-section is shown, the invention is not so limited. The cross-section may be square, elliptical, irregular, etc. Furthermore, the cross section may be generally constant as shown, or may be variable. If a variable cross-section is selected, the outer container  22  may be barrel shaped, hourglass shaped, or monotonically tapered. 
         [0047]    The outer container  22  may range from 6 to 40 cm in height, taken in the axial direction and from 4 to 60 cm in diameter if a round footprint is selected. The outer container  22  may have a volume ranging from 115 to 1000 cc exclusive of any components therein, such as a product delivery device. The outer container  22  may be injection stretch blow molded. If so, the injection stretch blow molding process may provide a stretch ratio of greater than 8, 8.5, 9, 9.5, 10, 12, 15 or 20. 
         [0048]    The outer container  22  may sit on a base. The base is disposed on the bottom of the outer container  22  and of the aerosol dispenser  20 . Suitable bases include petaloid bases, champagne bases, hemispherical or other convex bases used in conjunction with a base cup. Or the outer container  22  may have a flat base with an optional punt. 
         [0049]    A punt is a concavity in the bottom of the container and extending towards the neck  24  of the container. A punt is distinguishable from a general concavity in the bottom of a container, as a punt has a smaller diameter than is defined by the footprint of the bottom of the container. The punt may be axisymmetric about the longitudinal axis. The vertex of the punt may be coincident the longitudinal axis. 
         [0050]    The outer container  22  sidewall also defines a diameter. The sidewall and bottom of the container may be connected by a chamfer. As used herein a chamfer refers to an angled wall which is substantially flat as taken in the radial direction. The chamfer may be angled, relative to the longitudinal axis, at least 30, 35 or 40° and not more than 60, 55 or 50°. In a degenerate case, the chamfer may be angled at 45° relative to the longitudinal axis. 
         [0051]    If desired, the bottom of the container may comprise radially oriented internal ribs. The ribs may be of like geometry, and be spaced outwardly from the longitudinal axis. Each rib may intercept the sidewall of the outer container  22 . The ribs may be equally circumferentially spaced from adjacent ribs. 
         [0052]    It has been found that a plastic outer container  22  conforming to the aforementioned radius percentage and punt diameter to area ratio does not creep under pressures ranging from 100 to 970 kPa, and having a sidewall thickness less than 0.5 mm. The outer container  22  may be pressurized to an internal gage pressure of 100 to 970, 110 to 490 or 270 to 420 kPa. A particular aerosol dispenser  20  may have an initial propellant  40  pressure of 1100 kPA and a final propellant  40  pressure of 120 kPa, an initial propellant  40  pressure of 900 kPA and a final propellant  40  pressure of 300 kPa, an initial propellant  40  pressure of 500 kPA and a final propellant  40  pressure of 0 kPa, etc. 
         [0053]    The aerosol dispenser  20 , as presented to a user may have an initial pressure. The initial pressure is the highest pressure encountered for a particular filling operation, and corresponds to no product  42  yet being dispensed from the product delivery device. As product  42  is depleted, the outer container  22  approaches a final pressure. The final pressure corresponds to depletion of substantially all product  42 , except for small residual, from the product delivery device. 
         [0054]    Thus, a suitable outer container  22  can be made without excessive material usage and the associated cost and disposal problems associated therewith. By reducing material usage, the user can be assured that excessive landfill wasted is not produced and the carbon footprint is reduced. 
         [0055]    As the top of the outer container  22  is approached, the outer container  22  may have a neck  24 . The neck  24  may be connected to the container sidewall by a shoulder  25 . The shoulder  25  may more particularly be joined to the sidewall by a radius. The shoulder  25  may have an annular flat. The neck  24  may have a greater thickness at the top of the outer container  22  than at lower portions of the neck  24  to provide a differential thickness. Such differential thickness may be accomplished through having an internally stepped neck  24  thickness. 
         [0056]    Any suitable propellant  40  may be used. The propellant  40  may comprise a hydrocarbon as is known as in the art, nitrogen, air and mixtures thereof. Propellant  40  listed in the US Federal Register 49 CFR 1.73.115, Class 2, Division 2.2 are considered acceptable. The propellant  40  may particularly comprise a Trans-1,3,3,3-tetrafluoroprop-1-ene, and optionally a CAS number 1645-83-6 gas. 
         [0057]    Such propellant  40  provide the benefit that they are not flammable, although the invention is not limited to inflammable propellant  40 . One such propellant  40  is commercially available from Honeywell International of Morristown, N.J. under the trade name HFO-1234ze or GWP-6. 
         [0058]    If desired, the propellant  40  may be condensable. By condensable, it is meant that the propellant  40  transforms from a gaseous state of matter to a liquid state of matter within the outer container  22  and under the pressures encountered in use. Generally, the highest pressure occurs after the aerosol dispenser  20  is charged with product  42  but before that first dispensing of that product  42  by the user. A condensable propellant  40  provides the benefit of a flatter depressurization curve as product  42  is depleted during usage. 
         [0059]    A condensable propellant  40  provides the benefit that a greater volume of gas may be placed into the container at a given pressure. Upon dispensing of a sufficient volume of product  42  from the space between the outer container  22  and the product delivery device, the condensable propellant  40  may flash back to a gaseous state of matter. 
         [0060]    The propellant  40  may be provided at a pressure corresponding to the final pressure of the aerosol dispenser  20  when substantially all product  42  is depleted therefrom. The propellant  40  may be charged to a pressure of less than or equal to 300, 250, 225, 210, 200, 175 or 150 kPa. The propellant  40  may be charged to a pressure greater than or equal to 50, 75, 100 or 125 kPa. 
         [0061]    Referring to  FIGS. 8 and 9  the optional valve cup  26  may be sealed to the top of the outer container  22  while the outer container  22  is pressurized. The sealing process may be accomplished by providing the outer container  22  and valve cup  26 . One of skill will understand that if the valve assembly  28  fits to the neck  24 , the optional valve cup  26  may be omitted. In such an embodiment, the valve assembly  28  is directly sealed to the neck  24 . While the following description is directed to incorporating a valve cup  26 , one of skill will recognize the invention is not so limited. 
         [0062]    The valve cup  26  may have a valve cup  26  periphery complementary to the neck  24  periphery. At least one of the valve cup  26  and/or container neck  24  may have a channel  50  therethrough. Additionally or alternatively, the channel  50  may be formed at the interface between the valve cup  26  and container neck  24 . 
         [0063]    A channel  50  is considered to be functional, so long as it allows fluid communication from the ambient, or more particularly a filling manifold  52 , into the outer container  22 . In a degenerate case, the channel  50  may be coincident a radial direction or parallel to the longitudinal axis. 
         [0064]    A plurality of radial channel  50  may be provided, to allow for faster filling of the propellant  40 . The plurality of radial channel  50  may be generally equally circumferentially spaced or unequally spaced about the periphery of the outer container  22  and/or valve cup  26 . Likewise, the plurality of radial channel  50  made be of equal or unequal cross-section and of constant or variable cross-section. In a degenerate case, a single radial channel  50  may be provided. 
         [0065]    After the valve cup  26  is disposed onto the neck  24  of the container, or the top of the container if no neck  24  is utilized, the filling manifold  52  is applied over the valve cup  26 . The manifold  52  is in fluid communication with a supply of propellant  40  and with at least one channel  50 . 
         [0066]    The manifold  52  temporarily seals to an anvil. The anvil provides a temporary seal for the moving portion of the manifold  52 . The anvil may comprise a sleeve  54  into which the outer container  22  is placed. The sleeve  54  may be used to transport the pressurizable/pressurized container between stations during manufacture. Additionally or alternatively, the shoulder  25  of the outer container  22  may be used as the anvil. 
         [0067]    The temporary seal may be accomplished through compression, applied in the longitudinal direction, between the manifold  52  and the anvil. One of skill will understand that at least one channel  50  may be disposed through the sidewall, bottom, neck  24  and/or other suitable positions on the outer container  22 . Any such arrangement may be used, so long as a seal is established and the channel  50  is sealed, as described below. 
         [0068]    After the temporary seal is established, propellant  40  is introduced into the manifold  52  and flows, under pressure, from the supply, through one or a plurality of channel  50 , and into the outer container  22 . This step provides pressure to the inside of the outer container  22 . If a compressible flexible bag is selected for the product delivery device, the propellant  40  remains outside of the bag and the bag remains empty. 
         [0069]    When the desired propellant  40  pressure is reached, the valve cup  26  may be sealed to the neck  24  or top of the outer container  22  to prevent leakage therefrom. If channel  50  are used in a location other than at the interface between the valve cup  26  and container neck  24 , such channel  50  may likewise be sealed. 
         [0070]    Sealing may occur through sonic welding or untrasonic welding as are known in the art. Alternatively or additionally, sealing may occur through spin welding, vibration welding, adhesive bonding, laser welding, or fitting a plug into the port as are known in the art. If desired, the valve cup  26  and the outer container  22  may have identical, or closely matched, melt indices, to improve sealing. A welding apparatus is available from Branson Ultrasonics Corp., of Danbury Conn. 
         [0071]    Referring back to  FIG. 3A , if desired, the channel  50  may not be radially oriented, but instead may be axially oriented. Axial channel  50  may have an orientation primarily in the axial direction and provide fluid communication from the ambient to the inside of the outer container  22 . Of course channel  50  may be oriented in a skewed direction relative to the radial direction and the longitudinal direction. 
         [0072]    One of skill will recognize channel  50  having a combination of orientations may be utilized, so long as a filling manifold  52  having complementary sealing is provided. One of skill will further recognize that plural manifold  52  may be utilized. Plural manifold  52  provide the benefit that each manifold  52  may have a different propellant  40 , and the propellant  40  are not intermixed until filling occurs. Plural manifold  52  may also provide the benefit that different manifold  52  may be tailored to different channel  50 , so that a proper seal occurs during filling. 
         [0073]    When the outer container  22  is pressurized with propellant  40  to the desired pressure and the valve cup  26  is sealed thereon, the manifold  52  may be removed. Thus, under this manufacturing process, the valve cup  26  and outer container  22  are sealed while under pressure from the manifold  52  propellant  40 . The sealing step may occur during or after the propellant  40  charging step. 
         [0074]    During the propellant  40  charging operation, if desired, the collapsible bag  32  may be opened with a plunger. The plunger allows air within the bag to escape. As the bag collapses due to increasing pressure from the propellant  40 , air will be evacuated therefrom. Such evacuation minimizes problems during the sealing operation. 
         [0075]    If desired, the valve cup  26  may be sealed to the container utilizing a press fit, interference fit, solvent welding, laser welding, vibration welding, spin welding, adhesive or any combination thereof. An intermediate component, such as a sleeve  54  or connector may optionally be disposed intermediate the valve cup  26  and neck  24  or top of the outer container  22 . Any such arrangement is suitable, so long as a seal adequate to maintain the pressure results. 
         [0076]    Referring to  FIG. 10 , plural valves may be used with a single outer container  22 . This arrangement provides the benefit that product  42  and propellant  40  are mixed at the point of use, allowing synergistic results between incompatible materials. This arrangement also provides the benefit that delivery of the propellant  40  provides motive force to the product  42 , often resulting in smaller particle size distributions. Smaller particle size distributions can be advantageous for uniform product  42  distribution and minimizing undue wetting. 
         [0077]    This arrangement provides the additional benefit that relative proportions of different materials may be tuned to a particular ratio for dispensing. For example, a product  42  may be dispensed and having a 3.5:1 ratio of a first component to a second component. While  FIG. 10  illustrates an aerosol dispenser  20  having two valve assemblies, one of skill will recognize the invention is not so limited. The aerosol dispenser  20  may have three, four or more valve assemblies, with a like number of or lesser number of chambers  60  to isolate different product  42  materials until the point of use. 
         [0078]    Referring to  FIG. 11A , if desired the manufacture of the pressurizeable container according to the present invention may be divided into two or more phases according to time and/or location. For example, the outer container  22 , valve cup  26 , valve assembly  28 , product delivery device and propellant  40  may be manufactured as a unit. 
         [0079]    Such a unit may comprise a pressurizeable container. The product delivery device, as manufactured, is empty. By empty it is meant that the product delivery device contains no product  42  or traces thereof. Further, an product delivery device has never contained product  42 . Further, the product delivery device contains no air other than atmospheric or residual air inherent to the manufacturing process. If the product delivery device has been filled and depleted, it is no longer considered empty. Empty is a state which exists only prior to the first filling of the product delivery device with product  42 . Further the empty state must last longer than an incidental period of a few seconds during transport between stations to be considered a state. 
         [0080]    Thus, if the empty product delivery device comprises a collapsible bag  32 , the bag may have an open end joined and sealed to the valve cup  26 . However, the bag has no product  42  and no air at a pressure greater than atmospheric therein. 
         [0081]    Alternatively, if the product delivery device comprises a dip tube  34 , the dip tube  34  is open to the inside of the outer container  22 . The inside of the empty outer container  22  contains no product  42 , but may contain propellant  40  at a pressure greater than atmospheric pressure. 
         [0082]    In a first phase of manufacture, the pressurizeable container may be manufactured to have a propellant  40  therein. Propellant  40  is contained between the outer container  22  and the bag or within the outer container  22  if a dip tube  34  is used. Thus, at the end of the first phase of manufacture, the pressurized but container has propellant  40  sealed and pressurized therein but no product  42 . The propellant  40  pressure may be selected according to the dispensing conditions. The pressure within the pressurized container as manufactured and prior to charging with the product  42  may correspond to the final pressure that the user encounters when product  42  is depleted. 
         [0083]    Product  42  may be charged into the container through the valve assembly  28 , as is known in the art. When product  42  is charged into the container, the product  42  increases the pressure of the propellant  40 . The increase in propellant  40  pressure occurs due to the increase in volume of the collapsible bag  32  if such a bag is used as a product delivery device. Likewise, the increase in propellant  40  pressure occurs due to the increase in the number of moles of product  42  in the outer container  22  if a dip tube  34  is selected. 
         [0084]    The pressurizeable container may be charged with an amount of product  42  which brings the pressure, as initially presented to the user, sufficient to dispense and substantially deplete the product  42  from the aerosol dispenser  20 . The final pressure, after substantially all product  42  is depleted, is less than the initial pressure. 
         [0085]    The pressure of the propellant  40  at the end of the first phase of manufacture may correspond to the pressure at the end of the usable life of the aerosol dispenser  20 , herein referred to as the final pressure. The pressure of the propellant  40  at the end of the second phase of manufacture may correspond to the pressure as initially presented to the user. 
         [0086]    By dividing the manufacture into plural phases, unexpected cost reduction and manufacturing flexibility may result. Particularly, manufacturing plants using propellant  40  are typically required, based upon country location, to meet more stringent environmental and safety requirements than plants which do not involve propellant  40 . 
         [0087]    Thus, if desired, a limited number of plants may be selected to manufacture the pressurizeable container of the present invention. The pressurized containers may be shipped from the limited number of plants to other plants for completing the manufacturing process in a second phase, or in a plurality of later phases. Such plants may be at a first location or a respective plurality of first locations. 
         [0088]    The plants used to complete the second and later phases of the manufacturing process may be the same plant is used to complete the first phase. But, advantageously, the plants used to complete the second and later phases, if necessary, of the manufacturing process may be remote from the plant used to complete the first phase and produce the pressurizable container. 
         [0089]    Such plants may be disposed at a second location or a respective plurality of second locations. The second locations may be remote from, and domestically located in the same country as the first locations. Or the second locations may be remote from, and located in one or more foreign countries as the first locations. Or one or more plants at first locations may feed pressurizable containers to remote second locations one or more of which is domestic relative to the first location and to one or more second locations located in one or more foreign countries as the first locations. 
         [0090]    This arrangement provides the benefit that a pressurized container may be shipped from a first plant in a generic form having propellant  40  therein. The generic form has no label, no actuator  30  or other valve opening device and no product  42  therein. The pressurizable container may then be shipped to a second, different and/or remotely located plant for local completion of the second phase of manufacture. The remotely located plant may be in the same country as the first plant, or may be in a different country, so that international shipping is only with the subcombination having the generic form. 
         [0091]    By remote it is meant that the first plant and second plant are functionally separated so that specific transport therebetween is necessary. Transport may occur by truck, train, ship, combinations thereof, etc. Remote locations do not include separate rooms or facilities at a common plant. 
         [0092]    During the second phase of manufacture the pressurizeable container is charged with product  42 . The product  42  may be customized to the local country, or region thereof, where the second phase of manufacture is completed. For example, users in one particular country may prefer particular scents or greater amounts of scents. Users in another country may prefer greater amounts of disinfectant or product  42  free of a scent. Users in yet another country may prefer product  42  tinted to a particular color. 
         [0093]    By conducting the second phase, and later phases if necessary, of manufacture at local plants, such particular user preferences may be more readily accommodated than if both phases of manufacture occur remotely from the point of sale. Furthermore, the local plant completing the second phase of manufacture can more quickly respond to local consumer preferences as they change in a particular country or geography. 
         [0094]    Additionally, another advantage to the divided phase of manufacture is that individual regional decorating may occur. A label made in one country may not be optimum for aerosol dispensers  20  sold in another country. In a particular country, preferences may change or a particular fad may occur which would be desirable to add to the labeling or product  42 . Localized label graphics may provide more efficient use of space, providing improved communication and greater value to the consumer. With the divided manufacture of the present invention, this efficiency and rapid changes may be accommodated more readily than if a single, plant conducts both phases of manufacture remote from the point of sale. 
         [0095]    The divided manufacture provides yet another benefit. If desired, when the product  42  is depleted, the pressurized container may be refilled with a new charge of product  42 . To do so, the user simply takes the pressurized container which is depleted of product  42  to filling station at yet another location. At this location, a new charge of product  42  installed into the product delivery device. The refill could occur through the same valve assembly  28  utilized for the initial product  42  charge. The refill may be the same product  42  as originally presented to the consumer or may be a different product  42  to accommodate changing consumer preferences. 
         [0096]    In yet another embodiment, the user may purchase relatively larger pressurized container of product  42 . When the product  42  is depleted from the aerosol dispenser  20 , the user simply refills the product  42  from the larger pressurized container, which acts as a reservoir. This arrangement provides the convenience of not requiring a special trip to continue using the product  42 . 
         [0097]    This arrangement provides the benefit that the aerosol dispenser  20 , including the propellant  40  therein, can be reused and not require additional materials for manufacturing a new, single use aerosol dispenser  20 . This arrangement provides the further benefit that materials may be reused, and not prematurely discarded into a landfill. 
         [0098]    Referring to  FIG. 11B , if desired, the divided manufacturing process described herein may be further and advantageously subdivided to achieve even further unpredicted benefits. For example, the pressurizable container may be manufactured at a first location, and sealed, but not filled with propellant  40 . The pressurizable container having no propellant  40  may be transported to a second location. 
         [0099]    At the second location, the pressurizable container may be filled with propellant  40 . This arrangement provides the benefit that a separate cleaning operation, as is typical in the art after shipping open containers, may be advantageously omitted and obviated. 
         [0100]    The now pressurized container may also be filled with product  42  at the second location. Or, if desired, the now pressurized container may be transported to a third location. The pressurized container may be filled with product  42  at such third location. Of course, decorating and other ancillary operations may occur at the first, second, third or later location. 
         [0101]    The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”. 
         [0102]    Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. 
         [0103]    While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.