Abstract:
A valve assembly and an ergonomic, convenient to use container for liquids such as heavy duty detergents, fabric softeners and the like, which includes the valve assembly. The valve assembly preferably includes at least two separate pieces, (i) a valve, and (ii) a collar for securing the valve to the container.

Description:
BACKGROUND OF THE INVENTION 
     There has been a surge in popularity of the so-called “club” stores wherein consumers often purchase goods in larger quantities than has typically been the custom. The popularity of these outlets and the increased demand for larger volume units for selling consumer products has led to a need for improved packaging. 
     The need for updated packaging is particularly difficult to satisfy for heavy duty liquid detergents and other liquid consumer products since the weight of the enhanced volume of liquid product poses formidable challenges to the packaging engineer. For instance, despite its larger size the package must still permit convenient dispensing by consumers, who range in age from children through middle aged adults and up into the older population. In addition, with the larger volume of liquid product, the difficulties in ensuring structural integrity of the package are markedly increased. Moreover, it is desirable to provide such packaging at a low cost to consumers. 
     Various containers for carrying larger volumes of liquids by consumers are known. 
     Prior to the invention of the present invention, Chilton Products, Chilton, Wis. 53014 sold a 320 fluid ounce container (2.5 gallons) having a top wall with a centrally disposed handle, a vent opening and cap on one side of the handle and a dispensing opening and closure on the other side of the handle. 
     Prior to the invention of the present invention, a product called “Tide with Bleach Alternative” was sold in a 300 fluid ounce container having in a top wall, a centrally disposed handle, a vent and vent closure on one side of the handle and a spigot covered with a measuring cup on the other side of the handle. 
     SUMMARY OF THE INVENTION 
     The present inventors have discovered an ergonomic, convenient-to-use container for liquids such as heavy duty detergents, fabric softeners and the like. 
     In a first embodiment, the container includes a dispensing opening, a closure and a plurality of walls. At least one of the walls includes a non-uniform surface structured so that the dispensing closure can be disposed on the surface when the container is in its dispensing position. In a still preferred embodiment, the non-uniform surface is etched into the wall, preferably by etching into the mold which forms the wall. In a still more preferred embodiment, the closure is a measuring cup. The non-uniform surface preferably assists in retaining the measuring cup on the wall even if the wall is comprised of a material, such as thermoplastic, which would otherwise promote sliding of the closure on the wall in the event of any movement of the container. 
     In another preferred embodiment, the top wall of the container includes a vent, a vent cap forming a closure for the vent, a handle, a pouring aperture and a pouring closure covering the pouring aperture. The top surfaces of the vent cap, the handle and the pouring closure are generally parallel, and the height of the top surfaces of the vent cap and the pouring closure are within an inch of the height of the top surface of the handle. The presence of generally parallel surfaces at the top of the container which are of the same or similar height promotes stacking of the shipping containers, since an uneven effective top surface of the container would tend to result in uneven stacking. Preferably, the closure for the pouring aperture includes a measuring cup. 
     In another preferred embodiment, the top wall of the container includes a handle extending from a handle base within the top wall. A pouring aperture is surrounded by a pouring aperture base which also extends from the top wall. In accordance with this preferred aspect of the invention, the pouring aperture base is isolated from the interior handle base by the handle base exterior. By isolating the interior handle base areas from the base of the pouring aperture, it can be expected that if any residual liquid product is present in the pouring aperture base area after the container has been used, the isolation of such area from the interior handle area will diminish the likelihood that liquid product will find its way to the handle and inconvenience the consumer. 
     In another preferred embodiment, the invention comprises a valve assembly which preferably includes at least two separate pieces, (i) a valve and (ii) a collar for securing the valve to the container. The invention also comprises a container having the valve assembly. The valve may include a base, a valve head, a valve stem and a resilient valve actuator. 
     In its preferred form, the container of the invention includes in its top wall, a medial handle, a pouring aperture and over-fitting measuring/closure on one side of the handle, and a vent opening and vent cap on the opposite side thereof. Preferably the container includes at least six sides, more preferably at least eight sides, to enhance structural stability while at the same time permitting use of the minimal amounts of resin and other structural components possible. The at least 8 sides are believed to provide structural strength and bulge resistance. 
     In another preferred embodiment, the handle is generally curved, which applicants anticipate will result in improved compressive strength. It is believed that the presence of soft radii rather than sharp radii will enhance the compressive strength of the container, particularly relative to containers in which the handle contains sharp angles. 
     For a more complete understanding of the above and other features and advantages of the invention, reference should be made to the following Detailed Description of Preferred Embodiments and to the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a container according to the invention. 
     FIG. 2 is a side elevational view of the container of FIG.  1 . 
     FIG. 3 is a top plan view of the container of FIG.  1 . 
     FIG. 4 is a cross section along the lines of  4 — 4  of FIG.  2 . 
     FIG. 5 is a front elevational view of the container of FIG.  1 . 
     FIG. 6 is a rear elevational view of the container of FIG.  1 . 
     FIG. 7 is a bottom plan view of the container of FIG.  1 . 
     FIG. 8 is a cross section along the lines of  8 — 8  of FIG.  7 . 
     FIG. 9 is an exploded view of the pouring aperture, the pouring base, the pouring finish, the valve assembly and the valve collar of the invention. 
     FIG. 10 is a partial elevational view showing particularly the pouring opening, spigot and measuring cup/closure of the invention. 
     FIG. 11 is a cross section along the lines  11 — 11  of FIG.  10 . 
     FIG. 12 is a cross section along the lines  12 — 12  of FIG.  10 . 
     FIG. 13 is a cross sectional view along the lines  13 — 13  of FIG.  10 . 
     FIG. 14 is a perspective view of the bottle of FIG. 1 in the pouring position. 
     FIG. 15 is a cross section illustrating the venting of product through the vent hole and vent cap of the present invention. 
     FIG. 16 is a cross section illustrating the pouring of product through the spigot of the present container. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Container or bottle  20  includes top wall  22 , front wall  24 , side walls  26 ,  28 ,  30 ,  32 ,  34  and  35 , and rear wall  36 . 
     Bottom wall  38  supports the container. 
     Top wall  22  includes a recessed area  40  in which is disposed valve or spigot apparatus  42  and closure/measuring cup  44 , which will be described in greater detail below. Medially disposed with respect to valve or spigot assembly  42  is handle  46  which is integral with top wall  22 . Handle  46  includes a base  48  having an interior aspect  50  and an exterior aspect  52 . The interior of handle  46  is generally oval shaped as can be seen e.g., in FIG.  2 . 
     Disposed laterally to handle  46  and on an opposite side from spigot assembly  42  is vent  56  and vent cap  58 . The height of the highest point of wall  22  adjacent vent  56  is considerably higher than that in recessed area  40 . Rear wall  36  includes oval etched area  60 . The etching provides a non uniform or rough surface for reasons which will be discussed below. 
     As seen particularly in FIG. 2, the recessed area  40  in which the spigot assembly  42  is disposed is isolated from the interior aspect  50  of handle  46  by handle base  48 . It is anticipated that isolation of the spigot area from the interior of the handle will prevent itinerant liquid product from migrating from the spigot area to the interior of the handle. This can be expected to make it less likely that the consumer will find liquid product on his or her hand at the conclusion of the pouring operation. 
     As can be seen especially in FIG. 2, the top surfaces of measuring cup  44 , handle  46 , and vent cap  58  are generally parallel. Moreover, the heights of the top surfaces of the measuring cup  44  and the vent cap  58  are independently within one inch of the top surface of handle  46 , especially within ¾ of an inch of the top surface of handle  46 , and most preferably within ½ inch of the top surface of the handle  46 . Keeping the top surfaces parallel and at approximately the same height facilitates the stacking of containers in that the effective top surface of the container seen by a container stacked on top of it will be more or less even whereby to prevent uneven stacking of the containers. 
     The large oval handle aperture  70  facilitates gripping of the container by the consumer; there are no uneven edges to cause the consumers discomfort. This is particularly important given the substantial weight which the container is designed to contain. 
     The handle and top wall of the container body include several features which it is believed contribute to an improved compressive strength. The forward and rear walls  210 ,  212  of the handle are generally curved rather than having rectilinear sides which meet at relatively sharp angles with each other or with the top wall  22 . That is, the handle of this aspect of the present invention comprises arcs or substantially straight lines connected by arcs rather than substantially straight lines intersecting other substantially straight lines to form sharp angles. This refers not merely to the edges of the handle on the inside and outside surfaces but also to angles which would be formed at intersections of imaginary midlines, such as midline  310 , of the handle. Thus the handle should have arcs rather than sharp angles both on its inside and outside surfaces as well as at the intersections of imaginary midlines. Moreover, the base  48  of the handle at its front is immediately adjacent the base of the pouring opening, so it is disposed in an area of the top wall having a particularly sturdy structure. 
     Other features believed relevant to compressive strength include the fact that the base of the handle  48  at its front is in contact with the top wall of the container at a large number of points, extending e.g., from reference  214  on one side to  216  on the other, so that any force transmitted from above will be dissipated rather than concentrated at a few points. This is believed to make the container top wall, and therefore the container as a whole, less susceptible to failure. Indeed the width of the base at the handle&#39;s front end (measured along a horizontal axis, e.g., parallel to the top surface of the measuring cup/valve closure) is at least twice the width of the handle, preferably at least three times, still more preferably at least four or five times the width of the handle (also measured along a horizontal axis). In addition, the rear end of the handle merges curvedly with the elevated top wall  22  adjacent to the vent cap so that, again, any force transmitted from the handle is dissipated over a large area rather than concentrated at a few points. 
     As can be seen from the figures, the preferred package includes eight vertically extending side panels, including the front and rear walls. Use of six or more, especially use of eight or more side walls or panels is believed to enhance the compression strength of the container and to permit the use of less resource, e.g. thermoplastic polymers, in its manufacture. Use of less resource in manufacture in turn leads to less waste material after the useful life of the container is complete. 
     Referring especially to FIGS. 7 and 8, bottom wall  38  includes outer rim  80  which comprises the primary support for the container. Heel  80  extends downwardly further than other aspects of the bottom wall  38 . Wall  38  may include the base push-up construction shown in the FIG. 7 wherein an angled portion  82  is disposed inwardly of first ring  80  and medial aspect  84  of wall  38  is disposed further inwardly. 
     Parting line  86  (FIG. 7) is an artifact of container manufacture when the container is blow molded. Parting line  86  reflects the joining of two halves of the mold used to make the container. It may be desirable, as illustrated in FIGS. 7 and 8, to have a rib  90  of enhanced thickness and length at the parting line to provide support when the weight of the liquid product pushes downwardly on the medial aspect  84  of bottom wall  38 . In such circumstances, rib  90  will assist in supporting the weight of the product. The structural support rib along the middle of the push-up is known per se and is also called the “pinch-off.” As the push-up inverts due to the weight of the liquid contents, the rib may contact the flat surface and prevent further inversion of the push-up. Alternatively, there may be a series of parallel grooves in the bottle base&#39;s push-up to resist push-up inversion. The base push-up area may have one or two horizontally extending tiers for added strength, or may be waffled for increased strength. 
     Referring particularly to FIG. 9, top wall  22  has disposed therein annular dispensing opening  90 . Dispensing opening  90  is supported by base  92  and by finish  94 . Base  92  is generally circular and may include a plurality of levels as is illustrated in FIG.  9 . In at least one level, elongated tabs  96  which are equally spaced from each other along the circumference of the base, serve to mate with a bead on the measuring cup, as will be described below. Below tab  96  a step  98  is provided in base  92  to support the measuring cup  44  when it is in place over the spigot assembly. 
     At the bottom of finish  94  are disposed two oppositely positioned sets of ratchets  100 . Finish  94  is also provided with external threads  102  for mating with internal threads  104  on valve securement collar  106 . Top thread  108  includes mirror image wedges  110 ,  112  which serve to facilitate alignment of valve base  114  when the spigot is in place by providing lug confining walls. 
     Valve base  114  includes spigot or valve  116 , valve support column  118 , spigot support platform  120 , outer ring  122  and inner depending ring  124 . Spigot support  114  is placed within dispensing aperture  90  by snap fitting inner ring  124  within the mouth of aperture  90 . Outer ring  122  includes one or more oppositely disposed depending lugs  130 , which are accommodated in a space between each of the mirror image wedges  110 ,  112 . This facilitates the proper alignment of spigot supporting structure  114  and ultimately of spigot  116 . 
     Spigot  116  includes a valve mechanism of a type available from the Davis S. Smith Worldwide Dispensers of Merton, London of Great Britain. The spigot comprises spigot housing  134  resilient actuating button  136 , valve stem  138 , valve stem gripper  148  and valve  140 . Operation of this simple valve is best seen with reference to FIGS. 14 and 16. In order to dispense product, the consumer rests the container on front wall  24  by pivoting the container forward along the front section of ring  80  of bottom wall  38 . The consumer dispenses product by pressing the resilient actuator button  136 , which receives valve stem  138  in circular retaining structure, gripper  148 . Preferably, gripper  148  is also resilient and slightly narrower than the diameter of the valve stem  148 . The force applied by the consumer&#39;s finger is transmitted through valve stem  138  and forces valve  140  away from valve seat  150 . This permits product to flow through the spigot and into the wash, or more preferably, into measuring cup  44 . 
     Gripping wings  160 ,  162  are disposed on either side of valve housing  134  to permit the consumer to grasp the valve housing with two fingers while applying pressure with the thumb. 
     As best seen in FIGS. 9 and 13, the spigot assembly  116  is secured to bottle finish  94  by spigot or valve collar  106 . Internal threads  104  mate with external threads  102  on the bottle finish. Opening  170  on the spigot collar permits the spigot to extend outside of the collar. The top of the spigot collar includes flange  172  which rests upon outer ring  122  of the spigot base when the collar is secured in place on the spigot finish. Depending wall  176  of the spigot collar includes in addition to internal threads  104 , lugs  178  which mate with ratchet  100  at the bottom of the spigot finish to secure more or less permanently the collar to the container. 
     The outside of spigot collar  106  may be provided with vertically extending ribs  180  to assist in rotating the collar when it is applied to the container. 
     To facilitate dispensing of product, it is preferred that the container include a vent  56  and vent cap  58 . The container may also be filled through the vent, if so desired. Vent  56  comprises vent finish  166  which is threaded with external thread  168  to mate with internal thread  170  on vent cap  58 . As best seen in FIG. 15, loosening of vent cap  58  permits air to flow inwardly, as illustrated by the arrows in FIG. 15, and thereby to replace with air the volume of product lost when product is dispensed. In the illustrated embodiment, the vent opening finish is externally threaded and its external threads mate with internal threads on the vent closure. Alternatively, the vent closure may be a push/pull closure, disc-top or snap-top closure. Preferably, the cap employs a linerless seal (e.g., valve seal). However, the venting closure may have either a lined or linerless seal and have either a continuous thread or an interrupted thread to assist in venting air into the bottle upon slight twisting. The venting closure may have an anti-removal lug stopping against a lug on the bottle finish, such engagement occurring after ¼ to ¾ turns to loosen the closure. 
     It will be appreciated that when the container is in its dispensing position resting on front wall  24 , it may be desirable to rest momentarily measuring cup  44 . Particularly in view of the anticipated large volume of the container, it will be tempting to rest the measuring cup on one of the walls of the container, especially the wall opposite the wall on which the container is resting. Since it is envisioned that the container may be made of a material, such as certain thermoplastics, which is relatively smooth, in accordance with the invention, a non uniform section may be provided within one of the walls to assist in maintaining the cup in its position while it is disposed on the container. An example is illustrated in FIG. 14 wherein surface  60  which has a racetrack-like periphery, has been etched into rear wall  36 . This is expected to minimize any tendency of measuring cup  44  to slip or slide on the surface of the container. Front panel  24  includes a large flat area to provide a stable base and to resist rocking during the dispensing operation. The side of the bottle adjacent the top vent closure becomes the top of the bottle in the dispensing position. This panel  36  is flat and level and has the textured surface wherein the measuring, cup can be placed between uses in the upright position. 
     Measuring cup  44  serves the dual function of measuring cup and closure for the spigot assembly. Measuring cup  44  is releasably secured to the container in its inverted position by being snap fit over equi-spaced ribs or lugs  96 , which mate with bead  190  at the mouth of the cup. Alternatively, the measuring cup can be secured to the bottle base finish by use of a continuous thread to screw on the bottle base finish or by other means. 
     The cup&#39;s annular bead and the bottle&#39;s three or more lugs are designed to stay engaged during the impact of case packing as well to as withstand the rigors of shipping and warehousing without becoming dislodged. 
     The container may be mono-layer or multi-layer and may be made of HDPE, PP, PVC, PET, POLYCARBONATE or acrylic or nitrite base resins, and preferably contains a minimum of 25% PCR. 
     Preferably, the measuring cup has textured fill line bands etched into the interior of the cup to aid the consumer visually in filling to the proper dose. The measuring cup may have a v-groove channel on the exterior of the mouth, similar to a laboratory beaker, to aid in pretreating strains with precise pouring. This channel could have an anti-drip lip. Alternatively, there may be “V” or “U” notches in the top side wall for a controlled pour. 
     If so desired, the measuring cup can include a handle. The measuring cup could have an exterior, annular anti-drip lip. 
     The container or bottle of the inventions may be pigmented opaque or may be made clear by fabricating it from clarified grades of the aforementioned resins. 
     In addition to the vertical side panels, including the side panels at the vertical corner intersections, there may be other strengthening vertical design features such as outer ribs or inner grooves either at the corner intersections or elsewhere in the side panels, or at in both locations. 
     The bottle, valve, valve collar and vent closure may be made of anti-static grades of the aforementioned resins. The tap collar and vent closure are preferably made of a polyolefin resin, most preferably PP. Preferably, the pigmented tap body is the same color as the pigmented tap collar and vent closure. Alternatively, these components may be clear and the measuring cup could be opaque. 
     Preferably, the front and back panels of the bottle include in-mold labels (IML labels), preferably plastic IML&#39;s. Plastic IML&#39;s may be opaque or clear. Polypropylene (PP) IMLs may be used to reduce blistering given that the containers of the invention may have a relatively large label area. Alternatively, instead of an IML, there may be a stretch or shrink label which act like a “girdle” to resist bottle bulging with these labels. Also, the bottles front/back panels may be waffled. 
     There may be indicia cut into the molds and/or embossed on the molded bottle and vent closure which give instructions on use. 
     In an alternative design, the vent closure and the second bottle neck finish are in the same horizontal place as said first neck finish. In this configuration, the measuring cup may be attached to lugs at the base of the second neck finish and positioned over the vent closure. 
     To avoid label scuffing, the base of the bottle could be larger in length and thickness than the label panel&#39;s greatest length and thickness, so that labels would not contact the walls of the corrugated shipping container or the label of another bottle. 
     It should be understood of course that the specific forms of the invention herein illustrated and described are intended to be representative only as certain changes may be made therein without departing from the clear teachings of the disclosure. Accordingly, reference should be made to the following appended claims in determining the full scope of the invention.