Patent Description:
Closures may be secured to the container neck or to a neck opening of the container by various construction techniques, including snap-on constructions, threaded constructions and plug-in constructions, as some examples. In this manner, the closure can be selectively removed so that flowable products carried within the container can be selectively dispensed and used.

Container manufacturers often prefer to deliver additional functionality within such closures. Two of the more common approaches are child-resistant features, which require multiple, coordinated actions to enable removal of the closure from the container, and dispensing features, where by the closure includes structure to facilitate in the dosing and/or directional dispensing of fluid as it exits the container.

<CIT> contemplates a dispenser that integrates a dispensing nozzle with certain child-resistant features provided on the nozzle assembly itself. <CIT>; <CIT>; <CIT>; <CIT>; <CIT>; and <CIT> disclose various arrangements for a collapsible spout and cap combination. <CIT> discloses a screw top closure comprising a closure body having a radial flange and an annular skirt, a collapsible spout having a first and second cone section, and an overcap having a top panel with integral pull ring, a skirt and a child resistant protrusion. In all instances, these spouts are envisioned as being incorporated into the flat panel of drum or other industrial-sized container, with a periphery of the closure held within or around a flange (usually metallic) formed in the panel. As such, the spouts effectively become a permanent fixture of the container and, therefore, cannot be easily mounted on or removed from the container.

All of these structures must also be considered within the context of efficient, cost effective manufacturing techniques. Accordingly, manufacturers of containers and closures often prefer to use plastics, via common techniques such as thermoforming, compression or gas-assisted molding, and blow or injection molding. Blow and injection molding techniques are particularly prevalent within the closure and container field, with both involving the introduction of molten resin into a mold cavity (injection molding introduces the molten resin via predetermined entry ports within the cavity, whereas blow molding uses a molten preform placed within the mold cavity, which is then inflated with compressed gas/air in a manner somewhat similar to glass-blowing). However, one consideration particularly relevant to blow molding is the creation of "split line" and "pinch-off' points, based upon how the mold engages the preform. These points represent potential areas of structural weakness and, therefore, requires special consideration when integrating features onto a blow-molded part.

While many of the foregoing disclosures provide a convenient and useful way to deliver a spout within a closure, a collapsible spout that can be integrated within a screw-top-style closure is needed. Further, if such a closure and container combination possessed child resistant features, it would be welcome. Lastly, having a child-resistant spout that can be formed by blow molding would be particularly helpful.

A collapsible spout is integrated within a screw cap closure, so as to allow for mounting and/or removal of the closure assembly onto a variety of threaded container necks (as opposed to being captured within a flange on the flat panel of a drum). The closure and container possess cooperating, child resistant lugs, with the lugs on the container formed on opposing edges and away from the blow molded split line. The closure includes additional child resistant lugs to selectively restrain a cover cap over the spout opening. In some embodiments, the cover cap may also include tamper-evident, frangible connectors for added product/container security.

The claims below form an express portion of this written disclosure. The use and illustration of specific terms and structures does not necessarily preclude this disclosure from also encompassing other, similar terms and structures, as would be apparent to those working in this field.

The drawings referenced below show various embodiments of the invention. Any written matter, as well as dimensions and relative ratios or sizes that can be discerned or calculated from these drawings, is incorporated as written material herein. Also, the components and arrangements individually illustrated in the Figures are drawn to scale so that additional information about the relative size, spacing, arrangement, and attachment of the components can be discerned and, thereby, form an explicit part of this written disclosure.

The appended claims, drawings, and description all disclose certain elements of the invention. While specific embodiments are identified, it will be understood that elements from one described aspect may be combined with those from a separately identified aspect. In the same manner, a person of ordinary skill will have the requisite understanding of common processes, components, and methods, and this description is intended to encompass and disclose such common aspects even if they are not expressly identified herein.

As used herein, the words "example" and "exemplary" mean an instance, or illustration. The words "example" or "exemplary" do not indicate a key or preferred aspect or embodiment. The word "or" is intended to be inclusive rather an exclusive, unless context suggests otherwise. As an example, the phrase "A employs B or C," includes any inclusive permutation (e.g., A employs B; A employs C; or A employs both B and C). As another matter, the articles "a" and "an" are generally intended to mean "one or more" unless context suggest otherwise.

<FIG> and <FIG> illustrate certain features of the closure <NUM> as it is attached to a container <NUM>. Salient aspects of that container <NUM> are, in turn depicted in <FIG> though 3D. Details of specific features in the closure <NUM> are shown in a variety of states in the remaining figures. The following description may refer to any of these Figures.

Container <NUM> is preferably blow-molded to produce the split line <NUM>. However, other means of forming containers produce features/divisions that are common to split line <NUM>, so that the design principles contemplated herein could be applied to those forms as well (e.g., injection molding, etc.).

Lugs <NUM> are formed on an outer surface of the neck proximate to attachment threads <NUM> (which engage cooperating threads <NUM> on an inner facing of closure <NUM>). Lugs <NUM> take the form of one or more ramps or ratchet-style tooth/teeth projecting radially outward relative to the neck of container <NUM>. These ramps/teeth are sized to allow rotation of cooperating features <NUM> on the closure <NUM> in one direction while inhibiting or prohibiting rotation in the opposing direction. In this manner, closure <NUM> can be tightened onto the container <NUM> while preventing its subsequent removal therefrom (at least by way of rotation). Positioning of the lugs <NUM> away from split line <NUM> ensures the lugs <NUM> will not smear upon ejection from the mold cavity.

Opening <NUM> is sized to receive closure <NUM> so as to selectively restrain fluid within the container <NUM> depending upon the positioning and engagement of the features of closure <NUM>. Generally speaking, opening <NUM> should be circular and present with a flat top facing so as to allow for sealing with the closure <NUM>. The diameter of opening <NUM> must be sized to allow portions of closure <NUM> to extend axially downward into the inner volume of container <NUM> at or below its neck.

Closure <NUM> possesses a cup-like shape, with a skirt <NUM> extending axially downward to engage the container <NUM>. Threads <NUM> are formed along an inner facing of the skirt <NUM>. Annular flange or top panel <NUM> protrudes radially inward at an approximately orthogonal relationship to the skirt <NUM>. In turn, flange <NUM> defines an aperture which accommodates the other components of closure <NUM>. Also, flange <NUM> serves to seal the closure <NUM> against the top facing of the container sidewalls defining opening <NUM>.

Skirt <NUM> may include knurling, ribbing, or other grip-enhancing features. Additionally or alternatively, written indicia could be integrated or placed thereon. A reinforced, thicker annulus 112a may be provided at or proximate to the bottom, open end where the closure <NUM> is fitted over and coupled to the container <NUM>.

Along the inner facing of skirt <NUM> within the thicker annulus <NUM>, a plurality of lugs <NUM> project inwardly. Lugs <NUM> are formed to cooperate with corresponding lugs <NUM> on container <NUM>. As noted above, once the closure <NUM> is screwed downward, lugs <NUM>, <NUM> eventually come into alignment so as to prevent reverse motion that would result in the closure <NUM> being twisted upward/removed from the container <NUM>. Notably, the relatively thicker annulus 112a also improves the hoop strength and allows the remaining portions of the skirt <NUM> to be formed from less material.

Collapsible spout <NUM> is attached or engaged by the lower facing ledge of flange <NUM>. Because lugs <NUM>, 112a prevent removal of closure <NUM> from container <NUM>, it is possible to simply seat spout <NUM> between the flange <NUM> and the container <NUM> because axial movement will be restricted. Conversely, if spout <NUM> is formed as an integral part of closure <NUM>, enhanced protection against leakage is ensured. Attachment means (as defined below) can be formed at the interfacing edges of the skirt <NUM>/flange <NUM> and spout <NUM> to ensure these components remain in place.

Spout <NUM> includes an annular engagement flange <NUM>, a first invertible section or cone <NUM> and a second section or cone <NUM> that can be nested within section <NUM>. Threads <NUM> can be formed on section <NUM> to engage overcap <NUM>. Also, proximate to flange <NUM>, an axially-aligned sealing cone or plug seal <NUM> is formed coaxially to surround section <NUM>, thereby improving alignment and engagement between the closure <NUM> and container <NUM>.

A removable panel or tear out diaphragm <NUM> spans the spout opening defined by the inner facings of section <NUM>, with groove 126a defining the detachment point, with a grasping tab or ring 126b integrally formed on the top facing of panel <NUM> to facilitate detachment.

Overcap <NUM> is frangibly connected to or formed separately from the skirt <NUM>. A pull tab <NUM> attached to top panel <NUM> by way of element <NUM>. When overcap <NUM> is coupled to the spout <NUM> (e.g., by way of cooperating threads <NUM>, <NUM>), a user can pull axially upward to displace section <NUM> from its nested position within section <NUM> to form an extend pouring spout that remains affixed to the container <NUM>. Overcap <NUM> also has a cup-like shape, with a skirt <NUM> extending axially downward to coaxially receive section <NUM>. Notably, skirt <NUM> may extend between a radial gap formed between sections <NUM> and <NUM>.

The thickness and/or composition of sections <NUM>, <NUM>, <NUM> can be adjusted along the length or circumference of the cone shapes to facilitate deploying and retracting the spout, as well as to allow for the spout to be deployed at a specific angle. As shown, section <NUM> has a relatively thicker way section to accommodate the overcap <NUM> engagement and the child resistant features described below. Additionally or alternatively, ribs may be formed axially (as shown) or circumferentially to enhance the strength of the spout <NUM> and/or to facilitate its directional orientation. In view of the flexing action required to deploy and reinsert the spout <NUM> into its nested position, the use materials with sufficient strength and resilience is important.

While panel <NUM> is illustrated in <FIG>, <FIG> depicts an aspect in which the panel <NUM> is not necessarily required. <FIG> is also representative an arrangement in which the panel <NUM> has been removed but the overcap <NUM> was replaced).

Certain child-resistant and tamper evident features are also contemplated. First, frangible connectors <NUM> can be integrally formed between the pull ring <NUM> and the flange <NUM> to verify whether the closure <NUM> has been initially opened. Additional or alternative frangible connectors could also be formed between the overcap <NUM> and flange <NUM> and/or the overcap <NUM> and spout <NUM>.

Separately, one or more child resistant, cooperating tabs <NUM>, <NUM> are formed along the circumference of spout <NUM> and overcap <NUM>, respectively speaking. In one form, tab <NUM> is a ramped or ratcheted tooth or teeth projecting toward the overcap from section <NUM> and/or section <NUM>. The corresponding tab <NUM> is formed on or proximate to the bottom of skirt <NUM> on overcap <NUM>.

As shown, two separate pairs of tabs <NUM>, <NUM> are provided. This arrangement allows the user to grasp the side of skirt <NUM> at orthogonal positions so as to squeeze and deform the skirt <NUM>. This squeezing action causes the tabs <NUM> to move radially out of engagement relative to the tabs <NUM>, thereby allowing for rotation and removal of the overcap <NUM>. Arrow CR highlights the interface and position of these child-resistant features.

<FIG> depict a separate embodiment of child-resistant closure <NUM> also including a selectively extendible spout <NUM>. While specific features are shown in association with closure <NUM>, it will be understood that certain aspects of closures <NUM>, <NUM> can be freely applied to one another, particularly insofar as the final two digits of the reference numerals for components of closure <NUM> match those of corresponding closure <NUM> (e.g., skirt <NUM> is analogous to skirt <NUM>, etc.).

As above, closure <NUM> is affixed to container <NUM>. Container <NUM> possesses all of the same features described above, details of which are shown in <FIG>, including lugs <NUM>, threads <NUM>, and opening <NUM>. Closure <NUM> generally comprises a cup shaped skirt <NUM> and overcap assembly <NUM>, both of which conceal a spout <NUM> in its retracted position (as shown in <FIG>).

One key feature of closure <NUM> is the formation of child resistant ratchets <NUM> on the cap <NUM>. More specifically, ratchets <NUM> are positioned at the lower end of cap <NUM> so as to interface with corresponding features <NUM> formed on the spout <NUM>. More specifically, features <NUM> can be positioned on or proximate to one of the invertible sections <NUM>, <NUM> where the cap <NUM> interfaces therewith. These features <NUM> could also be provided on or along the interface between cap <NUM> and plug seal 225b. In operation, the resilient nature of the skirt portion <NUM> of cap <NUM> is sufficiently flexible to allow for squeezing at ratchets <NUM> to dislodge them from features <NUM>, thereby allowing the cap <NUM> to be rotated along threads <NUM>, <NUM> and disengaged from the spout <NUM>. Preferably, features <NUM> are provided around all or substantially all (≥ <NUM>%) of the inner facing circumference of the interfacing component (e.g., plug 225b), while ratchets <NUM> are provided on only a small arc (≤ <NUM>%) of the corresponding circumference of skirt <NUM>.

Notably, additional plug seals <NUM> may be provided on at least three different portions of spout <NUM> and/or cap <NUM>. A first plug seal 225a is formed as a cylindrical extension from the top panel <NUM> of cap <NUM>. Seal 225a abuts a terminal edge of spout <NUM> along second invertible cone section <NUM>. Seals 225b, 225c may be formed on opposing facings on or proximate to first invertible cone section <NUM>, with the former abutting the lower edge of cap <NUM> and the latter contacting one or both facing of the terminal edge of container <NUM> proximate to opening <NUM>.

Another distinctive feature of closure <NUM> is the provision of ratchets or ramps <NUM> along the top facing of flange <NUM>. Ramps <NUM> may cooperate with protrusions, lugs, or similar features on a bottom facing of flange <NUM> to secure the skirt <NUM> to the spout <NUM> and prevent relative movement and rotation when force is applied to unscrew cap <NUM> from spout <NUM>. Additionally or alternatively, finger-like lugs <NUM> may extend radially inward at the bottom end of skirt <NUM> to engage cooperating features on the container <NUM> (e.g., lugs <NUM>), so as to prevent unwanted rotation of closure <NUM> off of container <NUM>.

As best seen in <FIG>, written indicia <NUM> can be integrally formed on the closure <NUM> (e.g., along the panel <NUM> of cap <NUM>) to verify that pull ring <NUM> can be grasped by extending it upward, with grooves <NUM>. Anti-rotational lugs <NUM> formed on the flange portion <NUM> can cooperate with indents <NUM> at the periphery of panel <NUM> to serve as guides during the process of extending the inverted portions <NUM>, <NUM> of the spout <NUM>. The second step indicated on the written indicia <NUM>.

A method of manufacturing a closure is also contemplated. Here, a thermoplastic or thermosetting resin is melted into a preform. A two piece cavity mold is provided and pressed into the preform so as to join the two pieces into a single mold, with compressed gas introduced to cause the preform to conform to the cavity mold and create an internal volume within the container formed by this process. A pair of child resistant lugs are formed in each of the two piece of the mold but positioned away from the split line formed that will be formed when the cavity mold is joined into a single mold. Separately, a closure is formed with cooperating lugs so as to create a container having a closure with a permanently attached screw top.

Still other methods of manufacture and forming of containers and closures, including closures having a collapsible spout, are contemplated. These methods are similar to the foregoing method and involve the provision of additional components within one or both of the cavity mold pieces.

A particular advantage to the structures and process noted above is that a flexible, child resistant spout can be provided in conjunction with a screw-top container. Further, the spout is integrated as part of the closure itself, thereby requiring minimal (if any) alterations or design features on the container.

All components should be made of materials having sufficient flexibility and structural integrity, as well as a chemically inert nature. Certain grades of polypropylene and polyethylene may be particularly advantageous, although all grades of polymers capable of the molding techniques described herein could be used. Ultimately. the materials should be selected for workability, cost, and weight.

Certain structures which prevent or inhibit the relative rotation of components disclosed herein may be referred to as "anti-back off. " These structures may include simple protrusions or lugs received within cooperating pockets or more nuanced structures that involve ratchet teeth where a gently sloping ramp presents on one facing so as to allow sliding movement over that surface, while a more sharply angled ramp presents on the opposite facing so as to inhibit or prevent sliding move over its surface. Any actual or perceived ambiguity can be resolved by referring to the drawings, as well as the context of the accompanying description.

Claim 1:
A screw top closure (<NUM>) attachable to a container neck having cooperating screw-on features, the closure comprising:
a closure body having a radial flange (<NUM>), defining a central aperture, and an annular skirt (<NUM>) extending axially downward along an outer periphery of the radial flange;
a collapsible spout (<NUM>) having a first invertible cone section (<NUM>) with a peripheral container plug seal (<NUM>) sealingly engaging the radial flange, a second cone section (<NUM>) defining a dispensing aperture along an inner facing, and at least one overcap engagement protrusion (<NUM>) positioned on an outer facing of the first and/or second cone section(s) and wherein the first and second cone sections are contiguous so that, when the spout is collapsed, the second cone section nests within the first cone section so as to be at least partially coaxially nested within the annular skirt and, when the spout is extended, the second cone section extends axially above the first cone section; and
an overcap (<NUM>) attachable to the second cone section, the overcap having a top panel (<NUM>) with an integral pull ring (<NUM>), a deformable skirt (<NUM>) extending axially downward along an outer periphery of the top panel, and a child resistant protrusion (<NUM>) positioned proximate to a terminal edge of the deformable skirt and wherein the child resistant protrusion engages the overcap engagement protrusion to selectively prevent removal of the overcap from the spout except when the deformable skirt is squeezed with sufficient force to disengage the child resistant and overcap protrusions.