Patent Description:
The present disclosure relates generally to a recyclable metal container with a rolling component that applies product stored in the container onto an external surface. More specifically, this disclosure relates to a metallic roll-on container with a roller sphere.

Roll-on containers can be used to apply a product onto an external surface, for instance, deodorant onto skin. These containers are typically made from plastic materials such as high density polyethylene (HDPE) or polypropylene (PP). These plastic materials are used to make roll-on containers since the plastic materials can be cheaply manufactured into complex shapes, and the resulting containers are resistant to harmful chemicals, resistant to impacts, and are light in weight to reduce transportation costs.

However, there are several disadvantages with the use of these plastics to make containers. First, recycling plastic is inherently difficult, and mixing different types of plastics together for recycling has a negative effect on the resulting material. When different types of plastic are melted together, they tend to phase-separate, like oil and water, and set in these layers. The phase boundaries cause structural weakness in the resulting material, which is then useful in only limited applications. Notably, common plastics such as HDPE and PP exhibit this behavior, and therefore, have a limited usefulness when recycled. Moreover, each time plastic is recycled, new plastic material must be added to maintain the integrity of the resulting material. Even when recycled plastic has new plastic material added in, the same plastic can only be recycled two to three times before the quality of the resulting material decreases to the point where the plastic can no longer be used.

Plastics are also harmful to the environment, and recent environmental efforts have been focused on limiting the consumption of plastics, products wrapped in plastic, etc. Plastics can release harmful chemicals into the ground soil, which then moves into the ground water. This can cause wide ranging negative effects to wildlife, including animals that consume tainted ground water. This type of pollution is also apparent in the world's oceans where, as of <NUM>, there is an estimated <NUM> million tons of plastic pollution. In addition to the above issues and health effects, it takes a long time for plastic to degrade. It is estimated that a foam plastic cup will take <NUM> years, a plastic beverage holder will take <NUM> years, a disposable diaper will take <NUM> years, and fishing line will take <NUM> years to degrade. This obviously raises serious environmental concerns. <CIT> discloses a perfume dispenser comprising a bottle having a neck closed by a stopper which holds a rotating ball.

The present disclosure provides a metallic roll-on container comprising aluminum to address the above issues with plastic containers used by consumers. Aluminum containers can be recycled an infinite number of times, and aluminum can be recycled without the necessity of adding new materials during the recycling process. Moreover, aluminum containers can be manufactured using an impact extrusion process to create containers with complex shapes.

According to the invention, a metallic roll-on container is disclosed, as defined in claim <NUM>. It is an aspect of the present disclosure to provide a roll-on container with a roller sphere to transfer product from the container to an external surface. The roller sphere is retained in the container at an open upper end of the container so that the roller sphere can both rotate and move between various positions along a longitudinal axis of the container. One or more arcuate sidewalls of the container define an upper opening and a lower opening within the container, and the arcuate sidewalls and the roller sphere define a chamber between the openings that has a maximum inner diameter. An outer diameter of the roller sphere is greater than a diameter of the upper opening but less than the maximum inner diameter of the chamber. Thus, the roller sphere is retained within the container, and the roller sphere can move along a longitudinal axis of the container between a position against the upper opening and a position against the lower opening. As described in further detail below, this movement along the longitudinal axis allows product to move from within the container to the chamber and then from the chamber onto the roller sphere, and the product is subsequently applied to an external surface. In some embodiments, the maximum inner diameter is between approximately <NUM> % and <NUM> % larger than the diameter of the roller sphere to allow these functions.

It is another aspect of some embodiments of the present disclosure to provide a roll-on container with a roller sphere where at least the container is made from aluminum or an aluminum alloy to allow the recycling of the container. In some embodiments, the roller sphere can also be made from recyclable aluminum or an aluminum alloy, including aluminum or an aluminum alloy that has already been recycled at least once. As noted above, the roller sphere generally has a larger diameter than the upper opening defined by the arcuate sidewall to retain the roller sphere in the container. However, the roller sphere and the container body are initially made separately, and then the roller sphere is pressed into the open end of the container body, which temporarily deforms the arcuate sidewall such that the upper opening is as large as the diameter of the roller sphere. Then, the arcuate sidewall springs back after the diameter of the roller sphere passes the upper opening to retainer the roller sphere in the container.

Making plastic products with interference fits is relatively simple because of the low Young's modulus of plastic materials, meaning the material is easily bended or stretched. In contrast, Aluminum has a much different and higher Young's modulus. Thus, an aluminum or metallic product with an interference fit is different because the material is much more likely to be damaged or plastically deformed. Therefore, a specific relationship between a metallic container and the roller sphere is provided such that the arcuate sidewall of the metallic container can be deflected and then spring back to retain the roller sphere in the container. To provide for a sufficient amount of spring back from the aluminum material to retain the roller sphere within the container, the diameter of the roller sphere is approximately <NUM>% to <NUM>% larger than the diameter of the upper opening defined by the arcuate sidewall in some embodiments. In various embodiments, the diameter of the roller sphere can be approximately <NUM>, and the diameter of the upper opening can be at least <NUM>. Further of note, the aluminum material retains the same material properties through the recycling process, unlike plastic. Therefore, the specific relationship between the upper opening and the roller sphere holds true for the aluminum material, regardless of the number of times the material has been recycled.

It is a further aspect of some embodiments of the present disclosure to provide a cap that can securely fit onto a shoulder of the container and cover the roller sphere to prevent or reduce evaporation, spilling, or dehydration of the product stored in the container. In some embodiments, an inward curl defines an opening of the cap, and a diameter of the opening is smaller than a diameter of the shoulder. Thus, when the cap is pressed onto an end of the container, the inward curl can deform to create an interference fit between the inward curl and the shoulder. In addition, an interior surface of the cap can contact and move the roller sphere against a lower opening when the cap is secured to the shoulder to seal the product stored within the container and prevent dehydration of the product.

One specific embodiment of the present disclosure is a metallic roll-on container for applying a product onto an external surface such as a human body, comprising a metallic container body extending along a longitudinal axis from a closed bottom end to an open top end; at least one arcuate-shaped sidewall of the container body that defines an upper opening with a first diameter and a lower opening with a second diameter; a roller sphere positioned in the open top end of the container body and seated at least partially between the upper opening and the lower opening of the at least one arcuate-shaped sidewall to define a chamber between the roller sphere and the at least one arcuate-shaped sidewall, the roller sphere having a first extended position and a second depressed position; wherein, in the first extended position, the roller sphere is seated against the upper opening of the at least one arcuate-shaped sidewall, and the chamber is in communication with the container and can receive a product stored in the container; wherein, in the second depressed position, the roller sphere is seated against the lower opening of the at least one arcuate-shaped sidewall, and the chamber is no longer in communication with the product stored in the container, and wherein the roller sphere rotates to allow the application of the product in the chamber to an external surface.

According to the invention, the roller sphere has an outer diameter larger than the first and second diameters and smaller than a maximum diameter of the chamber. According to the invention, the outer diameter of the roller sphere is between approximately <NUM>% to <NUM>% larger than the first diameter of the upper opening. In some embodiments, the outer diameter of the roller sphere is approximately <NUM>, and the first diameter of the upper opening is between approximately <NUM> to <NUM>. In various embodiments, the container further comprises a shoulder extending from an outer surface of the container body proximate to the open top end of the container. In some embodiments, the container further comprises a cap having an inwardly-extending curl that defines a cap opening, wherein the cap is configured to selectively engage the shoulder of the container body such that the curl forms an interference fit with the shoulder, and the cap covers the roller sphere.

In various embodiments, the first diameter is larger than the second diameter. In some embodiments, the maximum diameter of the chamber is approximately <NUM>% larger than the outer diameter of the roller sphere. In various embodiments, the maximum diameter of the chamber is approximately <NUM>, and the outer diameter of the roller sphere is approximately <NUM>. In some embodiments, the maximum diameter of the chamber is offset from the upper opening along the axis by a predetermined distance, wherein the predetermined distance is approximately <NUM>. In various embodiments, wherein the container body is an aluminum alloy, and the roller sphere is one of a plastic material and an aluminum material or combinations therein.

Another particular embodiment of the present disclosure is a method for manufacturing a metallic roll-on container, comprising (i) forming a slug with a metallic material; (ii) impact extruding the slug to form a container body, wherein the container body extends from a closed bottom end to an open top end; (iii) forming arcuate-shaped sidewalls at the top end of the container body that define an upper opening with a first diameter and define a lower opening with a second diameter; and (iv) pressing a roller sphere into the sidewalls to deflect the sidewalls and position the roller sphere in the container body, the roller sphere and the sidewalls defining a chamber positioned between the upper and lower openings, wherein the roller sphere has an outer diameter that is larger than the first and second diameters and smaller than a maximum diameter of the chamber.

In some embodiments, the method further comprises (v) melting and casting the metallic material into a slab; (vi) rolling the slab to a predetermined thickness; (vii) cooling the slab at an ambient temperature between approximately <NUM>° C (<NUM>° F) to <NUM>° C (<NUM>° F); (viii) punching the slug from the cooled slab; and (ix) annealing the slug, wherein a peak temperature of the slug is between approximately <NUM>° C (<NUM>° F) to <NUM>° C (<NUM>° F). In various embodiments, the method further comprises (x) providing a scrap metallic material; (xi) melting the scrap metallic material with a <NUM> aluminum alloy to form the metallic material, wherein the metallic material comprises between <NUM> wt. % aluminum and <NUM> wt. % aluminum, between <NUM> wt. % Si and <NUM> wt. % Si, between <NUM> wt. % Fe and <NUM> wt. % Fe, between <NUM> wt. % Cu and <NUM> wt. % Cu, between <NUM> wt. % Mn and <NUM> wt. % Mn, between <NUM> wt. % Mg and <NUM> wt. % Mg, between <NUM> wt. % Zn and <NUM> wt. % Zn, between <NUM> wt. % Cr and <NUM> wt. % Cr, and between <NUM> wt. % Ti and <NUM> wt.

In some embodiments, approximately <NUM>% of the metallic material is the scrap metallic material and approximately <NUM>% of the metallic material is the <NUM> aluminum alloy. In various embodiments, the scrap metallic material comprises at least one of a <NUM>, a <NUM>, a <NUM>, a <NUM>, a <NUM> or a <NUM> aluminum alloy. In some embodiments, a titanium boride material is added to the scrap metallic material.

In various embodiments, the method further comprises (xii) forming a shoulder on an outer surface of the container body; (xiii) forming an inward curl on a cap that defines a cap opening; and (xiv) pressing the cap onto the shoulder such that the curl forms an interference fit with the shoulder, and the cap covers the roller sphere. In some embodiments, the method further comprises (xv) annealing the slug within a furnace at a temperature between approximately <NUM>,<NUM>° C (<NUM>,<NUM>° F) to <NUM>° C (<NUM>,<NUM>° F) for between approximately <NUM> hours to <NUM> hours. In various embodiments, the method further comprises (xvi) trimming at least a portion of the container body after the impact extruding.

In some embodiments, the method further comprises (xvii) moving the roller sphere to an extended position against the upper opening where the chamber forms a continuous volume with a container volume of the container body such that the chamber can receive a product stored in the container volume; and (xviii) moving the roller sphere to a depressed position against the lower opening where the chamber forms a continuous volume with an external environment such that the product from the chamber can be applied to the roller sphere as the roller sphere rotates against an external surface.

A further specific embodiment of the present disclosure is a metallic roll-on container for applying a product onto an external surface, comprising a metallic container body extending along a longitudinal axis from a closed bottom end to an open top end; at least one arcuate-shaped sidewall of the container body that defines an upper opening with a first diameter, a lower opening with a second diameter, and a maximum inner diameter between the upper and lower openings; a roller sphere positioned in the open top end of the container body and seated at least partially between the upper opening and the lower opening to define a chamber between the roller sphere and the at least one arcuate-shaped sidewall, wherein a diameter of the roller sphere is greater than the first diameter and greater than the second diameter, and the diameter of the roller sphere is less than the maximum inner diameter; wherein, in a first extended position, the roller sphere is seated against the upper opening of the at least one arcuate-shaped sidewall, and the chamber is in fluid communication with the container and can receive a product stored in the container; and wherein, in a second depressed position, the roller sphere is seated against the lower opening of the at least one arcuate-shaped sidewall, and the chamber is no longer in fluid communication with the product stored in the container, and wherein the roller sphere rotates to allow the application of the product in the chamber to an external surface.

According to the invention, the metallic container body comprises an aluminum material, and the diameter of the roller sphere is between approximately <NUM>% to <NUM>% larger than the first diameter of the upper opening. The metallic container body comprises an aluminum material, and in various embodiments, the diameter of the roller sphere is approximately <NUM>, and the first diameter of the upper opening is between approximately <NUM> to <NUM>. In some embodiments, the maximum inner diameter is between approximately <NUM>% and <NUM>% larger than the diameter of the roller sphere. In various embodiments, the first diameter is larger than the second diameter such that a larger portion of the roller sphere extends above the upper opening than below the lower opening. In some embodiments, the container further comprises a shoulder extending from an outer surface of the container body, wherein the shoulder is configured to selectively receive a cap with an interference fit, and the cap presses the roller sphere into the second depressed position when the cap is received on the shoulder.

Another particular embodiment of the present disclosure is a method for manufacturing a metallic roll-on container for applying a product onto an external surface, comprising (xix) forming a container body from a slug of metallic material, wherein the container body extends from a closed bottom end to an open top end, and the container body has at least one arcuate-shaped sidewall that defines an upper opening at the top end with a first diameter, a lower opening with a second diameter; (xx) providing a roller sphere having an outer diameter that is larger than the first diameter of the upper opening; (xxi) pressing a roller sphere into the at least one sidewall at the upper opening to deform the at least one sidewall such that the first diameter increases to match the outer diameter of the roller sphere; and (xxii) releasing an elastic portion of the deformation of the at least one sidewall after the roller sphere passes through the upper opening such that the outer diameter of the roller sphere remains larger than the first diameter of the upper opening, and the roller sphere is retained within the container body.

In some embodiments, the forming the container body comprises impact extruding the slug of the metallic material. In various embodiments, the method further comprises (xxiii) trimming at least a portion of the container body after the impact extruding. In some embodiments, the method further comprises (xxiv) melting and casting the metallic material into a slab; (xxv) rolling the slab to a predetermined thickness; (xxvi) cooling the slab at an ambient temperature between approximately <NUM>° C (<NUM>° F) to <NUM>° C (<NUM>° F); (xxvii) punching the slug from the cooled slab; and (xxviii) annealing the slug, wherein a peak temperature of the slug is between approximately <NUM>° C (<NUM>° F) to <NUM>° C (<NUM>° F). In some embodiments, the method further comprises (xxix) providing a scrap metallic material; (xxx) melting the scrap metallic material with a <NUM> aluminum alloy to form the slug of metallic material having between <NUM> wt. % aluminum and <NUM> wt. % aluminum, between <NUM> wt. % Si and <NUM> wt. % Si, between <NUM> wt. % Fe and <NUM> wt. % Fe, between <NUM> wt. % Cu and <NUM> wt. % Cu, between <NUM> wt. % Mn and <NUM> wt. % Mn, between <NUM> wt. % Mg and <NUM> wt. % Mg, between <NUM> wt. % Zn and <NUM> wt. % Zn, between <NUM> wt. % Cr and <NUM> wt. % Cr, and between <NUM> wt. % Ti and <NUM> wt.

In various embodiments, the method further comprises (xxxi) forming a shoulder on an outer surface of the container body; (xxxii) forming an inward curl on a cap that defines a cap opening; and (xxxiii) pressing the cap onto the shoulder such that the curl forms an interference fit with the shoulder, and the cap presses the roller sphere into the lower opening. In some embodiments, the metallic container body comprises an aluminum material, and the diameter of the roller sphere is between approximately <NUM>% to <NUM>% larger than the first diameter of the upper opening. In various embodiments, the method further comprises (xxxiv) moving the roller sphere to a first extended position, wherein the roller sphere is seated against the upper opening of the at least one arcuate-shaped sidewall, and a chamber between the roller sphere and the at least one arcuate-shaped sidewall is in fluid communication with the container body and can receive a product stored in the container body; and (xxxv) moving the roller sphere to a second depressed position, the roller sphere is seated against the lower opening of the at least one arcuate-shaped sidewall, and the chamber is no longer in fluid communication with the product stored in the container body, and wherein the roller sphere rotates to allow the application of the product in the chamber to an external surface.

An example of the present disclosure is a metallic roll-on container system for applying a liquid product onto a user's skin, comprising a metallic container body extending along a longitudinal axis from a closed bottom end to an open top end; at least one arcuate-shaped sidewall of the container body that defines an upper opening with a first diameter, a lower opening with a second diameter, and a maximum inner diameter located between the upper and lower openings; a roller sphere positioned in the open top end of the container body and seated at least partially between the upper opening and the lower opening to define a chamber between the roller sphere and the at least one arcuate-shaped sidewall, wherein a diameter of the roller sphere is greater than the first diameter and greater than the second diameter, and the diameter of the roller sphere is less than the maximum inner diameter; an outwardly-extending shoulder of the metallic container body positioned below the lower opening along the longitudinal axis, the shoulder having a diameter that is larger than the maximum inner diameter; and a cap selectively connected to the shoulder with an interference fit, wherein, when the cap is selectively connected to the shoulder, the cap presses the roller sphere against the lower opening, wherein the metallic container body and the cap are each made of a material having a Young's Modulus greater than <NUM> GPa.

In some embodiments, the cap has an inwardly-extending curl that defines an opening with an inner diameter that is less than the diameter of the shoulder to form the interference fit. In various embodiments, the system further comprises a first recess extending into an outer surface of the metallic container body, wherein the metallic container body defines the lower opening at the first recess; and a second recess extending into an outer surface of the metallic container body, wherein the curl of the cap extends into the second recess wherein the cap is selectively connected to the metallic container body. The metallic container body comprises an aluminum material, and the diameter of the roller sphere is between approximately <NUM>% to <NUM>% larger than the first diameter of the upper opening. In various embodiments, a first distance between the maximum inner diameter to the upper opening along the longitudinal axis is less than a second distance between the maximum inner diameter to the lower opening along the longitudinal axis such that a larger portion of the roller sphere extends above the upper opening than below the lower opening. In some embodiments, the at least one arcuate sidewall comprises a first arcuate sidewall that defines the upper opening and a second arcuate sidewall that defines the lower opening.

Although generally referred to herein as a "bottle," "metallic bottle," "metallic container," "container," "aluminum bottle," "can," and "container," as will be appreciated by one of skill in the art, the methods and apparatus of the present disclosure may be used for any type of container and are not specifically limited to a beverage container such as a soft drink or beer can.

The terms "metal" or "metallic" as used hereinto refer to any metallic material that may be used to form a container, including without limitation aluminum, steel, tin, and any combination thereof.

The phrases "at least one," "one or more," and "and/or," as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and/or C" means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term "about" or "approximately. " One skilled in the art will appreciate that these terms, for instance, can imply variation, on a relative basis, of less than <NUM>%.

Accordingly, the terms "including," "comprising," or "having" and variations thereof can be used interchangeably herein.

It shall be understood that the term "means" as used herein shall be given its broadest possible interpretation. Accordingly, a claim incorporating the term "means" shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the Summary, Brief Description of the Drawings, Detailed Description, Abstract, and Claims themselves.

The Summary is neither intended, nor should it be construed, as being representative of the full extent and scope of the present disclosure. Moreover, references made herein to "the present disclosure" or aspects thereof should be understood to mean certain embodiments of the present disclosure and should not necessarily be construed as limiting all embodiments to a particular description. The present disclosure is set forth in various levels of detail in the Summary as well as in the attached Drawings and the Detailed Description and no limitation as to the scope of the present disclosure is intended by either the inclusion or non-inclusion of elements or components. Additional aspects of the present disclosure will become more readily apparent from the Detailed Description, particularly when taken together with the Drawings.

The accompanying Drawings, which are incorporated herein and constitute a part of the specification, illustrate embodiments of the disclosure and together with the Summary given above and the Detailed Description given below serve to explain the principles of these embodiments. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the present disclosure is not necessarily limited to the particular embodiments illustrated herein. Additionally, it should be understood that the Drawings are not necessarily to scale.

To assist in the understanding the present disclosure the following list of components and associated numbering found in the Drawings is provided herein:.

Referring now to <FIG>, a front elevation view of the aluminum roll-on container <NUM> is provided. The container <NUM> in this embodiment comprises a body <NUM> that generally extends along a longitudinal axis from a closed end <NUM> to an open end <NUM>. A roller sphere <NUM> is positioned in the open end <NUM> to dispense product stored within the container <NUM> onto an external surface. For instance, a deodorant product can be stored within the container <NUM>, and movement of the roller sphere <NUM> at the open end <NUM> coats part of the roller sphere <NUM> with the deodorant product. Then, a user can move the container <NUM> such that the roller sphere <NUM> rotates at the open end <NUM>, and the deodorant product is transferred from the roller sphere <NUM> to the skin of the user. It will be appreciated that the roller sphere <NUM> can be made from a variety of materials including aluminum, plastic, etc. It will be further appreciated that the product stored in the container <NUM> can include sunscreen, insect repellant, lotion, pressurized contents, non-pressurized contents, etc. Moreover, while the roller sphere <NUM> is depicted as a smooth sphere, the present disclosure encompasses embodiments where the roller sphere <NUM> has, for example, a textured surface such as a dimpled surface that helps retain product received from the within the container <NUM>.

Referring now to <FIG>, a partial cross-sectional view of the container <NUM> is provided. The cross-section is taken partially along line <NUM>-<NUM> of <FIG> such that a quarter of the container <NUM> is removed to reveal more of the roller sphere <NUM>. An arcuate sidewall <NUM> is formed at the open end <NUM> of the container <NUM>, and the roller sphere <NUM> is positioned within the arcuate sidewall <NUM>. The arcuate sidewall <NUM> can be described as a single sidewall <NUM> or a plurality of sidewalls that circumscribe the roller sphere <NUM>. As described in further detail below, the arrangement between the roller sphere <NUM> and the arcuate sidewall <NUM> allows product stored in the container <NUM> to move into a chamber between the roller sphere <NUM> and the arcuate sidewall <NUM>. Then, the roller sphere <NUM> can transfer the product to an external surface.

Referring now to <FIG>, cross-sectional views of the arcuate sidewall <NUM> and the roller sphere <NUM> taken along line <NUM>-<NUM> of <FIG> are depicted in a first position and a second position. As shown in <FIG>, the roller sphere <NUM> is in a first, upward position to move product into a chamber <NUM> between the roller sphere <NUM> and the arcuate sidewall <NUM>. As shown in <FIG>, the roller sphere <NUM> is in a second, downward position to apply product to an external surface. The arcuate sidewall <NUM> defines an upper opening <NUM> and a lower opening <NUM> within the container, and the roller sphere <NUM> and an inner surface <NUM> of the arcuate sidewall <NUM> define a chamber <NUM> positioned between the upper opening <NUM> and the lower opening <NUM>. The upper opening <NUM> serves as the opening for the container <NUM>, and the lower opening <NUM> joins the chamber <NUM> with a container volume <NUM> that stores a product. The chamber <NUM> of the container <NUM> generally receives the roller sphere <NUM>, though portions of the roller sphere <NUM> extend into the container volume <NUM> and into the external environment.

Also depicted is the diameter <NUM> of the roller sphere <NUM> which, as described in more detail below, allows the roller sphere <NUM> to be retained within the container <NUM> while moving within the container <NUM>. Specifically, the diameter of the roller sphere <NUM> is greater than the diameter of the upper opening <NUM> but less than the maximum inner diameter <NUM> of the chamber <NUM> as defined by the arcuate sidewall <NUM>. In various embodiments the diameter <NUM> is between approximately <NUM> and <NUM>. In some embodiments, the diameter <NUM> is approximately <NUM>.

In addition, the diameter of the lower opening <NUM> can be smaller than the diameter of the upper opening <NUM> to expose more of the roller sphere <NUM> to an external environment. In the example of deodorant, a limited area of the roller sphere <NUM> that is exposed to the external environment would result in less transfer the deodorant product from the roller sphere <NUM> to the skin. With the depicted relationship between the diameters of the openings <NUM>, <NUM>, a greater area of the roller sphere <NUM> is exposed to the external environment to contact more skin or other surfaces. Yet, the upper opening <NUM> cannot be so large as to interfere with the assembly process or to let the roller sphere <NUM> fall out. Thus, in some embodiments, the diameter of the upper opening <NUM> is between approximately <NUM> % and <NUM> % larger than the diameter of the lower opening <NUM>. In various embodiments, the diameter of the upper opening <NUM> is approximately <NUM> % larger than the diameter of the lower opening <NUM> to achieve the above functions while avoiding the above issues.

The roller sphere <NUM> in <FIG> is in a first position such that the roller sphere <NUM> is seated against the upper opening <NUM>. This can be accomplished in many different ways, including inverting the container <NUM> such that gravity pulls the roller sphere <NUM> against the upper opening <NUM>. Similarly, the container volume <NUM> can be pressurized to bias the roller sphere <NUM> against the upper opening <NUM>. Further still, a user can shake the container <NUM> to at least temporarily move the roller sphere <NUM> against the upper opening <NUM>. With the roller sphere <NUM> seated against the upper opening <NUM>, the chamber <NUM> forms a continuous volume with the container volume <NUM>. This allows product stored in the container volume <NUM> to move into the chamber <NUM>.

The roller sphere <NUM> in <FIG> is in a second position such that the roller sphere <NUM> is seated against the lower opening <NUM>. This can be accomplished by pressing the roller sphere <NUM> against an external surface such as skin. Now the chamber <NUM> forms a continuous volume with an external environment, and the product that is in the chamber <NUM> can coat part of the roller sphere <NUM> as the roller sphere <NUM> rotates against an external surface. This arrangement also limits the amount of product that can be used since, generally, only the product transferred to the chamber <NUM> coats the roller sphere <NUM>. As a result, the product is meted out in a controlled manner, which conserves the limited supply of product stored in the container <NUM>.

Now referring to <FIG> and <FIG>, a cross-sectional view and an elevation view of another embodiment of the container <NUM> are provided, respectively. The cross-section in <FIG> is taken along line <NUM>-<NUM> shown in <FIG>. These figures depict aspects of the container <NUM> that allow various components to function as described herein. For example, since the roller sphere is larger than the upper opening, and the roller sphere is pressed through the upper opening to assemble the container, the sidewall that defines the upper opening will deform until the diameter of the upper opening is temporarily the same as the diameter of the roller sphere. For a material like aluminum, or a material that at least partially comprises aluminum, the relative sizes between the roller sphere and upper opening are critical for allowing for at least some elastic deformation of the sidewall of the container as the roller sphere enters the container and a sufficient amount of spring back from the aluminum material of the sidewall to retain the roller sphere within the container.

The diameter of the roller sphere is approximately <NUM>% to <NUM>% larger than the diameter of the upper opening <NUM> defined by the arcuate sidewall. In some embodiments, the diameter of the roller sphere is approximately <NUM> % larger than the diameter of the upper opening <NUM> defined by the arcuate sidewall. Stated differently, the diameter of the upper opening <NUM> is between approximately <NUM> % and <NUM> % of the diameter of the roller sphere in various embodiments. In some embodiments, the diameter of the upper opening <NUM> is approximately <NUM>% of the diameter of the roller sphere. In further embodiments, the diameter of the upper opening <NUM> is between approximately <NUM> % to <NUM>% of the diameter of the roller sphere. In various embodiments, the diameter of the roller sphere can be approximately <NUM>, and the diameter of the upper opening is at least <NUM>. In various embodiments, the upper opening diameter <NUM> is between approximately <NUM> and <NUM>. In some embodiments, the upper opening diameter <NUM> is between approximately <NUM> and <NUM>. In various embodiments, the upper opening diameter is approximately <NUM>. It will be appreciated that further embodiments of the present disclosure can include a roller sphere having a diameter, for instance, between approximately <NUM> and <NUM> in accordance with the relative relationships described herein.

In a further example, the relationship between the roller sphere and the maximum inner diameter <NUM> of the arcuate sidewall is important, even critical, to the movement of the roller sphere between first and second positions. In some embodiments, the maximum inner diameter <NUM> is between approximately <NUM> and <NUM>, and in various embodiments, the maximum inner diameter <NUM> is approximately <NUM> when the roller sphere has a diameter of <NUM>. It will be appreciated that the diameter of the roller sphere and the maximum inner diameter <NUM> can be expressed in relative terms to allow the roller sphere to move between positions once assembled with the container body, where the maximum inner diameter <NUM> is between approximately <NUM> % and <NUM> % larger that the diameter of the roller sphere. In various embodiments, the maximum inner diameter <NUM> is approximately <NUM> % larger than the diameter of the roller sphere. In some embodiments, an outer dimension <NUM> is between approximately <NUM> and <NUM>, and in various embodiments, the outer dimension <NUM> is approximately <NUM>.

In the embodiment depicted in <FIG> and <FIG>, the first arcuate sidewall <NUM> establishes these dimensions <NUM>, <NUM>, <NUM>, and a second arcuate sidewall <NUM> establishes a recess at an outer surface and defines a lower opening at an inner surface where the lower opening interacts with the roller sphere as described herein. A transition sidewall <NUM> can join the first and second arcuate sidewalls <NUM>, <NUM>. In various embodiments, the lower opening diameter <NUM> is between approximately <NUM> and <NUM>. In some embodiments, the lower opening diameter <NUM> is approximately <NUM>. At a lower end, the second arcuate sidewall <NUM> joins a first taper sidewall <NUM>, which extends outwardly and joins a third arcuate sidewall <NUM>. The third arcuate sidewall <NUM>, a shoulder sidewall <NUM>, and a second taper sidewall <NUM> generally define a shoulder where the shoulder sidewall <NUM> is substantially parallel with a longitudinal axis of the container <NUM>. A third taper sidewall <NUM> tapers inwardly and joins a recess sidewall <NUM>, which is substantially parallel with a longitudinal axis of the container <NUM>. The recess sidewall <NUM> defines a second recess at an outer surface and a lower recess diameter <NUM> at an inner surface. In some embodiments, the lower recess diameter <NUM> is between approximately <NUM> and <NUM>. In various embodiments, the lower recess diameter <NUM> is approximately <NUM>. Finally, a fourth arcuate sidewall <NUM> and a fifth arcuate sidewall <NUM> extend outwardly to join the remaining body <NUM> of the container <NUM>.

<FIG> is an elevation view of a container <NUM> where further diameters are shown. For instance, an outermost diameter <NUM> is defined by the first arcuate sidewall, and in some embodiments, the outermost diameter <NUM> is between approximately <NUM> and <NUM>. In various embodiments, the outermost diameter <NUM> is approximately <NUM>. Below this diameter <NUM>, the sidewalls define a first recess <NUM>, a shoulder <NUM>, and a second recess <NUM>. In some embodiments, the first recess diameter <NUM> is between approximately <NUM> and <NUM>. In various embodiments, the first recess diameter <NUM> is approximately <NUM>. In some embodiments, the shoulder diameter <NUM> is between approximately <NUM> and <NUM>. In various embodiments, the shoulder diameter <NUM> is approximately <NUM>. In some embodiments, the second recess diameter <NUM> is between approximately <NUM> and <NUM>. In various embodiments, the second recess diameter <NUM> is approximately <NUM>. In some embodiments, a diameter <NUM> of the remaining body <NUM> is between approximately <NUM> and <NUM>. In various embodiments, the body diameter <NUM> is approximately <NUM>.

These features and components, including their absolute dimensions and dimensions relative to each other, can serve various functions of the container. Generally, the first recess <NUM> defines the diameter of the lower opening within the container. The shoulder diameter <NUM> is larger than the outermost diameter <NUM> to provide clearance for a cap that selectively connects to the shoulder. Moreover, the shoulder <NUM> is positioned between two recesses <NUM>, <NUM> to help a user located a cap on the shoulder <NUM> and to also add rigidity to the shoulder <NUM> that may experience many selective connections of a cap over the life of the container. The rigidity is added by a sidewall that extends inwardly from an upper edge of the shoulder sidewall and a sidewall that extends inwardly from a lower edge of the shoulder sidewall. These sidewalls buttress and support the shoulder sidewall to increase the rigidity of the overall shoulder. In this sense, the shoulder <NUM> has a higher rigidity than the curl of the cap, as described in greater detail below. The second recess <NUM>, as described in further detail below can receive part of a curl of the cap to help secure the cap to the shoulder <NUM>.

<FIG> also shows the various radii of curvature along which the arcuate sidewalls extend. In some embodiments, the first arcuate sidewall extends along a radius <NUM> between approximately <NUM> and <NUM>. In some embodiments, the radius <NUM> is approximately <NUM>. In various embodiments, the second arcuate sidewall extends along a radius <NUM> between approximately <NUM> and <NUM>. In some embodiments, the radius <NUM> is approximately <NUM>. In various embodiments, the third arcuate sidewall extends along a radius <NUM> between approximately <NUM> and <NUM>. In some embodiments, the radius <NUM> is approximately <NUM>. In various embodiments, the fourth arcuate sidewall extends along a radius <NUM> between approximately <NUM> and <NUM>. In some embodiments, the radius <NUM> is approximately <NUM>. In various embodiments, the fifth arcuate sidewall extends along a radius <NUM> between approximately <NUM> and <NUM>. In some embodiments, the radius <NUM> is approximately <NUM>.

In addition, <FIG> shows various dimensions <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> of points along the sidewalls relative to the top surface of the container <NUM>. Thus, for instance, a first dimension <NUM> and an eighth dimension <NUM> are both measured from the top surface of the container <NUM>. In various embodiments, a first dimension <NUM> to an outermost diameter of the first arcuate sidewall is between approximately <NUM> and <NUM>. In some embodiments, the first dimension <NUM> is approximately <NUM>. The outermost diameter corresponds to the maximum inner diameter defined by an inner surface of the arcuate sidewall, and this offset of the maximum inner diameter from the upper surface helps retain the roller sphere within the container body. In various embodiments, a second dimension <NUM> to the narrowest diameter of the first recess is between approximately <NUM> and <NUM>. In some embodiments, the second dimension <NUM> is approximately <NUM>. In some embodiments, the second dimension <NUM> is greater than twice the first dimension <NUM> such that a larger portion of the roller sphere extends above the upper opening than below the lower opening. In various embodiments, a third dimension <NUM> to an upper edge of the shoulder sidewall is between approximately <NUM> and <NUM>. In some embodiments, the third dimension <NUM> is approximately <NUM>. In various embodiments, a fourth dimension <NUM> to a lower edge of the shoulder sidewall is between approximately <NUM> and <NUM>. In some embodiments, the fourth dimension <NUM> is approximately <NUM>.

In various embodiments, a fifth dimension <NUM> to an upper edge of the recess sidewall is between approximately <NUM> and <NUM>. In some embodiments, the fifth dimension <NUM> is approximately <NUM>. In various embodiments, a sixth dimension <NUM> to a lower edge of the recess sidewall is between approximately <NUM> and <NUM>. In some embodiments, the sixth dimension <NUM> is approximately <NUM>. In various embodiments, a seventh dimension <NUM> to an inflection point between the fourth and fifth arcuate sidewalls is between approximately <NUM> and <NUM>. In some embodiments, the seventh dimension <NUM> is approximately <NUM>. In various embodiments, an eighth dimension <NUM> to the remaining body of the container <NUM> is between approximately <NUM> and <NUM>. In some embodiments, the eighth dimension <NUM> is approximately <NUM>.

Now referring to <FIG>, perspective views of a container without and with a cap <NUM> are provided, respectively. An exposed roller sphere can dehydrate a product such as deodorant and inhibit operation of the aluminum roll-on container. A cap <NUM> positioned over the roller sphere while the aluminum roll-on container is not in operation can help prevent evaporation or slow down dehydration of a product stored in the container. A shoulder <NUM> is formed on an outer surface of the container <NUM>, and the cap <NUM> can selectively connect to the shoulder <NUM> in an interference fit to at least reduce evaporation or dehydration of the product.

Referring now to <FIG> and <FIG>, cross-sectional views of a container <NUM> without and with a cap <NUM> are provided, respectively. The cross-section in <FIG> is taken along line 7A-7A of <FIG>, and the cross-section in <FIG> is taken along line 7B-7B of <FIG>. The cap <NUM> has an opening at a lower end that is defined by an inwardly-extending curl <NUM>, which provides resiliency or elasticity to the end of the cap <NUM> when the cap <NUM> is placed on the shoulder of the container. Thus, the shoulder has a diameter that is larger than the diameter of the opening of the cap <NUM>, and the inward curl <NUM> of the cap <NUM> can deflect to form an interference fit with the container <NUM> and retain the cap <NUM> on the container <NUM>. Specifically, the curl <NUM> is supported at one end, the lowermost end of the cap <NUM>, and not support at an opposing end. Thus, the curl <NUM> deflects in when engaged with the shoulder of the container, which is supported and is a more rigid structure. The cap <NUM> can be made from a variety of materials including aluminum, plastic, etc..

When the cap <NUM> is in the position shown in <FIG> the curl <NUM> is selectively connected to the shoulder. More specifically, the curl <NUM> is partially positioned in the recess below the shoulder <NUM>, and the curl <NUM> contacts a lower edge of the shoulder <NUM>. The height <NUM> of the cap <NUM> is selected such that an inner surface of the cap <NUM> contacts the roller sphere to press the roller sphere against the lower opening and preserve the contents of the container.

In addition, it will be appreciated that the roll-on container, including the various aspects of the container such as the arcuate sidewall, can be produced using an impact extrusion process. This process can form a material such as an aluminum into complex shapes. <CIT> provides additional background and context regarding the impact extrusion process and forming aluminum into complex shapes. It will be appreciated that embodiments of the present disclosure can be manufactured according to other methods such as drawing and ironing, etc..

Claim 1:
A metallic roll-on container (<NUM>) for applying a product onto an external surface, comprising:
a metallic container body (<NUM>) extending along a longitudinal axis from a closed bottom end (<NUM>) to an open top end (<NUM>) wherein said metallic container body (<NUM>) comprises an aluminum material;
at least one arcuate-shaped sidewall (<NUM>) of said metallic container body (<NUM>) that defines an upper opening (<NUM>) with a first diameter (<NUM>), a lower opening (<NUM>) with a second diameter (<NUM>), and a maximum inner diameter (<NUM>) between said upper and lower openings (<NUM>, <NUM>);
a roller sphere (<NUM>) positioned in said open top end (<NUM>) of said metallic container body (<NUM>) and seated at least partially between said upper opening (<NUM>) and said lower opening (<NUM>) to define a chamber (<NUM>) between said roller sphere (<NUM>) and said at least one arcuate-shaped sidewall (<NUM>), wherein a diameter (<NUM>) of said roller sphere (<NUM>) is greater than said first diameter (<NUM>) and greater than said second diameter (<NUM>), and said diameter (<NUM>) of said roller sphere (<NUM>) is less than said maximum inner diameter (<NUM>) wherein said diameter (<NUM>) of said roller sphere (<NUM>) is between approximately <NUM>% to <NUM>% larger than said first diameter (<NUM>) of said upper opening (<NUM>);
wherein, in a first extended position, said roller sphere (<NUM>) is seated against said upper opening (<NUM>) of said at least one arcuate-shaped sidewall (<NUM>), and said chamber (<NUM>) is in fluid communication with said container (<NUM>) and can receive a product stored in said container (<NUM>); and
wherein, in a second depressed position, said roller sphere (<NUM>) is seated against said lower opening (<NUM>) of said at least one arcuate-shaped sidewall (<NUM>), and said chamber (<NUM>) is no longer in fluid communication with said product stored in said container (<NUM>), and wherein said roller sphere (<NUM>) rotates to allow the application of said product in said chamber (<NUM>) to an external surface.