Patent Document

RELATED APPLICATIONS 
       [0001]    This application claims priority benefit of U.S. Provisional Application Ser. No. 61/980,141 filed Apr. 16, 2014; the contents of which are hereby incorporated by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention in general relates to containers, and in particular to a bottle for dispensing fluids directly into a fuel system filler neck equipped with a capless filler. 
       BACKGROUND OF THE INVENTION 
       [0003]    A recent design trend has been the introduction of capless filler systems for vehicle fuel systems. A capless filler does away with the traditional screw-on fuel cap in favor of an automatic seal which is opened upon the insertion of the nozzle of a fuel hose from a gas station pump. A capless filler has one or more spring loaded flappers that are actuated by the insertion of a nozzle, and the flapper automatically springs back to a closed sealing position with the withdrawal of the inserted nozzle. The seal provided by the spring loaded flapper is generally tighter and more reliable than the traditional screw-on fuel cap, which is important to maintain the pressure in a vehicle fuel system, and to prevent gas fumes from escaping into the environment.  FIG. 1  shows a prior art capless filler  64  mounted on the side of a vehicle  62 . 
         [0004]    Capless fillers provide several benefits to a user including reducing the chance for a gas smell on their hands, since the user simply flips open the fuel door and inserts the pump nozzle in the opening of the capless filler. Not having a twist-on/off gas cap is one less contact with a gasoline-vapor odor source, and prevents the discomfort experienced by people with arthritis or other impairments that make the act of twisting a cap awkward or painful. The possibility of a gas cap dangling and scratching the paint during fueling in eliminated, as well as the embarrassment of a forgotten gas cap left dangling or lost if forgotten by the driver after the refueling stop. 
         [0005]    While there are many positive aspects to the use of capless fillers, existing automotive fuel additive packaging, and certain other fuel loading containers are incompatible with the capless mechanism. In general, existing fuel and additive treatment packages and fuel handling containers have external threads that get caught up in the flapper seals, and cannot be retracted after insertion into the filler neck to the gas tank. Furthermore, existing containers are not shaped or contoured for insertion and actuation of flapper seals in a vehicles capless filler system. 
         [0006]    Thus, there exists a need for containers that are compatible with capless filler systems for manually dispensing fuel, fuel treatments, fuel additives, and engine treatments into the vehicles fuel system. 
       SUMMARY OF THE INVENTION 
       [0007]    A bottle for dispensing fluids into a capless filler system, the bottle configured with an elongated smooth neck designed for insertion into a capless filler opening to actuate and displace one or more flapper seals when emptying the fluid into the capless filler. The bottle is sealed with a cap with a first set of screw threads that engages the neck at a top portion with a second set of screw threads on an interior surface of the top portion of the neck. The cap may be a child proof cap. The bottle may be made of plastic that is clear or opaque. 
         [0008]    A method of for using the bottle is provided that includes opening the bottle by unscrewing the cap from the elongated smooth neck of the bottle, inserting the elongated smooth neck into the capless filler of a vehicle, and retracting the bottle from the capless filler after introducing a liquid held in the bottle. 
         [0009]    A method for forming a capless filler bottle is provided that includes placing a threaded insert into an injection mold, introducing a thermoplastic into the injection mold, and wherein the threaded insert forms a set of internal threads on an inner top portion of the elongated smooth neck of the bottle. The thermoplastic is introduced by injection or blow molding, where blow molding is by at least one of extrusion blow molding, injection blow molding, and injection stretch blow molding. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which: 
           [0011]      FIG. 1  illustrates a view of a typical prior art capless filler system of a vehicle; 
           [0012]      FIG. 2A  is a front, upper perspective view of an embodiment of the inventive bottle; 
           [0013]      FIG. 2B  is a front view of the bottle depicted in  FIG. 2A , where side views and the rear view are identical to that depicted in  FIG. 2B ; 
           [0014]      FIG. 2C  is a top view of the bottle depicted in  FIG. 1 ; 
           [0015]      FIG. 2D  is a bottom view of the bottle depicted in  FIG. 1 ; 
           [0016]      FIG. 3A  is a front view of the bottle of  FIG. 2A  with a cap screwed on according to an embodiment of the invention; 
           [0017]      FIG. 3B  is a cross-section view along line A-A of  FIG. 3A  showing the cap attached to the bottle with the cap threads internal to the bottle according to embodiments of the invention; 
           [0018]      FIG. 4A  is a front view of a bottle with a series of slots or wedges at the top according to an embodiment of the invention; 
           [0019]      FIG. 4B  is a cross-section view along line B-B of  FIG. 4A  showing internal cap threads molded into the elongated neck of the bottle according to embodiments of the invention; 
           [0020]      FIG. 4C  is a top view of the bottle depicted in  FIG. 4A ; 
           [0021]      FIG. 4D  is a bottom view of the bottle depicted in  FIG. 4A ; 
           [0022]      FIG. 4E  is a front view of the bottle of  FIG. 4A  with a series of slots or wedges in detail B and cross section C-C line at the base according to an embodiment of the invention; 
           [0023]      FIG. 4F  is a detail view of a slot from the series of slots or wedges in the top portion of the elongated neck according to embodiments of the invention; 
           [0024]      FIG. 4G  is a cross section view along line C-C according to embodiments of the invention; 
           [0025]      FIG. 4H  is a perspective view of the bottle of  FIGS. 4A and 4E ; 
           [0026]      FIG. 5A  is a perspective view of the bottle of  FIG. 2A  with the internal threaded cap attached to the bottle according to an embodiment of the invention; 
           [0027]      FIG. 5B  is a detailed perspective view showing the cap of  FIG. 5A  detached from the internal threads of the bottle according to an embodiment of the invention; 
           [0028]      FIG. 6A  is a front perspective view of a clear bottle filled with a liquid that has internal threads for securing a cap and an elongated neck for actuating the flapper seals during insertion into a capless filler according to embodiments of the invention; 
           [0029]      FIG. 6B  is a front view of the liquid filled clear bottle of  FIG. 6A  with the cap removed according to an embodiment of the invention; 
           [0030]      FIG. 7A  is a front perspective view of the bottle of  FIG. 6A  with product labeling applied according to an embodiment of the invention; 
           [0031]      FIG. 7B  is a front view of the existing product packaging; and 
           [0032]      FIGS. 8A and 8B  illustrate the process of inserting an embodiment of the inventive bottle into a capless filler system. 
       
    
    
       [0033]    The detailed description explains the preferred embodiments of the invention. 
       DESCRIPTION OF THE INVENTION 
       [0034]    The present invention has utility as a container or bottle for dispensing fuel, fuel additives, and engine treatments into a fuel system equipped with a capless filler. Embodiments of the inventive bottle have an elongated neck dimensioned to allow insertion into the capless filler opening and to actuate and displace one or more flapper seals along the fuel fill tube leading to the vehicle gas tank. In certain embodiments the elongated neck is terminated with a ledge or flared out area that forms a tangible stopping point when inserting the bottle or container into the capless filler of a vehicle fuel system. Furthermore, the base area of embodiments of the inventive bottle or container is widened to serve as a grab point when the bottle is inserted in the fuel system. Embodiments of the inventive bottle have internal threads at the top inner portion of the elongated bottle neck for engagement with a twist off cap, so as to facilitate removal of the inserted bottle from the capless filler. Existing bottle designs with the threads on the exterior perimeter of a bottle top have a tendency to engage the flapper of a capless filler, and the inserted bottle is then hard to retract and remove, and may ultimately get stuck. In a specific embodiment of the inventive bottle, the bottle cap may be a child proof cap. 
         [0035]    Embodiments of the inventive container or bottle may be opaque or clear, and formed from various plastics and composites. An example of a thermoplastic that may be used to form embodiments of the inventive bottle is polyethylene terephthalate (PET). Depending on the processing and thermal history of the polyethylene terephthalate, the PET may exist both as an amorphous (transparent) and as a semi-crystalline polymer. The semicrystalline material might appear transparent (particle size &lt;500 nm) or opaque and white (particle size up to a few microns) depending on its crystal structure and particle size. PET is a recyclable material. 
         [0036]    Embodiments of the inventive bottle may be formed through a blow molding process. Blow molding is a manufacturing process by which hollow plastic parts are formed. In general, there are three main types of blow molding: extrusion blow molding, injection blow molding, and injection stretch blow molding. The blow molding process begins with melting down the plastic and forming it into a parison or in the case of injection and injection stretch blow molding (ISB) a preform. The parison is a tube-like piece of plastic with a hole in one end through which compressed air can pass. The parison is then clamped into a mold and air is blown into it. The air pressure then pushes the plastic out to match the mold. Once the plastic has cooled and hardened the mold opens up and the part is ejected. 
         [0037]    Embodiments of the inventive bottle may be formed by placing a threaded insert into an injection mold. In a specific embodiment, the internal threads on the inner wall of the top portion of the neck may be formed during the molding process with a threaded insert that serves as part of the preform injection mold and then the injection molded preform would be heated and formed into the final form. 
         [0038]    In other embodiments of the inventive bottle, the inner threads may be tapped with a tool following the bottle&#39;s formation. And in still other embodiments, the internal threads may be manufactured by creating a separate component, with the threads included, that would then be joined to the top portion of the neck of the container. 
         [0039]    Referring now to the figures,  FIGS. 2A-2D ,  FIGS. 3A and 3B , and  FIGS. 5A and 5B  are a series of views of an embodiment of the inventive bottle  10 . The bottle  10  has a smooth elongated neck  16  with a circular cross-section that has a top end that has internal threads  22  designed to engage a screw on cap  24  with engagement threads  26  as shown in the cross section A-A of  FIG. 3B  and as shown in  FIG. 5B . The internal threads  22  allow the elongated neck  16  to be completely smooth so as to allow for the ease of insertion and extraction of the bottle  10  from the capless filler system without engaging one or more flapper seals. The engagements  27  are for a child proof cap, which when downward pressure is applied allows the cap  24  to be unscrewed. The bottom of the elongated neck terminates in a ledge  20  and a flared out area  18  that forms a tangible stopping point when inserting the bottle  10  or container into the capless filler of a vehicle fuel system. The flared area  18  terminates to form the cross sectional area of the storage portion  12  of the bottle  10 . The bottle  10  has a square storage portion  12  as shown in  FIGS. 2C and 2D  of the top and bottom views, respectively, however other cross sections for the storage portion  12  are also readily available including circular, triangular, hexagonal, etc. The base area  14  of embodiments of the inventive bottle or container is widened to serve as a grab point when the bottle is inserted in the fuel system. 
         [0040]      FIGS. 4A-4H  are a series of views of an embodiment of the inventive bottle  70  with one or more slots or wedges  72  in the top portion of the elongated neck  16 . The bottle  70  has a smooth elongated neck  16  with a circular cross-section that has a top end that has internal threads  22 A designed to engage a screw on cap with engagement threads (not shown) in the cross section B-B of  FIG. 4B . In a specific embodiment, the internal thread  22 A has an M-style thread finish with two threads that start 180° apart. The internal threads  22 A allow the elongated neck  16  to be smooth so as to allow for the ease of insertion and extraction of the bottle  70  from the capless filler system without engaging one or more flapper seals. The bottom of the elongated neck  16  terminates in a ledge  20  and a flared out area  18  that forms a tangible stopping point when inserting the bottle  70  or container into the capless filler of a vehicle fuel system. The flared area  18  terminates to form the cross sectional area of the storage portion  12  of the bottle  70 . The bottle  70  has a square storage portion  12  as shown in  FIGS. 4C and 4D  of the top and bottom views, respectively, however other cross sections for the storage portion  12  are also readily available including circular, triangular, hexagonal, etc. The base area  14 A of embodiments of the inventive bottle or container is widened to serve as a grab point when the bottle is inserted in the fuel system. In some inventive embodiments slot details are provided on the elongated neck  16  that are sufficiently small so as to not to interfere with the insertion or removal of the bottle from a capless system.  FIG. 4F  is a detail view of the one or more slots or wedges  72  in the top region of the elongated neck  16 . The slot  72  may be straight or have a slight upward taper in the shape of a wedge as the slot  72  extend upward toward the lip  74  at the top of the bottle  70   FIG. 4G  is a cross section view of the bottom of the base  76  along section C-C of bottle  70  as shown in  FIG. 4E .  FIG. 4H  is a perspective view of the bottle of  FIG. 4A  and  FIG. 4E  with the threads  22 A visible. 
         [0041]      FIGS. 6A and 6B  show an embodiment of a clear bottle  30  filled with a liquid in the storage portion  42  terminated in a base  44 . The smooth elongated neck  38  has internal threads  36  for engaging and securing a cap  34  with threads  35 . The elongated neck  38  actuates or pushes the flapper seals open during insertion into a capless filler according to embodiments of the invention. The thinner circular elongated neck  38  transitions in region  40  to the wider storage area  42 .  FIG. 7A  shows the bottle  30  fitted with a label  46  for product description of the liquid in the bottle  30 . For comparison, an existing bottle  50  that is not suitable for use with capless filler systems is shown in  FIG. 7B . The bottle  50  has external threads  54  for engaging a cap  52 , and a short and thick neck  56  that terminates in a storage portion  58  and a base  60 . The stout neck  56  will not work with a capless filler system, and the external threads  54  would also not work even if the neck  56  were able to reach the flapper seals. 
         [0042]      FIGS. 8A and 8B  illustrate the use of the inventive bottle  30  with a capless filler  64  of a vehicle  62 . In  FIG. 8A  a user unscrews the cap  34  from the bottle  30 , and in  FIG. 8B  the user inserts the neck  38  of the bottle  30  into the capless filler  64 . 
         [0043]    The foregoing description is illustrative of particular embodiments of the invention, but is not meant to be a limitation upon the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the invention.

Technology Category: 7