ONE PIECE DISPENSING COMPONENT

FIELD OF THE INVENTION

The present invention relates to a one piece dispensing component. More particularly, the present invention relates to a one piece dispensing component that includes a body and a flip cap attached to the body with a hinge, wherein the one piece dispensing component is permanently connected to a container.

BACKGROUND OF THE INVENTION

The consumer products industry is a multi-billion dollar industry. Consumer product packaging and dispensers is one piece to this large industry. Such packages and/or dispensers are designed to hold and/or dispense the consumer product contained within the package and/or dispenser. There are a variety of consumer product packaging and dispensers commercially available.

SUMMARY OF THE INVENTION

The present invention is directed to a one piece dispensing component and/or package. One embodiment of the present invention is a one piece dispensing component comprising a flip cap and a body, wherein the body includes a shoulder permanently connecting the body to a container and a nozzle connected to the shoulder. The flip cap is connected to the body with a hinge.

Another embodiment of the present invention is a one piece dispensing component comprising a body, a flip cap, and a hinge. The body including a nozzle and a shoulder connected to a product container, wherein a longitudinal axis of the nozzle is offset from a longitudinal axis of the body.

Yet another embodiment of the present invention is a product dispensing package comprising a non- injection molded container for holding a product and having an open end and a one piece dispensing component. The one piece dispensing component includes a shoulder, a nozzle connected to the shoulder and having an orifice, a flip cap operable to close the orifice, and a hinge connecting the flip cap to the nozzle. The shoulder permanently connecting the one piece dispensing component to the open end of the container such that the orifice is in fluid communication with the open end.

Still yet another exemplary embodiment of the present invention is a process of manufacturing a one piece dispensing package that includes the steps of producing a one piece dispensing component, producing non-injection-molded tube having an open end and a closed end opposite the open end, and permanently connecting the one piece dispensing component to the open end of the tube. The one piece dispensing component includes a shoulder, a nozzle, a flip cap, and a hinge attaching the flip cap to the nozzle.

Embodiments are described in further detail herein, and these and other features, aspects, and advantages of the present invention will become evident to those skilled in the art from a reading of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming the invention, it is believed the same will be better understood from the following description taken in conjunction with the accompanying drawings in which:

Fig. 1 is a schematical perspective view of an exemplary one piece dispensing component according to an embodiment of the present invention;

Fig. 2 is a top plan view of the exemplary one piece dispensing component according to Fig. 1;

Fig. 3 is a cross sectional view taken along 1-1 of the exemplary one piece dispensing component according to Fig. 2;

Fig. 4 is a side elevational view of the exemplary one piece dispensing component according to Fig. 1 ;

Fig. 5 is a perspective view of an exemplary one piece dispensing component according to another embodiment of the present invention;

Fig. 6 is a top plan view of the exemplary one piece dispensing component according to Fig. 5;

Fig. 7 is a side elevational view of the exemplary one piece dispensing component according to Fig. 5;

Fig. 8 is a bottom plan view of the exemplary one piece dispensing component according to Fig. 5;

Fig. 9 is a perspective view of an exemplary one piece dispensing component according to another embodiment of the present invention;

Fig. 10 is a top plan view of the exemplary one piece dispensing component according to Fig. 9;

Fig. 11 is a side elevational view of the exemplary one piece dispensing component according to Fig. 9;

Fig. 12 is a back side elevational view of the exemplary one piece dispensing component according to Fig. 9;

Fig. 13 is a perspective view of an exemplary one piece dispensing component according to another embodiment of the present invention;

Fig. 14 is a top plan view of the exemplary one piece dispensing component according to Fig. 13;

Fig. 15 is a side elevational view of the exemplary one piece dispensing component according to Fig. 13; and

Fig. 16 is a bottom plan view of the exemplary one piece dispensing component according to Fig. 13.

The embodiments set forth in the drawings are illustrative in nature and not intended to be limiting of the invention defined by the claims. Moreover, individual features of the drawings and the invention will be more fully apparent and understood in view of the detailed description.

DETAILED DESCRIPTION OF THE INVENTION

The following text sets forth a broad description of numerous different embodiments of the present invention. The description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible, and it will be understood that any feature, characteristic, component, composition, ingredient, product, step or methodology described herein can be deleted, combined with or substituted for, in whole or part, any other feature, characteristic, component, composition, ingredient, product, step or methodology described herein. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. While the specification concludes with claims that particularly point out and distinctly claim the invention, it is believed the present invention will be better understood from the following description.

Referring to Figs. 1 - 4, an exemplary embodiment of a product dispensing package 10 and a one piece dispensing component 30 of the present invention is shown. Product dispensing package 10 generally includes a container 20 for holding a product 50 and one piece dispensing component 30 connected to container 20. Container 20 may include, as shown in the exemplary

embodiment, a side wall 22 encompassing a product reservoir 24, an open end 26, and a closed end 28 to form a tube-shaped, open-ended container.

In the exemplary embodiment, side wall 22 is fabricated from a flexible substrate, thus making container 20 flexible. The substrate of side wall 22 may include a metalized substrate such as a foil layer to provide oxygen and vapor barrier characteristics. 'Metalized substrate', as used herein, is defined as a substrate comprising at least a thin metal layer such as, for example, a foil layer. Exemplary metals that may be used in the metal layer may include, but not be limited to, aluminum, lead, tin and any combinations thereof. The 'metalized substrate' and/or side wall 22 may further comprise additional materials to be combined with the metal layer such as polypropylene (PP), polyethylene (PE), nylon, Ethylene Vinyl Alcohol (EVOH), Ethylene vinyl acetate (EVA), Ethylene Acrylic Acid (EAA), Ethylene Methyl acrylate (EMA), thermoplastic elastomer (e.g., SEBS, EP rubber, etc.), Thermoplastic Polyurethane (TPU), polyvinylchloride (PVC), polyvinyl dichloride (PVDC), Styrene-Butadiene Copolymer, polyester (e.g., Polyethylene Terephthalate (PET), PolyButylene Terephthalate (PBT), etc.), copolymers of the same, combinations thereof, or any other container materials as known to one of ordinary skill in the art.

Container 20 may be fabricated using a variety of molding processes as known to one of ordinary skill in the art. In one exemplary embodiment, container 20 is fabricated using a non- injection molding process. As used herein, a 'non-injection molded' or 'non-injection molding' is defined as any molding process to fabricate components, but a strict injection molding process. For example, injection blow molding, compression molding, and blow molding processes are all, for the purposes of this invention, considered non-injection molding processes, as defined herein. To form closed end 28 of container 20, an end 27 of sidewall 22 may be overlapped upon itself and then heat-sealed or glued to oneself as known to one of ordinary skill in the art. It is understood that other methods as known to one of ordinary skill in the art to close and/or seam

closed end 28 may be used with the present invention. However, it is understood that container 20 may comprise any type of conventional container shape and configuration, including but not limited to a stand-up tube, stand-up container, pump container, squeeze container, and any other container known to one of ordinary skill in the art.

One piece dispensing component 30 includes a body generally shown as 32 and a flip cap 38. As shown in Figs. 1-4, body 32 may include a shoulder generally shown as 34, a nozzle 36 connected to shoulder 34, an orifice 37 disposed at a distal end 41 of nozzle 36, and a hinge 39 connecting flip cap 38 to nozzle 36. Shoulder 34 may further comprise a side wall 31, a top wall 33, and an angled wall 35 connecting side wall 31 and top wall 33. It is understood that shoulder 34 may comprise a variety of shapes and configurations as known to one of ordinary skill in the art, including but not limited to a smooth or continuous curvature defining shoulder 34.

As used herein, 'one piece component' is defined as a single, molded unit, wherein none of the components are separable, particularly under normal use conditions. As such, one piece dispensing component 30, which includes flip cap 38 and body 32, i.e., flip cap 38, nozzle 36, orifice 37, hinge 39, top wall 33, angled wall 35, and side wall 31, are all molded as one single, integral component that is non-separable under normal use conditions. It has been discovered that the one piece flip cap and body of the present invention saves manufacturing time, money, and material over prior art flip cap closures that had to be threadingly connected to a nozzle of a container.

One piece dispensing component 30 may be fabricated from a variety of plastic and/or polymeric materials. Exemplary materials that may be used to fabricate dispensing component 30 include, but are not limited to, polypropylene, polyethylene, nylon, EVOH, EVA, EAA, EMA, thermoplastic elastomer (e.g., SEBS, EP rubber, etc.), TPU, PVDC, PVC, Styrene- Butadiene Copolymer, polyester (e.g., PET, PBT, etc.), or any other conventional materials known to one of ordinary skill in the art. In one exemplary embodiment, dispensing component

30 is molded from a single polymer or blended polymers. Alternatively, multiple materials and/or polymers may be used in the fabrication of the one piece dispensing component 30.

One piece dispensing component 30 may be fabricated using an injection molding or a compression molding process. The process of injection molding requires filling a part cavity with molten plastic using pressure generated via the injection molding machine. Once filled, the cavity remains closed so the molten plastic can begin cooling and solidifying. After cooling for a period of time, usually a few seconds, the mold is opened and the cooled part, i.e., dispensing component 30, is ejected from the mold. With compression molding, a 'slug' of plastic of a predetermined gram weight is placed in the mold cavity. Two halves of a mold are brought together and squeeze the slug of plastic, forcing it to flow through the cavity and creating the finished dispensing component 30. Once finished, dispensing component 30 is either ejected or manually removed from the compression tool. The present invention permits the manufacture of a flip cap closure for a product dispenser to only require one mold, to use less material, and to require less than time compared to conventional flip cap dispensers.

As shown in Fig.3, flip cap 38 of the exemplary embodiment has a diameter (a) that is substantially the same as a diameter (b) of nozzle 36. In other words, flip cap 38 is substantially the same size as nozzle 36. As also shown, diameter (a) of flip cap 38 is less than a diameter (c) of shoulder 34. Additionally, in the exemplary embodiment, diameter (a) of flip cap 38 may substantially less than diameter (c) of shoulder 34, yet diameter (a) is of sufficient size that flip cap 38 may still cover and/or close orifice 37.

Distal end 41 of nozzle 36 and an inside surface 44 of flip cap 38 may include respective snap on mechanisms, snap fit geometry (e.g., annular ring snap geometry), interference fit mechanisms, interfering geometry, notches, and/or protrusions as known to one of ordinary skill in the art that permit flip cap 38 to be releasably attached onto distal end 41 in order to cover and/or close orifice 37. In the exemplary embodiment shown in Figs. 1-4, an annular ring snap

bead 40 extends radially outward from distal end 41. Flip cap 38 has an interference channel 42 disposed on inside surface 44 of the flip cap. When the flip cap is moved to close orifice 37, it is flipped over and on top of distal end 41 such that bead 40 engages interference channel 42 in an interference fit relationship, i.e., bead 39 is 'snapped' into channel 42. It is understood that other conventional connection devices may be used to releasably connect or attach flip cap over orifice 37 and nozzle 36 as known to one of ordinary skill in the art.

Hinge 39 may comprise a flexible hinge, wherein the hinge is fabricated from a thin flexible piece of plastic material that is integral to and connected to both flip cap 38 and nozzle 36 as known to one of ordinary skill in the art. As set forth above, hinge 39 may be fabricated from the same material as used in the entire one piece dispensing component 30. Alternatively, hinge 39 may be fabricated from a one material such as, for example, polypropylene that is different from a second material such as, for example, polyethylene that may be used to fabricate the remainder of dispensing component 30, using either a two shot injection molding process or an over molding process. In an alternative embodiment, hinge 39 may comprise other conventional hinge strap designs such as, for example, hinge straps that are bi-stable in function or a single strap "butterfly" hinge design as known to one of ordinary skill in the art and described below herein.

One piece dispensing component 30 is permanently connected to container 20 at open end 26. As used herein, 'permanently connected' is defined as a connection between two components that is not designed to be separated or disconnected under normal use conditions. For example, a threaded connection between two components would not be a permanent connection as defined and used herein. To permanently connect dispensing component 30 to container 20, side wall 22 may be sonic welded, glued, adhered, press sealed, Over molding, Insert molding, and Bi- product injection molding to side wall 31. When dispensing component 30 is connected to

container 20, orifice 37 is placed in fluid communication with reservoir 24 of container 20 such that product 50 may be dispensed from the reservoir through orifice 37.

Referring to Figs. 5-8, another exemplary embodiment of a one piece dispensing component 130 of the present invention is shown. Although not shown, it is understood that one piece dispensing component 130 may be connected to a variety of containers as known to one of ordinary skill in the art, including but not limited to any of the exemplary containers set forth herein. For example, dispenser component 130 may be connected to open end 26 of container 20 as described above and shown in Figs. 1-4 such that product 50 may be dispensed from reservoir 24 and through and out of dispensing component 130.

One piece dispensing component 130 includes a body generally shown as 132 and a flip cap 138. As shown in Figs. 5-8, body 132 may include a shoulder generally shown as 134, a nozzle 136 connected to shoulder 134, an orifice 137 disposed at a distal end 141 of nozzle 136, and a hinge 145 connecting flip cap 138 to nozzle 136. Shoulder 134 may further comprise a lower side wall 131 disposed at an end of component 130 opposite nozzle 136, a top wall 133, and a curved wall connecting side wall 131 to top wall 133. Body 132 had a longitudinal axis A'- A, and as shown, both shoulder 134 and nozzle 136 are coaxially aligned about axis A'-A. One piece dispensing component 130 may also be fabricated using a variety of materials (e.g., polymeric materials), singularly or in combination, as known to one of ordinary skill in the art and as set forth above herein with reference to one piece dispensing component 30. The present invention also permits one mold to be used to form the dispensing component 130. It is understood that shoulder 134 may comprise a variety of shapes and configurations as known to one of ordinary skill in the art, including but not limited to angular, discontinuous, and other geometric forms.

As shown in Fig. 6, flip cap 138 of the exemplary embodiment has a diameter (a) that is substantially the same as a diameter (b) of nozzle 136. In other words, flip cap 138 is

substantially the same size as nozzle 136. As also shown, diameter (a) of flip cap 138 is less than a diameter (c) of shoulder 134. Additionally, in the exemplary embodiment, diameter (a) of flip cap 138 may substantially less than diameter (c) of shoulder 134, yet diameter (a) is of sufficient size that flip cap 138 may still cover and/or close orifice 137.

Distal end 141 of nozzle 136 includes an annular ring snap bead 140 that extends radially outward from distal end 141. Hip cap 138 has an interference channel 142 disposed on inside surface 144 of the flip cap. When the flip cap is moved to close orifice 137, it is flipped over and on top of distal end 141 such that bead 140 engages interference channel 142 in an interference fit, i.e., bead 140 is 'snapped' into channel 142. The flip cap and the nozzle may include variety of conventional mechanisms as known to one of ordinary skill in the art to permit flip cap 138 to releasably attach to and close nozzle 136 and orifice 137 including those set forth above with reference to the exemplary embodiment shown in Figs. 1-4.

Hinge 145 may include a hinge strap design, which comprises two outer hinge straps 146 and a center hinge 148 that hingedly connect flip cap 138 to nozzle 136 as known to one of ordinary skill in the art. Hinge 145 includes a bi-stable function. By design, the hinge straps that are bi-stable in function tend to snap flip cap 138 to either an open or closed position. When snapped to the open position, hinge straps 146 of this embodiment keep flip cap 138 out of the line of site and out of the way of any product being dispensed from the nozzle. When snapped to the closed position, hinge straps 146 make closing the flip cap easier because the hinge straps snap flip cap 138 into a position directly over nozzle 136 and/or orifice 137. In such a hinge strap design, outer straps 146 function as the pivot point and center hinge 148 creates and provides the bi-stable characteristic.

The bi-stable characteristic is achieved by controlling the length of center strap(s) 148 relative to hinge pivot point. The center strap(s), being slightly shorter than overall hinge length, passes through a point of tension during opening and closing of flip cap 138. As used herein, the

overall hinge length is the linear distance between the hinge's attachment to the Cap and the hinge's attachment to the Nozzle. The hinge pivot point, as used herein, is a point equal distance from the center of flip cap 138 to center of nozzle 136. When center strap(s) 148 passes through the point of tension, it creates a 'snap to position', or bi-stable effect, at each end of the opening and closing motion of flip cap 138. Such a hinge strap design is known to one of ordinary skill in the art. As set forth above, hinge 145 may be fabricated from either the same material as the remainder of dispensing component 130 or a second material different from the material used to fabricate the remainder of component 130, using a two shot injection molding process or an over molding process as known to one of ordinary skill in the art. While this alternative embodiment includes 3 straps, the same function can be achieved using either two straps without a center hinge (e.g., without center hinge 148) or a hinge with a conventional single strap "butterfly" hinge design as also known to one of ordinary skill in the art.

Referring to Figs. 9-12, another exemplary embodiment of a one piece dispensing component 230 of the present invention is shown. Although not shown, it is understood that one piece dispensing component 230 may be connected to a variety of containers as known to one of ordinary skill in the art, including but not limited to any of the exemplary containers set forth herein. For example, dispenser component 230 may be connected to open end 26 of container 20 as described above and shown in Figs. 1-4 such that product 50 may be dispensed from reservoir 24 and through and out of dispensing component 230.

One piece dispensing component 230 includes a body generally shown as 232 and a flip cap 238. As shown in Figs. 9-12, body 232 may include a shoulder generally shown as 234, a nozzle 236 connected to shoulder 234, an orifice 237 disposed at a distal end 241 of nozzle 236, and a hinge 245 connecting flip cap 238 to nozzle 236. Shoulder 234 may further comprise a lower side wall 231 disposed at an end of component 230 opposite nozzle 236, and a curved top wall 233 and a substantially vertical wall 229 connecting the side wall 231 to the nozzle. Curved

top wall 233 comprises a smooth and/or continuous curve-shape. Body 232 has a longitudinal axis B'-B and nozzle 236 has a longitudinal axis A'-A separate from longitudinal axis B'-B that is offset a distance (X) from the body's longitudinal axis B'-B. Offset distance (X) may be greater than about 0.5 mm. In one exemplary embodiment, offset distance (X) is from about 7 mm to about 15 mm. Due to nozzle longitudinal axis A'-A being offset a distance (X) from body longitudinal axis B'-B, shoulder 234, and particularly top wall 233 has an asymmetrical shape about longitudinal axis B'-B as shown in Figs. 9-12. It is understood that shoulder 234 may comprise a variety of shapes and configurations as known to one of ordinary skill in the art, including but not limited to angular, discontinuous, and other geometric forms.

One piece dispensing component 230 may also be fabricated using a variety of materials (e.g., polymeric materials), singularly or in combination, as known to one of ordinary skill in the art and as set forth above herein with reference to one piece dispensing component 30. The present invention also permits one mold to be used to form the dispensing component 230. This offset nozzle design of the present invention permits the mold to be pulled straight apart when removing the mold from the dispensing component 230, which simplifies and eases the removal of the component from the mold. In comparison, a coaxially nozzle dispensing component design such as shown in Figs. 1-4, the mold must be slid to the side when opening the mold and then pulled up and away from the dispensing component 30, making the removal of the component from the mold much more difficult and cumbersome. As can be seen, the offset nozzle configuration of this exemplary embodiment provides a design that simplifies and improves the efficiency of the removal of the component from the mold.

As shown in Fig.10, flip cap 238 of the exemplary embodiment has a diameter (a) that is substantially the same as a diameter (b) of nozzle 136. In other words, flip cap 238 is substantially the same size as nozzle 236. As also shown, diameter (a) of flip cap 238 is less than a diameter (c) of shoulder 234. Additionally, in the exemplary embodiment, diameter (a) of flip

cap 238 may substantially less than diameter (c) of shoulder 234, yet diameter (a) is of sufficient size that flip cap 238 may still cover and/or close orifice 237.

Distal end 241 of nozzle 236 includes an annular ring snap bead 240 that extends radially outward from distal end 241. Hip cap 238 has an interference channel 242 disposed on inside surface 244 of the flip cap. When the flip cap is moved to close orifice 237, it is flipped over and on top of distal end 241 such that bead 240 engages interference channel 242 in an interference fit, i.e., bead 240 is 'snapped' into channel 242. The flip cap and the nozzle may include variety of conventional mechanisms as known to one of ordinary skill in the art to permit flip cap 238 to releasably attach to and close nozzle 236 and orifice 237 including those set forth above with reference to the exemplary embodiment shown in Figs. 1-8.

Hinge 245 may include a hinge strap design, which comprises two outer hinge straps 146 and a center hinge 248 that hingedly connect flip cap 238 to nozzle 236 as known to one of ordinary skill in the art. In the exemplary embodiment shown in Figs. 9-12, flip cap 238 and hinge 245 are disposed and connected to nozzle 236 on the same side as curved top wall 233, which is opposite substantially vertical wall 229. In an alternative embodiment shown in Figs. 13-16, dispensing component 230 includes flip cap 238 and hinge 245 disposed and connected to nozzle 236 on the same side as substantially vertical wall 229, opposite curved top wall 233. Other than this difference in positioning of flip cap 238 and hinge 245, the dispensing component in the alternative embodiment of Figs. 13-16 is the same as the exemplary embodiment in Figs. 9-12.

Referring back to Figs. 9-12, hinge 245 includes a bi-stable function as set forth above herein. In such a hinge strap design, hinge 245 includes two outer straps 246 that function as the pivot point and a center hinge 248 creating the bi-stable characteristic as described above herein. It is understood that hinge 245 may comprise other conventional hinge designs such as, for example, a single strap hinge, a single strap "butterfly" hinge, or two hinge straps without a

center hinge as known to one of ordinary skill in the art. Hinge 245 may be fabricated from either the same material as the remainder of dispensing component 230 or a second material different from the material used to fabricate the remainder of component 230, using a two shot injection molding process or an over molding process as known to one of ordinary skill in the art.

All documents cited in the Detailed Description of the Invention are, in relevant part, incorporated herein by reference; the citation of any document is not to be construed as an admission that it is prior art with respect to the present invention.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.