AN INSERT

The present invention relates to an insert for defining the shape and size of an orifice in a dispensing closure. The insert may be fitted into, and retained within, a dispensing closure.

A dispensing closure is one which is typically held in place on, and associated with, the mouth of a container. It has an orifice which is associated with the orifice in the container such that the contents of the container may only be dispensed via the orifice in the closure. Such dispensing closures typically also comprise a lid which may be hinged to the dispensing closure and which may be formed integrally therewith. The purpose of the lid is to seal the orifice in the closure so that, in the closed position, no product may be dispensed whether deliberately or accidentally.

To control the dispensing of product, contained within the container, the orifice in the closure is specifically designed in shape and size for the relevant product. This design not only takes into account the properties of the product but also the volume flow rate at which such products are typically dispensed. For instance, it is typical to want to dispense ketchup at a greater volume flow rate than vinegar. Accordingly, closures for dispensing ketchup require larger orifices than closures for dispensing vinegar. Furthermore, some products are more viscous than others and accordingly the orifice in the closure has to be specifically chosen for the product. For instance, it would be difficult to dispense ketchup through a relatively small orifice and yet a large orifice would not be suitable for products which require more controlled dispensing such as a

hot chilli sauce. Consequently, due to the great variety of products, many different dispensing closures have to be produced each with an orifice having a shape and size different from the next.

Typically, dispensing closures are manufactured from injection moulded plastics and accordingly, when it is necessary to change from making a closure with one type of orifice to a closure with a different type of orifice the tooling has to be changed also. This leads to lost production time and hence increased costs.

A dispensing closure is known which has a self-closing valve. The valve sits inside the closure and restricts the orifice therein. These valves may be flexible, substantially convex in shape, silicon members comprising one or more slits. When the container is squeezed the product is forced through the slits of the valve which open in response to the increase in pressure within the container. However, such valves do not perform well with certain types of products such that the valves either leak or do not open. Such problems with particular products may be caused by their viscosity or required flow rate, or alternatively, the problems could be due to a chemical reaction between the product and the silicon valve.

Accordingly, it is desirable to have a dispensing closure which can be produced with an orifice with a standard shape and size but which also can be adapted to meet the requirements of the particular customer and/or product.

According to a first aspect of the present invention there is provided an insert for a dispensing closure of the type having a housing with engagement means adapted to receive a valved dispensing body, the insert comprising a single-piece, valveless, orifice-defining body having standardised insert engagement means adapted to engage the housing engagement means and thereby to be received directly into the closure housing in use.

In a further aspect the invention provides an insert for defining the shape and size of an orifice in a dispensing closure comprising an outer body having insert engagement means for retaining the insert in the closure and an inner orifice having an appropriate size and shape.

The insert may be retained within the dispensing closure so that it restricts, or reduces, the orifice therein. Accordingly, it is possible to have a variety of inserts for various applications such that the dispensing closure is produced with an orifice having a standard shape and size but which may be subsequently adapted for any particular product merely by introducing the insert therein.

The insert may be produced with a standard outer size so that it fits the standard dispensing closure.

Ih one embodiment, the insert engaging means may include a bead projecting radially outward from an exterior wall for snap-fitting the insert into the dispensing closure.

The bead for snap-fitting may be arranged so that it seals against the dispensing closure so that the product only passes through the orifice of the insert and not around the sides.

Alternatively and/or additionally, the insert could be glued, welded and/or retained in the closure by other means.

The insert may include an inner sealing bead projecting axially outward from an exterior wall for providing a seal between the insert and closure in use.

Alternatively and/or additionally, the insert may include means to locate the insert in a closure in use, wherein the means project axially outward from an exterior wall of the insert. The locating means may provide a seal against the closure, in use.

The orifice of the insert may have a regular geometric shape or an irregular geometric shape. In one embodiment the size of the orifice may be substantially smaller than the size of the orifice in the associated dispensing closure. The term "size" refers to the area as measured across the plane of the orifice. The ratio of sizes of the insert orifice to the dispensing orifice may vary between 1% and 100%. However, the ratio may preferably lie in the range 5% to 50%, or may even lie in the range 5% to 25%.

In another aspect, the invention provides a combination of a dispensing closure and an insert comprising one or more of the features described above.

The insert may be produced from plastics, which in one embodiment are injection moulded. However, other methods of manufacture are contemplated. Accordingly, if a specific orifice shape and size is required, only minimal changes need to be made to the tooling for the moulds. Further, since the dispensing closure may be standardised and yet adapted to a specific customer's or product's requirements, costs are kept to a minimum.

According to a further aspect there is provided a cap assembly for a container, comprising: a unitary dispensing closure for engagement with a mouth of the container, the unitary dispensing closure defining a cavity shaped to receive any one of a plurality of inserts; and each of the plurality of inserts having identically shaped engagement means for cooperating with the cavity to retain the insert therein and each of the plurality of inserts defining a differing shaped orifice, the one of the any one of a plurality of inserts being selected dependent on the properties of a material to be dispensed from the container through the orifice.

According to a further aspect there is provided a method of assembling a cap for a container, comprising the steps of: providing a unitary dispensing closure for engagement with a mouth of the container, the unitary dispensing closure defining a cavity shaped to receive any one of a plurality of inserts; providing a plurality of inserts, each of the plurality of inserts having identically shaped engagement means for cooperating with the cavity to retain the insert therein and each of the plurality of inserts defining a differing shaped orifice; and selecting one of a plurality of inserts

dependent on the properties of a material to be dispensed from the container through the orifice.

Furthermore, the dispensing closures manufactured for use with the present invention may also be used with silicon valves without any changes since the means for retaining the silicon valves in place in the closures could be the same as the means for retaining the inserts. Accordingly, standardisation of the dispensing closure is attained. This minimises costs.

The insert could also be described as a dispensing closure orifice reduction insert.

The present invention and its advantages will be better understood by referring, by way of example, to the following detailed description and the attached figures, in which:

Figure 1 is a section of a known self-closing valve sub-assembly;

Figure 2 is a section of an insert formed according to an embodiment of the present invention;

Figure 3 is a side view of the insert of Figure 2;

Figure 4 is a section of a dispensing closure fitted with an insert formed in accordance with the present invention;

Figure 5 is a magnified view of the region A of Figure 4; Figure 6 is a magnified view of the point of connection between the insert and the dispensing closure shown in Figures 4 and 5; and

Figure 7 is a plan view of a selection of inserts having various orifice sizes and shapes.

In the following description, all orientational terms, such as upper, lower, radially and axially are used in relation to the cross-sectional drawings shown in Figures 1 and 2 and should not be interpreted so as to limit the invention.

Referring to Figure 1 a self-closing valve sub-assembly is generally indicated 1. The sub-assembly 1 is described in detail in WO2006/021509.

A retaining ring 2 consists of a moulded single-piece article with a so called "chimney" in the form of a circular wall 3. The chimney 3 provides a surface for assembly machinery to handle the retaining ring 2. At one end of the chimney 3 is a radially outwardly sloping surface 4. At the outer radial end of this sloping surface 4 another circular wall 5, which has the same rotational axis as chimney 3, extends upwards.

Along the circumference of the radially outer surface of wall 5 is a projection in the form of an external sealing bead 6.

At the end of wall 5 is a crimping flange 7 which in its uncrimped condition (not shown) is a relatively short upstanding wall.

A flexible self-closing valve 8 typically has the features shown in Figure 1. For instance, such a valve 8 has a head portion 8 a which is thicker towards the edge than the centre and which has at least one slit 8b therein. The head portion 8a is concave with respect to a container (not shown). This pre-stresses the valve so that it self-closes more easily.

A side-wall portion 8c connects the head portion 8a with a flange 8d. Flange 8d is typically shaped such that it has a relatively substantial size in the form of a rim. It is this flange 8d which rests on the sloping surface 4 of the retaining ring 2 when it is located correctly.

To crimp the valve 8 in place, the crimping flange 7 is bent over until is sandwiches the flange 8d between itself and the sloping surface 4 as shown in the Figure.

The crimping flange 7 is bent over along the entire circumference of the retaining ring 1 and valve 2.

The sub-assembly 1 allows the valve 8 to be presented in a form which can be easily manipulated and fitted into a dispensing closure. The bead 6 allows the ring 2 to be snap-fitted into a closure with a corresponding bead to hold the ring 2, and consequently the valve, firmly in place.

Referring to Figure 2, an insert 110, consists of a moulded single-piece article with a cylindrical portion 112 in the form of a circular wall. This portion 112 provides a surface for assembly machinery to handle the insert 110. At one end of the portion 112 an outer body 114 is provided. This outer body has an outer radial surface upon which a sealing bead 116 is provided. This sealing bead 116 projects radially outwardly in the form of an annular bulge. At the upper end of the outer body 114 a stop 118 and an inner sealing bead 124 are provided. The functions of these two features will be described below. An orifice wall 120 is provided radially inwardly from the outer

body 114. This orifice wall has an orifice 122 provided therein through which the product may be dispensed. The orifice 122 is defined by the edge 121 which borders the hole in the orifice wall 120.

Figure 3 shows a side view of the insert 110 wherein the cylindrical portion 112, sealing bead 116 and outer end 118 are shown.

The form of the insert 110 is very similar to the ring 2 shown in Figure 1. In particular the periphery of the insert 110 is designed to be standardised with existing retaining rings. This means that valved and valveless inserts can be used interchangeably on the same dispensing closures. Moreover, as will be described in more detail below, by standardising at least the engaging parts of the insert it becomes very simple to interchange different orifices into the same basic dispensing closure.

Figure 4 to 6 shows a cross-sectional side view of the insert 110 in place in a dispensing closure 130. The lid 140 of the closure is also shown.

A snap-fit seal is achieved between the sealing bead 116 and a corresponding projection 131 on the surface of the inner radial wall 132 of the dispensing closure 130. Further, it is seen that the surface of the inner radial wall 132 of the closure is formed so as to help retain the insert 110 in place. This is achieved by the inner radial wall 132 having a reduced diameter at the lower end such that the insert 110 has to be forced past this reduced diameter before reaching the section of the closure which has a slightly greater diameter. The diameter of the section of the closure 130, which is

slightly reduced in diameter, is less than the maximum diameter of the insert (as measured in the plane of the annular sealing bead 116).

The stop 118 helps locate the insert 110 in relation to the closure 130 such that when the insert 110 is pushed into the closure 130 it limits how far the insert may be moved relative to the closure. This limitation is caused by the upper end of the stop 118 abutting the underside 134 of the closure 130. A seal between the upper end of the stop 118 and the underside 134 of the closure 130 may also be achieved. The inner sealing bead 124 provides a seal between the insert 110 and the underside of the upper radial wall of the closure 130. This seal is in addition to the one provided by the interaction, or interference, of the sealing bead 116 and inner radial wall 132 of the closure 130. This additional seal helps prevent product contained in the container (not shown) from leaking around the outside of the insert 110.

The lid 140 has two depending annular projections 142, 144. These projections also aid in sealing the combination of insert, closure and lid to prevent accidental and unwanted leakage of product from the associated container. The outer annular projection 142 presses against an inner radial surface, which defines the orifice of the closure 130. An interference fit between these two surfaces is thus achieved. The lower end of this projection 142 also presses against the top of the inner sealing bead 124, so that at this location, the insert, the closure and the lid all meet to provide a seal.

The inner projection 144 presses against the upper surface of the insert 110 radially outside of the insert's orifice 122. This interaction provides a seal between the lid 140

and the insert 110 so that product contained in the associated container (not shown) cannot leak out when the lid 140 is in the closed position.

Figure 7a to 7o shows a plan view of various inserts 210a to o each having a differently shaped and sized orifice. The orifices are provided in the orifice wall. As may be seen, it is possible to have a variety of shapes, some of which may be geometrically regular and some of which may be geometrically irregular. Such shapes could take the form of a regular circle, square, triangle etc. Alternatively, the shapes could take the form of numbers or letters of the alphabet.