BACKGROUND OF THE INVENTION This invention relates to safety closures for containers. More particularly, the present invention relates to a safety closure over a container opening having a dispenser with a peelable seal.

The use of safety closures on containers to prevent vulnerable individuals, particularly children, from gaining access to potentially harmful contents within a container is known in the art. For example, a safety closure may have a pair of opposable locking lugs projecting inward from a flexible annular skirt. A container for the closure is also provided with a container neck portion having on an exterior surface a pair of opposable outwardly projecting lugs. When the safety closure is threadably engaged to the container, the locking lugs and outwardly projecting lugs interfere with each other preventing removal of the closure from the container. The closure is only removable when the user applies pressure to the annular skirt deforming it sufficiently to remove the interference between the locking lugs and the outwardly projecting lugs.

In another safety closure device, the closure has an outer cap and an inner cap. The inner cap is threadably engaged to a container neck. The inner cap is not removable from the container cap until a downward pressure is applied to the outer cap while simultaneously

turning the outer cap. The downward pressure engages ratchets within the inner and outer cap to each other and permits turning of the inner cap along with the outer cap. The simultaneous downward pressure and turning motion requires a minimal amount of strength and dexterity that a child will not possess.

Although s afety c losures for c ommon c ontainers are g enerally known in the art, other containers dispensing some common household products have not been constructed with safety closures. In particular, containers dispensing low viscosity hydrocarbons such as baby oil, sunscreens, bath oils, makeup removers and some cleaning solvents are often packaged with closures that have flip-open tops and dispensing spouts. Due to the low viscosity of the product, it is also necessary to use a seal with the closure. However, a deficiency in this packaging is that if the consumer does not keep the container upright at all times, the low viscosity fluid will eventually leak past the threads of the closure.

Some common low viscosity hydrocarbons are dangerous if taken internally.

Aspiration of hydrocarbon products, such as baby oil, can cause serious injury including fatal pneumonia. Other hydrocarbon products are poisonous if ingested. Since closures for containers dispensing these products do not usually have safety features, these packaging materials may pose a danger to children and others unaware of the risk.

A traditional safety closure as described above is not designed to be used with closures having pour spouts. Therefore, it is desirable to have a new type of closure that will seal a container tightly during shipping and even after initial use of the product by the consumer regardless of the position of the container during storage. The new closure must also have a dispensing spout and safety features that prevent access to the contents of the container by children and others incapable of understanding the risks inherent in the product. Further, it is desirable to have such a product that is simple and inexpensive to

manufacture by using existing closure technology.

SUMMARY OF THE INVENTION It is accordingly a primary object of the present invention to provide a container with a safety closure and a dispenser for dispensing the product contained therein.

It is a further object of the present invention to provide a container with a dispenser that can be used with existing safety closures and containers.

It is an even further object of the present invention to provide a container with a pour spout dispenser that is part of a barrier film welded across the opening of the container and sealing the opening preventing leakage of the container contents during shipping and before purchase.

A container with a safety closure and dispenser according to the present invention includes a safety closure for preventing access by children and other at risk groups as is known in the art, a container with a neck and an opening, and a dispenser affixed to the container neck and sealing the opening. The dispenser is a barrier film with an aperture therein that acts as a pour spout for dispensing the container contents. The barrier film may be of multilayer construction. The aperture has a peelable seal to prevent leakage of the container contents before purchase and use by the consumer.

The design of the present invention provides the previously unrealized advantage of providing a container having a safety closure with the added feature of a dispenser for dispensing regulatable quantities of the container contents. The container and safety closure utilized for the present invention are previously known in the art and so provide a cost effective means of producing a new and safer container for dispensing potentially hazardous products such as low viscosity hydrocarbons in a manner accustomed to by consumers, namely by way of a pour spout.

All of the above outlined objectives are to be understood as exemplary only and many more objectives of the invention may be gleaned from the disclosure herein.

Therefore, no limiting interpretation of the objectives noted is to be understood without further reading of the entire specification, claims, and drawings included herewith.

Various other feature of the present invention will become obvious to one skilled in the art upon reading the disclosure set forth herein.

BRIEF DESCRIPTION OF THE DRAWINGS A better understanding of the invention will be had upon reference to the following description in conjunction with the accompanying drawings in which like numerals refer to like parts throughout the several views and wherein: FIG. 1 is a perspective view of a container illustrating an embodiment of the dispenser of the present invention illustrating a seal with a pull tab covering an aperture of the dispenser; FIG. 2 is a perspective view of a container and attached safety closure embodiment of a style requiring simultaneous downward pressure and rotational force in order to remove the closure as illustrated; FIG. 3 is a perspective view of a container and attached safety closure embodiment of a style requiring simultaneous inward pressure on a flexible annular skirt and rotational force in order to remove the closure; FIG. 4 is a perspective view illustrating the container and dispenser shown in FIG.

1 with the seal over the aperture removed ; FIG. 5 is a perspective view illustrating the container and attached safety closure shown in FIG. 2 with a portion of the outer closure cut away to reveal the inner closure;

FIG. 6 is a perspective view illustrating the container and attached safety closure shown in FIG. 3 with a portion of the closure cut away to reveal the neck of the container and locking tab of the closure; FIG. 7 is a perspective view illustrating the container and dispenser shown in FIG.

1 with an alternative embodiment of the seal; FIG. 8 is a perspective view illustrating the container and dispenser shown in FIG.

4 with an alternative embodiment of the seal; FIG 9 is a side sectional view of the barrier film used in the present invention; FIG 10 and 10a are side sectional views of the aperture seals used in the present invention.

DETAILED DESCRIPTION OF THE PREFFERED EMBODIMENT The present invention provides a means for safely containing and dispensing potentially hazardous substances such as low viscosity hydrocarbons.

The container 12 with safety closure 30,40 and dispenser 20 according to one embodiment is shown in FIGS. 1,2 and 3. The container 12 has a neck 14 with an opening therein. The opening is sealed with a dispenser 20 to prevent leakage of the contents from the container 12 and easy dispensing of the product by the consumer. The dispenser 20 is covered by a safety closure 30,40 and threadably affixed to the neck 14 of the container. The safety closure 30,40 has"child resistant"features that discourage access to the contents of the container by children and others unable to recognize the danger.

As shown in FIG. 1, container 12 may generally have an elongated cylindrical shape, but is not limited to such and may be of any shape that best contains the product or has the greatest aesthetic appeal. The container 12 has a shoulder 13 narrowing to a neck

14 that is of sufficient length to accommodate an external thread for threadably affixing a closure 30,40 to the container 12. At the top of the neck 14 is an opening permitting access to the contents of the container 12. At the base of the neck 14, adjacent the shoulder 13 is at least one lug 16 and possibly two, placed on opposing sides of neck 14.

Lug 16 acts as a barrier to removal of closure 30 and 40 and is an integral component of the safety closure system. The container is of unitary construction and may be made of any of numerous materials commonly known in the art depending on specific product and environmental conditions. Some common examples of materials include but are not limited to polyethylene, polypropylene and polyethylene terephthalate.

FIGS. 1 and 4 detail one embodiment of the dispenser 20. The dispenser 20 is designed so that it can be retrofitted onto a standard container 12 and a variety of common closures 30,40. In this manner, the requirement for a dispensing means for certain compounds such as low viscosity hydrocarbons can be accommodated with dispenser 20 in combination with numerous commonly available containers and safety closures. This provides an economical packaging and dispensing system with safety features.

The dispenser 20 includes barrier film 21 and aperture 25, and may also include overlap tab 22. Barrier film 21 is sealed to the lip of the container 12 opening so that even low viscosity fluids can not leak from the container 12 even if the container is not stored in an upright position. Barrier film 21 may be sealed to the container 21 lip by a variety of means known in the art including but not limited to conduction and induction welding.

Barrier film 21 may be a laminate. An exemplary description of a laminate embodiment of barrier film 21 is shown in FIG. 9. A first layer 61 is in direct contact and permanently bonded with the rim of container neck 14. The first layer 61 may be composed of the same material as the container is made, for example, polyethylene,

polypropylene and polyethylene terephthalate. Alternatively, the first layer 61 may be a bonding material such as ethylene vinyl acetate. In a preferred embodiment the thickness of the first layer 61 is between. 001 and. 002 inches. In another embodiment, barrier film 21 is peelable from the rim of neck 14. In this embodiment, the first layer 61 may be composed of a weaker layer of bonding material such as ethylene vinyl acetate. Or, the first layer 61 may itself be a multilayer material consisting of a very thin (approximately . 0001 inch) and weak fracture layer the same as the container 12 is constructed coextruded with a similar but thicker (approximately. 001 inch) and stronger layer. If barrier layer 21 is peelable from container 12, barrier layer 21 may have a tab for grasping such as overlap tab 22. Overlap tab 22 is an extension of barrier layer 21 beyond the lip of neck 14. The grasping tab may be of different size and shape as needed.

A second layer 62 is in direct contact with the top surface of the first layer 61 and sandwiches the first layer 61 between the second layer 62 and the lip of neck 14. The second layer 62 is an adhesive, such as an epoxy. The second layer 62 is preferably about . 0001 inch thick. The second layer 62 functions to bond the first layer 61 to the next layer.

A third layer 63 is in direct contact with the top surface of the second layer 62 and sandwiches the second layer 62 between the third layer 63 and the first layer 61. The third layer 63 is a conductive metal, for example aluminum. It preferably has a thickness of between. 0005 and. 001 inch. If barrier film 21 is induction welded to the lip of neck 14, the metallic third layer 63 functions to generate heat for the bonding process.

Alternatively, or in addition to its role in induction welding, the third layer 63 may function as a barrier layer to gases or solvents that would otherwise permeate a polymer layer.

A fourth layer 64 is in direct contact with the top surface of the third layer 63 and

sandwiches the third layer 63 between the second layer 62 and fourth layer 64. The fourth layer 64 is another adhesive layer and may be of the same material and thickness as the second layer 62, such as an epoxy of about. 0001 inch thick.

A fifth layer 65 is in direct contact with the top surface of the fourth layer 64 and sandwiches the fourth layer 64 between the third layer 63 and the fifth layer 65. The fifth layer 65 may be polyethylene, polypropylene, polyester or other such materials as is known. The fifth layer 65 provides strength and rigidity to barrier film 21. In a preferred embodiment, the fifth layer 65 has a thickness of from about. 001 to. 002 inch. The fifth layer 65 may also be foamed so as to add greater thickness to barrier film 21. If the fifth layer 65 is foamed, the preferred thickness is about. 03 inch.

As shown in FIG. 4, dispenser 20 has as a means of dispensing container 12 contents an aperture 2 5 through b arrier film 2 1. Aperture 25 acts equivalent to a pour spout, providing a narrowed opening through which a more controlled amount of product may be dispensed than is possible with an unrestricted opening. The presence of aperture 25 through barrier film 21 allows a consumer to squeeze or pour out a small amount of product as needed for use. Further, should container 12 tip over, the smaller opening of aperture 25 will prevent a large quantity of a potentially dangerous product from spilling out. The diameter of aperture 25 is chosen according to the particular qualities and uses of the product within container 12. In one embodiment of the present invention, the diameter of aperture 25 is between about. 0625 and. 125 inch. The figures show aperture 25 positioned in the center of barrier film 21. Of course, aperture 25 may also be positioned near the periphery of barrier film 21 should this location provide a better location for the particular product being dispensed. Further, a particular dispensing system may require more than one aperture 25, and such an embodiment would fall within the spirit of the

present invention. For example, a second aperture 25 may provide venting that helps dispense container 12 contents more rapidly.

Prior to use by the consumer, aperture 25 is sealed with aperture seal 23 as is best illustrated in FIG. 1. Aperture seal 23 is attached to the surface of barrier film 21, is peelable and completely seals aperture 25 preventing any of container 12 contents from leaking during shipping and storage, regardless of the position of container 12. Aperture seal 23 may also be gas impermeable, thus protecting the contents of container 12 from reacting with exterior gases assuring the contents remain as they were when bottled.

Before dispensing the contents, the consumer removes the outer safety closure and peals aperture seal 23 away from barrier film 21 as is shown in FIG. 4. The seal between barrier film 21 and aperture seal 23 is strong enough to create a barrier between the outside and inside environments, yet weak enough to be peeled with relative ease by the consumer.

In order to facilitate peeling by the consumer, aperture seal 23 may be fitted with pull tab 24. Pull tab 24 may be a flap that lifts up as illustrated in FIGS. 1 and 4. An alternative embodiment is illustrated in FIGS. 7 and 8. Aperture seal 53 does not have a separate pull tab 24, but rather the seal holding aperture seal 53 to barrier film 51 does not extend tot he outer periphery of aperture seal 5 3. A portion of aperture seal 53 is left unattached to barrier film 51. The unattached portion is sufficiently large enough for the consumer to grasp and use as a tab for pulling aperture seal 53 free of barrier film 51 as shown in FIG. 8. The shape of aperture seal 53 may be oval while the sealed portion of aperture seal 53 is round, thus leaving either end free for grasping by the consumer. Of course, other shapes such as wedges with extending appendages may be utilized to provide a free portion for grasping by the consumer and still remain within the spirit of the present invention.

Aperture seals 23 and 53 may be laminates. An exemplary description of a laminate embodiment of aperture seals 23 and 53 is shown in FIG. 10. A first layer 71 is in direct contact and peelably bonded with barrier film 21 or 51, respectively. The first layer 71 may be composed of the same material as barrier film 21 or 51, for example, polyethylene, polypropylene or polyethylene terephthalate. Alternatively, the first layer 71 may be a bonding material such as ethylene vinyl acetate. In a preferred embodiment the thickness of the first layer 71 is between. 001 and. 002 inch. In order for the first layer 71 to be peelable the first layer may be composed of a weak layer of bonding material such as ethylene vinyl acetate. Or, the first layer 71 may itself be a multilayer material consisting of a very thin (approximately. 0001 inch) and weak fracture layer the same as the container 12 is constructed coextruded with a similar but thicker (approximately 0.001 to 0.002 inch) and stronger layer.

A second layer 72 is in direct contact with the top surface of the first layer 71 and sandwiches the first layer 71 between the second layer 72 and the top surface of barrier film 21 or 51. The second layer 72 is an adhesive, such as an epoxy. The second layer 72 is preferably about 0. 0001 inch thick. The second layer 72 functions to bond the first layer 71 to the next layer.

A third layer 73 is in direct contact with the top surface of the second layer 72 and sandwiches the second layer 72 between the third layer 73 and the first layer 71. The third layer 73 is a conductive metal, for example aluminum. It preferably has a thickness of between 0.0005 and 0.001 inch. If aperture seal 23 or 53 is induction welded to barrier film 21 or 51, the metallic third layer 73 functions to generate heat for the bonding process. Alternatively, or in addition to its role in induction welding, the third layer 73 may function as a barrier layer to gases or solvents that would otherwise permeate a

polymer layer.

A fourth layer 74 is in direct contact with the top surface of the third layer 73 and sandwiches the third layer 73 between the second layer 72 and fourth layer 74. The fourth layer 74 is another adhesive layer and may be of the same material and thickness as the second layer 72, such as an epoxy of about 0.0001 inch thick.

A fifth layer 75 is in direct contact with the top surface of the fourth layer 74 and sandwiches the fourth layer 74 between the third layer 73 and the fifth layer 75. The fifth layer 75 may be polyethylene, polypropylene, polyester or other such materials as is known. The fifth layer 75 provides strength and rigidity to aperture seal 23 or 53. In a preferred embodiment, the fifth layer 75 has a thickness of from about 0.001 to 0.002 inch.

The fifth layer 75 may also be foamed so as to add greater thickness to aperture seal 23 or 53. If the fifth layer 75 is foamed, the preferred thickness is about 0.03 inch. If, as shown in FIG. 1, aperture seal 23 has pull tab 24, the pull tab may be the fifth layer 75 of aperture seal 23. If this is the case, the fourth adhesive layer 74 would cover only a portion, for example one-half, of the underlying third metallic layer 73 such as depicted in FIG 10a.

The unbonded portion of the fifth layer 75 could be lifted as pull tab 24 and grasped for peeling aperture seal 23 free from barrier film 21. Alternatively, if the fourth adhesive layer 74 covers all of the underlying metallic layer 73 the aperture seal 53 would remain as one flat piece as shown in FIG. 7.

In a preferred embodiment, closure 30 is a safety closure ; however, any threaded closure may be used and still fall within the spirit of the present invention. If container 12 contents pose a hazard to children or others unable to appreciate the risk, a safety closure may be most desirable.

Any number of safety closures known in the art may be used in an embodiment of

the present invention without any necessary adaptation to the closure. For example, as illustrated in FIG. 3, a single-walled"squeeze and turn"safety closure may be utilized.

The squeeze and turn closure 40 has a top 46 and a deformable annular side skirt 41 depending from top 46. Opposing squeeze pads 42 and 43 are formed on the lower portion of annular skirt 41 to provide a guide for the proper location to apply pressure to deform annular skirt 41 in order to overcome the safety features preventing removal of closure 40.

Turning to FIG. 6, a cut away of annular skirt 41 illustrates the closure 45 safety mechanism. Lug 16 positioned on lower container neck 14 has an abutment face 17 that prevents removal of closure 46 by interferingly engaging lug engaging face 45on locking tab 44 positioned on the bottom inside of annular skirt 41. In order to overcome the safety lock, inward pressure must be applied to both squeeze pads 42 and 43 to ovalize annular skirt 41 while simultaneously turning closure 40. Ovalizing annular skirt 41lucking tab 44 out of interference contact with abutment face 17 and permits rotational motion and removal of closure 40.

FIG. 2 illustrates another safety closure 30 usable with an embodiment of the present invention. Closure 30, generally referred to as a"push and turn"closure, is double-shelled. FIG. 5 shows in a cutaway section that closure 30 has an outer closure 31 and an inner closure 33 fitted within outer closure 31. Outer closure 31 has an annular outer side skirt 31 depending downward form a top 31. On the inside surface of top 31 and depending downward are a plurality of upper ratchet teeth 38. Inner closure 33 has depending upward from a top surface a plurality of lower ratchet teeth 37 that can lockingly engage upper ratchet teeth 38. Outer closure 31 and inner closure 33 are loosely fitted together. Turning outer closure 31 will not normally turn inner closure 33, which is threadably attached to neck 14. Thus, simple rotational motion of outer closure 31 will not

remove closure 30 from container 35. However, simultaneous rotational force along with a downwardly directed force will overcome the safety feature and permit removal of closure 30 from container 35. The downward force causes upper ratchet teeth 38 to locking engage lower ratchet teeth 37, transferring the rotational force applied to outer closure 31 to inner closure 33 and permitting removal of closure 30 from container 35.

The foregoing detailed description is given primarily for clearness of understanding. No unnecessary limitations are to be understood therefrom for modifications will become obvious to those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention and scope of the appended claims.