阅读说明：本技术 容器、封闭件及制造方法 (Container, closure and method of manufacture ) 是由 B·希尔特塞 G·卢艾伯 于 2019-12-19 设计创作，主要内容包括：在一些实施例中,本文提供的装置和方法可用于分配流体,诸如触变流体。在一些实施例中,具有封盖的瓶包括翻盖、基部和盘,其中基部和盘限定了混合室,该混合室构造为有利于混合从流体中分离出来的任何浆液或液体回到其中。在某些构造中,基部具有中央开口和内轴,流体通过中央开口流出,内轴的非平面端表面与中央开口相对。在一些构造中,非平面端表面和盘在混合室和内轴之间限定了通道。在一些实施例中,盘包括：中央开口、多个穿过盘的平面表面的部分环形开口、以及延伸入混合室的凸起。(In some embodiments, the devices and methods provided herein can be used to dispense fluids, such as thixotropic fluids. In some embodiments, a bottle with a lid includes a flip cap, a base, and a tray, wherein the base and the tray define a mixing chamber configured to facilitate mixing of any slurry or liquid separated from the fluid back therein. In some configurations, the base has a central opening through which fluid flows out and an inner shaft having a non-planar end surface opposite the central opening. In some configurations, the non-planar end surface and the disc define a channel between the mixing chamber and the inner shaft. In some embodiments, the disc comprises: a central opening, a plurality of partial annular openings through the planar surface of the disk, and a protrusion extending into the mixing chamber.)

1. A dispensing bottle, comprising:

a container body having a thixotropic fluid therein, the container body having a neck with threads thereon;

a cover having a base and a flip,

the base has: a skirt having base threads thereon configured to engage the threads on the neck; a fixing ring; and a central portion having an opening therein aligned with an inner shaft terminating in a non-planar end surface opposite the central portion, the opening allowing the fluid to flow therethrough when unobstructed,

said flap having an internal protrusion and being reclosable movable between a closed first position and an open second position, wherein said protrusion blocks said opening of said base in said first position, inhibiting egress of said fluid from within said container body, and said second position allows egress of said fluid through said opening of said base;

a disk attached to the interior of the base, the disk having a needle aperture and a partial annular groove disposed around the needle aperture; and

a mixing chamber defined by the disc, the central portion, the skirt, and the inner shaft, wherein a plurality of fluid passages are formed by the non-planar end surface of the inner shaft and the disc:

wherein the lid is capable of maintaining the thixotropic fluid in a stable equilibrium without leaking when the bottle is in an inverted position such that the lid is at its bottom and the flip lid is in the closed first position; and

wherein application of pressure to the container body when the flip cap is in the open second position controls dispensing of the thixotropic fluid, which is dispensed through the partial annular opening, through the mixing chamber and through the fluid passageway and then out of the dispensing bottle via the opening in the base, and wherein release of pressure on the container body allows air to flow back into the container body, rapidly stopping dispensing, the flow of thixotropic fluid in the internal passageway rebounds and reverses without movement of the disk relative to the base.

2. The dispense vial of claim 1, wherein the mixing chamber has a capacity of about 2mL to about 11mL, and wherein the disk is attached to the base via a securing ring.

3. The dispense vial of claim 2, wherein the mixing chamber has a capacity of about 5mL to about 7mL for a dispense vial having a capacity of about 250mL to 1000 mL.

4. The dispenser bottle of claim 1, wherein said mixing chamber prevents slurry from leaking from said dispenser bottle and returns slurry separated from the thixotropic fluid into said thixotropic fluid.

5. The dispensing bottle of claim 1, wherein the thixotropic fluid passes from the container body through the partial annular groove, through the mixing chamber, through the passageway formed by the inner shaft and the disk, and through the opening in the central portion of the base, and through a needle hole in the disk during dispensing.

6. The dispense bottle of claim 1, further comprising an internal stopper having a ledge inside the opening.

7. The dispense bottle of claim 1, wherein the central portion comprises a domed central surface with a peripheral planar surface therearound.

8. The dispense bottle of claim 1, wherein the non-planar end surface opposite the central portion that terminates the inner shaft comprises a stepped structure that forms a plurality of teeth and a plurality of depressions in the non-planar end surface.

9. The dispense vial of claim 1, wherein the non-planar end surface terminating the inner shaft opposite the central portion comprises at least some arcuate surface portions forming one or more depressions.

10. The dispense bottle of claim 1, wherein the disk has a diameter of about 20-40mm, the inner spindle has a height of about 4-12mm, and a diameter of about 3-9 mm.

11. The dispense bottle of claim 1, wherein the tray is stationary relative to the base and both the lid and the tray are comprised of a single food grade plastic.

12. The dispense bottle of claim 1, wherein air enters through at least one of the needle aperture and the partial annular groove.

13. The dispense bottle of claim 1, wherein the tray further comprises a plurality of extensions extending from a first side of the tray such that when the tray is attached to the base, the extensions extend toward the base.

14. The dispensing bottle of claim 1, wherein said securing ring comprises two securing rings, wherein one of said two securing rings has a bottle gasket associated therewith, said bottle gasket sealing said thixotropic fluid within said container body.

15. The dispense vial of claim 1, wherein the disk further comprises one or more intermediate openings between the annular groove and the needle aperture.

16. A method of manufacturing a filled dispense vial, the method comprising:

molding a container;

filling the container with a thixotropic fluid;

molding a cover having a base and a flip top,

the base has: an inner skirt and an outer skirt, the inner skirt configured with base threads configured to engage the threads on the neck; a securing ring on the inner skirt; and a central domed portion having an opening therein aligned with an inner shaft terminating at a non-planar end surface opposite the central domed portion, the opening being unobstructed to allow the fluid to flow therethrough,

said flap having an internal protrusion and being movable between a first position in which said protrusion blocks said opening of said base inhibiting egress of said fluid from within said container body and a second position in which said fluid is allowed to egress through said opening of said base;

snapping a disk into the base of the closure, the disk having a needle aperture and a partial annular groove disposed around the needle aperture, wherein the disk, the central portion of the base, the inner skirt of the base, and the inner shaft of the base form a mixing chamber, a plurality of fluid passages being formed by the non-planar end surface of the inner shaft and the disk; and

closing the filled container with the closure.

17. The method of making a filled dispensing bottle according to claim 16 further comprising sealing said container with a gasket associated with said closure.

18. A closure for a container, the closure comprising:

a base having at least: a dome-shaped wall having an opening therethrough; an inner skirt edge; an outer skirt connected by a planar portion; threads and a retaining ring on the inner skirt; and an inner shaft depending inwardly from the dome-shaped wall, the inner shaft terminating at a non-planar end surface;

a flap hingedly connected to the base, the flap having a protrusion and being movable between a first position in which the protrusion blocks the opening and a second position in which the protrusion does not block the opening of the base; and

a tray attached to an interior of the base by snapping the tray into the base, the tray having: a needle aperture, a partial annular groove disposed around the needle aperture, and a flange extending toward the base, the flange disposed between the inner shaft and the partial annular groove when the disc is attached to the base; and

a mixing chamber defined by the disc, the dome-shaped wall, the inner skirt, and the inner shaft, wherein a plurality of fluid passages are formed by the non-planar end surface of the inner shaft and the disc.

19. The lid as in claim 18, wherein the mixing chamber has a volume of about 7mL to about 11mL, and wherein the disk is attached to the base via a securing ring.

20. The closure in accordance with claim 18, wherein terminating the non-planar end surface of the inner shaft opposite the central portion comprises a stepped structure forming a plurality of teeth and a plurality of depressions in the non-planar end surface.

21. The closure of claim 18, wherein said non-planar end surface terminating said inner shaft opposite said central portion comprises at least some arcuate surface forming one or more depressions.

22. The closure of claim 18, wherein the disc has a diameter of about 20-40mm, the inner shaft has a height of about 4-12mm and a diameter of about 3-9 mm.

23. The closure in accordance with claim 18 in which said tray is stationary relative to said base and both said cover and said tray are comprised of a single food grade plastic.

24. The closure in accordance with claim 18 further comprising an internal tab having a ledge inside the opening.

25. The closure in accordance with claim 18 in which said closure comprises only two separate components, said combination of said base and flip cover being a unitary, integral, unitary, one-piece structure, and said tray being molded separately.

26. The closure in accordance with claim 18 in which said inner shaft supports said disc when said disc is attached to said inner shaft, and said inner shaft has an inner wall with at least one of a circular or parabolic shape.

27. The closure in accordance with claim 26 in which said inner wall is inclined inwardly toward an opening in said base at an end of said inner wall opposite said non-planar end surface, and said inner shaft has a diameter that varies along a length of said inner shaft.

28. The closure in accordance with claim 19 in which said securing ring comprises two securing rings, wherein one of said two securing rings has a bottle liner associated therewith.

29. The closure in accordance with claim 19 in which said disc further comprises a conically shaped extension extending from said disc toward said base.

30. A method of manufacturing a closure, the method comprising:

forming a flip cover in a mold, the flip cover comprising:

the base has at least: a dome-shaped wall having an opening therethrough; an inner skirt edge; an outer skirt connected by a planar portion; threads and a retaining ring on the inner skirt; and an inner shaft depending inwardly from the dome-shaped wall, the inner shaft terminating at a non-planar end surface, an

A flap hingedly connected to the base, the flap having an interior protrusion and being movable between a first position in which the protrusion blocks the opening and a second position in which the protrusion does not block the opening of the base; and

snapping a disk into the base of the flip cover, the disk having a pin hole, a partial annular groove disposed around the pin hole, and a flange extending toward the base, the flange disposed between the inner shaft and the partial annular groove when the disk is attached to the base;

wherein the disc and the base form a mixing chamber defined by the disc, the domed wall, the inner skirt, and the inner shaft, wherein a plurality of fluid passages are formed by the non-planar end surface of the inner shaft and the disc.

31. The method of claim 30, wherein the cover is made of only two separate pieces, including the flip cover and the tray, and the flip cover includes the base and the flip cover formed as a single, unitary, one-piece structure, and wherein the two separate pieces are made of the same material and are assembled.

32. The method of claim 30, wherein the disc is snapped into one or more retaining rings, and further comprising attaching a liner to the retaining ring disposed furthest from the inner shaft.

33. A closure for a container, the closure comprising:

a base having at least: a dome-shaped wall having an opening therethrough; an inner skirt edge; an outer skirt connected by a planar portion; a thread; and an inner shaft depending inwardly from the dome-shaped wall, the inner shaft terminating at a non-planar end surface;

a flap hingedly connected to the base, the flap having a protrusion and being movable between a first position in which the protrusion blocks the opening and a second position in which the protrusion does not block the opening of the base; and

a tray attached to the interior of the base by snapping the tray into the base, the tray having one or more flanges extending from the tray toward the base, a centrally disposed post, and a plurality of openings therethrough; and

a mixing chamber defined by the disc, the dome-shaped wall, the inner skirt, and the inner shaft, wherein a plurality of fluid passages are formed by the non-planar end surface of the inner shaft and the disc.

34. A closure for a container, the closure comprising:

a base having at least: a dome-shaped wall having an opening therethrough; an inner skirt edge; an outer skirt connected by a planar portion; a thread; and an inner shaft depending inwardly from the dome-shaped wall, the inner shaft terminating at a non-planar end surface;

a flap hingedly connected to the base, the flap having a protrusion and being movable between a first position in which the protrusion blocks the opening and a second position in which the protrusion does not block the opening of the base; and

a disk connected to the interior of the base by snapping the disk into the base, the disk having a plurality of annular grooves and a plurality of intermediate openings therethrough, wherein the intermediate openings are disposed between the plurality of annular grooves and a center of the disk; and

a mixing chamber defined by the disc, the dome-shaped wall, the inner skirt, and the inner shaft, wherein a plurality of fluid passages are formed by the non-planar end surface of the inner shaft and the disc.

Technical Field

The present disclosure generally relates to containers for fluids. More particularly, the present disclosure relates generally to containers with closures.

Background

Fluid containers occasionally have dosing and leakage problems, particularly during transport and/or when the container is placed in certain configurations. Many bottled type consumer products may suffer from such drawbacks. For example, thixotropic fluids, such as ketchup or certain liquid soaps, are sometimes sold in bottles that use flexible plastic film valves with "X" shaped slits. These bottles are sometimes used as inverted bottles that rest on the cap of the bottle when not in use, so that gravity can hold the product in place adjacent the valve.

One problem with this type of valve is that in some cases, product may leak through the valve when the bottle is not in use. Another problem is that the product may be ejected from the opening at an undesirably high velocity during dispensing, which increases the risk of splashing. The high speed discharge of the product also makes proper metering difficult because control of the product is often inadequate at high speeds. A third problem is that the valve may resist or prevent the inflow of air to maintain the dispensed internal volume, resulting in a sub-atmospheric pressure, i.e., partial vacuum, within the bottle. This can lead to panelization, i.e. bowing, or other undesirable inward deflection of the container wall, which can create aesthetic problems, as well as functional problems, as it can increase the manual pressure required to dispense the product, and can lead to uneven or inconsistent dispensing in response to squeezing, i.e. manual application of pressure to the exterior of the container.

Another problem is that such membrane valves are typically formed of silicon, while the rest of the lid is typically formed of another material, such as polypropylene. Making the closure of multiple materials increases the complexity and cost of manufacture and may make recycling difficult and/or impractical, making the solution less attractive for large scale use.

Furthermore, such membrane valves and other similar solutions do not always adequately address the problem of product separation that often occurs in fluids, such as when serum, water, or another thin liquid component of relatively low viscosity separates from the rest of the fluid, such as tomato paste. This separation can increase leakage, increase splashing, and cause the thin liquid component to be dispensed separately from the rest of the product.

Drawings

Embodiments of systems, devices, and methods related to containers, closures, and methods of manufacture are disclosed herein. The description includes the accompanying drawings, in which:

fig. 1A is a perspective view of a bottle with a cap according to some embodiments.

FIG. 1B is a cross-sectional view of the bottle of FIG. 1A in an inverted position.

Fig. 2 is a perspective view of a cap and a portion of a bottle according to several embodiments.

Fig. 3 is a perspective view of the lid of fig. 2 in an open configuration.

Fig. 4 is a perspective cross-sectional view of a portion of the cap in an inverted orientation.

Fig. 5 is a perspective view of a bottom surface of a portion of a cover with a tray removed therefrom according to some embodiments.

FIG. 6 is a perspective view of a bottom surface of a tray according to several embodiments.

Fig. 7A and 7B are top and bottom plan views of a tray according to several embodiments.

Fig. 7C is a bottom side view of the tray of fig. 7a and 7 b.

Fig. 7D is a cross-sectional view taken along line D-D of fig. 7 b.

Fig. 7E is a cross-sectional view taken along line E-E of fig. 7 b.

Fig. 8 is a perspective cross-sectional partial view of a lid in a closed configuration with a tray removed therefrom according to several embodiments.

Fig. 9 is a perspective cross-sectional view of a portion of a cover without a tray attached to the cover, in accordance with several embodiments.

Fig. 10 is a perspective cross-sectional view of a portion of a cover without a tray attached to the cover, in accordance with several embodiments.

FIG. 11 is a perspective cross-sectional view of a portion of a cover according to several embodiments.

FIG. 12 is a cross-sectional view of a portion of an inner shaft at a cap opening according to several embodiments.

FIG. 13 is a cross-sectional view of a portion of an inner shaft at a cap opening according to several embodiments.

Fig. 14 and 15 are partial cross-sectional views of a portion of an alternative embodiment.

Fig. 16 and 17 are partial cross-sectional views of a portion of a cover according to several embodiments.

FIG. 18 is a perspective cross-sectional view of a portion of a cover illustrating an alternative embodiment.

Fig. 19 is a cross-sectional view of the embodiment of fig. 18.

Fig. 20 is a perspective cross-sectional view showing a portion of a cover of an alternative embodiment.

Fig. 21 is a cross-sectional view of the embodiment of fig. 20.

FIG. 22 is a perspective cross-sectional view of a portion of a cover illustrating an alternative embodiment.

Fig. 23 is a cross-sectional view of the embodiment of fig. 22.

Fig. 24 is a side view of a lid in an open configuration according to several embodiments.

Fig. 25 and 26 are partial cross-sectional views of the cap of fig. 24.

Fig. 27 is a side view of a lid in an open configuration according to several embodiments.

Fig. 28 and 29 are partial cross-sectional views of the cap of fig. 27.

Fig. 30 is a side view of a lid in an open configuration according to several embodiments.

Fig. 31 and 32 are partial cross-sectional views of the cap of fig. 30.

Fig. 33 and 34 are cross-sectional views showing alternative mixing chambers.

35-37 are partial cross-sectional views illustrating an alternative inner shaft according to several embodiments.

FIG. 38 is a cross-sectional view of the cover with enlarged detail to show various finishing options for the inner shaft.

39-44 are partial perspective views with portions removed to illustrate alternative embodiments of the inner shaft of the base.

Fig. 45A-45I are top plan views of alternative embodiments of the tray.

Fig. 46A and 46B are cross-sectional views of alternative embodiments of a disk.

Fig. 47A-47I are perspective views of the bottom surface of an alternative embodiment of a tray.

Fig. 48 is a perspective cross-sectional view of a portion of an alternative cover in accordance with several embodiments.

For simplicity and clarity, elements are shown in the figures and are not necessarily drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Additionally, common but well-understood elements that are useful or necessary in a commercially feasible embodiment may be omitted so as to facilitate a less obstructed view of these various embodiments of the present invention. Certain actions and/or steps may be described or depicted in a particular order of occurrence while, in fact, no specificity with respect to sequence is required. The terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.

Detailed Description

Described herein are systems, devices, and methods for facilitating the dispensing of fluids, such as thixotropic fluids, from bottles. Some embodiments include a closure for such bottles. The cover may include a flipper, a base, and a tray, wherein the base and the tray define a mixing chamber configured to facilitate mixing of the fluid, which may be mixing of the slurry or mixing of the liquid separated from the fluid back therein. In some configurations, the base has a central opening through which fluid flows out, and a hollow inner shaft with a non-planar end surface opposite the central opening, the non-planar end surface and the disc defining one or more passages between the mixing chamber and the interior of the shaft. (in other constructions, the shaft may have a planar end surface opposite the opening, and the shaft may have a bore formed therein.) in some embodiments, the disk includes a central opening, a plurality of partial annular openings through the planar surface of the disk, and a protrusion extending into the mixing chamber. To exit the vial, fluid is advanced from the reservoir or body, through an opening in the disk (e.g., a partial annular opening or central pinhole), and out of the central opening of the base through a slide formed by the inner shaft. Fluid is advanced through these openings and channels by manual pressure applied to the body by the user.

In some embodiments, a dispensing bottle includes a body of a container having a neck with external threads that engage internal threads on a closure that includes a base and a flip top. In one illustrative embodiment, the base of the closure has a skirt with a base thread disposed thereon, wherein the base thread is configured to engage with an external thread on the neck of the bottle. Further, in some embodiments, the base includes one or more securing elements, protrusions, or rings on an inner surface of the base (e.g., on an inner surface of the skirt), and a central portion having an opening aligned with the inner shaft, wherein fluid is allowed to flow therefrom when the opening is unobstructed. According to one method, the inner shaft terminates at a non-planar end surface opposite the central portion. Further, the inner shaft may have a disk mounted adjacent thereto.

As previously mentioned, the lid has a flip cover, and in one illustrative construction, the flip cover has an internal projection that is movable between a closed first position, in which fluid is prevented or inhibited from flowing from within the container body, and an open second position, in which fluid is permitted to flow through the opening of the base. Further, in one illustrative embodiment, the disk is attached to the interior of the base by snapping the disk into place at the retaining ring(s), the disk having a central needle hole and a partial annular groove disposed around the central needle hole. In one exemplary configuration, the mixing chamber is formed by the central portions of the disk and base, as well as the skirt and inner shaft. Further, in some configurations, the plurality of fluid passages are formed by a non-planar end surface of the inner shaft and a disc that allows fluid to flow from the mixing chamber to the inner shaft.

In some embodiments, the closure in the closed position enables the thixotropic fluid to maintain a stable equilibrium in the bottle without leaking when the bottle is in an inverted position such that the mouth of the bottle is positioned below the body of the container. In some embodiments, the configuration of the closure controls the dispensing of the thixotropic fluid during the application of pressure to the container body when the closure is in the open position, and the release of pressure on the container body rapidly stops the dispensing, such as by allowing air to flow back into the container body, causing the bottle to rebound and reversing the flow of the thixotropic fluid in the interior channel. Further, in one illustrative configuration, this occurs without the need for the disk to move relative to the base. According to one approach, the spring back is achieved by allowing air to quickly enter the bottle to replace the dispensed volume of fluid, which allows the bottle to quickly return to its original shape.

In one illustrative method, at least a portion of the fluid is dispensed by pushing downward through the partial annular opening, through the mixing chamber, then inward through a fluid passageway defined between the disc and the non-planar end of the inner shaft, and then downward through the interior of the shaft before exiting the dispense bottle via the central opening. According to one method, a thixotropic fluid disposed in a bottle may be squeezed from the bottle, propelled through a portion of the annular groove in the tray, and passed through a mixing chamber where any separated slurry may be mixed into the fluid, before the thixotropic fluid moves through the channel formed by the end of the inner shaft and the tray and out of the central opening of the base. In addition, a portion of the fluid may also be propelled downward through small holes or pinholes in the disk and through the central opening of the base. As mentioned above, in operation, the bottle is able to quickly recover its shape after it ceases to be pressurized. Air may flow into the bottle through one or both of these paths, for example, through pinholes in the disk and/or through the annular opening, such that air can flow into the bottle through the internal chamber, the passage, the pinholes, the mixing chamber, and/or a portion of the annular groove. Generally, when the pressure on the body or container of the bottle is released, air is pulled into the bottle. Thus, in short, air flows into the main chamber of the bottle through at least one central pinhole or partial annular groove of the disc. Further, once the disk is mounted to the base of the cover, the disk remains stationary relative to the base according to one method.

In some embodiments, the cover, including the base, flip top and tray, are generally composed of polypropylene materials so that the entire cover can be recycled as a unit. Furthermore, because there is no silicon film, in some embodiments, the strength of the seal does not significantly degrade over time, and there is little degradation in performance. In some embodiments, the pressure required to dispense fluid from the bottle varies little over the life of the bottle.

As described herein, the closure may allow for better metering. It prevents the product from being accidentally expelled from the bottle at high speed, which might be messy, and prevents permanent collapse or other permanent inward deformation of the bottle. In addition, the closure configuration may reduce splashing. Additionally, as described below, the mixing chamber may be configured to facilitate cleaning of its exterior surfaces, for example, by having an outwardly convex or dome-shaped exterior surface.

According to one method, the outside, bottom (when the bottle is inverted) surface of the base, adjacent the central opening through which fluid is dispensed, has an arcuate or dome-shaped central portion with a planar peripheral surface therearound. In one example, the interior of the base has an internal shaft that extends, at least to some extent, parallel to the skirt of the base. In some configurations, the base includes an internal stop disposed adjacent the central opening, wherein an inner diameter of the inner shaft sharply decreases. According to one method, the blocking sheet has sharp edges without burrs. In some configurations, the inner diameter of the opening itself is different than that of the inner shaft wall. More particularly, in such a configuration, the diameter of the opening into the container is less than the diameter between the inner axial walls, this reduction in size and the relatively sharp edges therebetween help to facilitate reduced tail formation of the product by retaining portions of the product at the seal. In addition, surface tension and the size of the opening also help to reduce tail formation of the product. Although such a blocking tab does not prevent the product from flowing out of the opening of the closure, it reduces the amount released under a certain pressure by slowing down the flow rate. According to one method, the blocking tab is relatively small compared to the diameter of the shaft, and in some configurations the width of the internal cutting tab is about 1mm, while the diameter of the opening into the container itself is about 3mm to about 7 mm. In another configuration, the opening has a diameter of about 3.5mm to about 4.5 mm. In another embodiment, the diameter of the opening is about 4mm and the diameter of the inner shaft is about 6 mm. Accordingly, in some configurations, the blocking sheet has a width of about 1 mm.

While the stopper helps to quickly stop the dispensing of liquid, the disc (and its interface with the inner shaft) also reduces the pressure caused by the product in the bottle when the pressure on the bottle is released, which helps to stop dispensing. As discussed below, the size and configuration of the openings in the disc facilitates flow monitoring, and the geometry of the disc can be adjusted to accommodate different fluids depending on the viscosity and surface tension of the product.

At the upper end of the inner shaft, disposed away from the opening in the base, the inner shaft has a non-planar end surface in some embodiments. According to one method, the non-planar end surface has a stepped configuration forming a plurality of teeth and depressions. According to another configuration, the non-planar end surface is configured with undulating, sinusoidal, or other arcuate depressions.

As noted above, the bottles and caps described herein may be used for the use of various fluids. In one illustrative configuration, the bottle is filled with a thixotropic fluid, such as some condiments, sauces, or some consumer product, such as shampoo or body wash. Such applications may be particularly advantageous because they allow a consumer or user to easily and quickly dispense a desired amount of fluid without spilling or otherwise causing unintended mess of the liquid. According to one method, the capped dispensing bottles may have a capacity of about 250mL to about 1000 mL. In addition, various container configurations are also contemplated, including some containers stored in an inverted configuration, wherein the bottle rests on the closure. In one illustrative method, the disc diameter is between about 20 to about 40mm, the height of the inner shaft is between about 4 to about 12mm, and the diameter of the inner shaft is between about 3 to about 9 mm. In other constructions, the inner shaft has a height of about 5 to about 9mm and a diameter of about 3 to 5 mm.

As described above, the lid has a mixing chamber formed by a portion of the base with the disc secured thereto. According to one method, the mixing chamber includes a plurality of extensions from the disc therein. More particularly, in some configurations, the tray includes a plurality of extending flanges that extend downwardly from the bottom of the tray (when the bottle is inverted) into the mixing chamber. The mixing chamber described herein helps prevent slurry from leaking from the dispensing bottle, in part by remixing slurry separated from the thixotropic fluid to the remainder of the thixotropic fluid. According to one method, the mixing chamber prevents the separated slurry from leaking from the bottle by mixing it back into the liquid before it leaves the bottle opening. In some embodiments, the mixing chamber has a capacity of, or retains, 2mL to 11mL, 3mL to 9mL, or 5 to 7mL, or about 6 mL. The disc extensions may aid in remixing of the separated slurry by slowing the flow of fluid through the mixing chamber, creating or increasing turbulence, and/or otherwise increasing the interaction between the separated slurry and the remainder of the fluid.

According to one approach, a plurality of securing rings may be provided, and one of the securing rings may have a vial or cap liner associated therewith that may seal the vial after the cap is attached thereto. For example, the first and second retaining rings may be spaced apart from each other in the axial (vertical) direction with the edge of the disk captured therebetween. The upper ring (when the bottle is inverted) may have a removable membrane or liner member associated therewith which seals the opening at the neck of the bottle prior to use. The consumer may manually remove the cushion member prior to dispensing the product.

The capped bottles described herein may be formed, filled, and sealed in high speed, high volume, mass production operations, or in other types of operations. In one approach, the method of making the dispensing bottle generally includes forming a squeezable flexible bottle, for example, by blow molding, injection molding, or other methods; forming a tray and a cover having a base and a flip by injection molding or other methods; snapping the disk into the base; filling the container with a fluid (e.g., a thixotropic fluid); and securing the closure to the filled container. In some embodiments, the base has an inner skirt and an outer skirt, the inner skirt having a base thread on an interior thereof (wherein the base thread is configured to engage a thread on an exterior of the bottle neck), a securing ring on an interior of the inner skirt, and a central dome portion having an opening therein aligned with the inner shaft terminating in a non-planar end surface opposite the central opening. The dome-shaped portion includes an opening that allows fluid to flow therethrough when the opening is unobstructed, and the flip cap has an internal protrusion that moves between a first position and a second position, wherein in the first position the internal protrusion blocks the opening of the base, inhibiting or preventing fluid flow, and in the second position the internal protrusion allows fluid flow through the opening of the base. In some embodiments, the disk has a central needle aperture, and a partial annular groove disposed around the central needle aperture, wherein the disk, a central portion of the base, the inner skirt, and an outer surface of the inner shaft define a mixing chamber, and wherein a plurality of fluid passages are formed between the non-planar end surface of the inner shaft and the disk. In some configurations, the method further includes sealing the container with a removable liner associated with the closure to seal the product in the body of the bottle. As discussed further below, the base and flap may be molded with the tray or may be molded separately therefrom.

In one illustrative construction, a closure for a container includes a flip top and a base having at least a domed wall with an opening therethrough, an inner skirt, an outer skirt joined by an upper planar portion, threads on the inner skirt and one or more retaining rings, and an inner shaft depending inwardly from the domed wall. According to one method, the inner shaft terminates at a non-planar end surface. Further, in such a configuration, the flip has a protrusion and is movable between a first position in which the protrusion obstructs the opening and a second position in which the protrusion does not obstruct the opening of the base. In some configurations, the lid has a disk that is attached to the interior of the base by snapping the disk into a retaining ring(s). In such a configuration, the disk has a central needle hole, a partial annular groove disposed around the central needle hole, and a flange extending toward the base, the flange being disposed between the inner shaft and the partial annular groove when the disk is connected to the base. Further, according to one method, the closure includes a mixing chamber defined by a disc, a dome-shaped wall, an inner skirt, and an inner shaft, wherein the plurality of fluid passages are formed by the inner shaft and the non-planar end surfaces of the disc.

In another method, a method of making a closure includes forming a flip top in a mold having (a) a base having at least a domed wall with an opening therethrough, an inner skirt, an outer skirt joined by a planar portion, threads on the inner skirt and a retaining ring, and an inner shaft depending inwardly from the domed wall and terminating at a non-planar end surface, and (b) a flip top hingedly connected to the base, the flip top having an inner protrusion and being movable from a first position in which the inner protrusion blocks the opening to a second position in which the inner protrusion does not block the opening of the base. Further, in some methods, the method further includes snapping a disk into a retaining ring of a base of the flip cover, the disk having a central pin hole, a partial annular groove disposed around the central pin hole, and a flange extending toward the base, the flange being disposed between the inner shaft and the partial annular groove when the disk is attached to the base. Further, in some embodiments, the disc and the base form a mixing chamber defined by the disc, the dome-shaped wall, the inner skirt, and the inner shaft, wherein the plurality of fluid passages are formed by the inner shaft and the non-planar end surfaces of the disc.

Further, in some configurations, the method further comprises forming the cover as two separate components, including a flip cover and a tray, wherein the flip cover comprises a base and a flip cover formed as a single, unitary, one-piece structure, and wherein the two separate components are made of the same material and assembled at a mold or separation station.

Fig. 1A and 1B illustrate a packaged food product comprising a bottle 10 containing a fluid food product 5, such as ketchup, mayonnaise, barbecue sauce, mustard, or other product, with a closure 18 attached to a container body 12 via engagement of internal threads 32 (see, e.g., fig. 4) of the closure 18 with external threads 16 of the container body 12. For illustrative purposes, a portion of the cover 18 is shown transparently in FIG. 1A. Although fig. 1A shows the bottle in an upright position, in some embodiments, the bottle 10 is configured to be stored upside down while resting on its closure, such as shown in fig. 1B. Thus, during storage and dispensing, the bottle 10 may position the closure 18 under the container body 12 of the bottle 10 without accidental leakage of the liquid 5 from the bottle 10.

As shown in fig. 2 and 3, the cover 18 includes a base 20 and a hinged cover or flip top 22. To open bottle 10 so that liquid 5 can be easily dispensed therefrom, a user may pivot flip 22 from the closed configuration of fig. 2 to the open configuration of fig. 3. To this end, a user or consumer may apply an upward force to the lid 22 by engaging the mouth indentation 70 defined by the upper surface 72 and the lower surface 74. According to one method, the user will manually grasp and pull the upper surface 72 upward, pulling it away from the base 20 and the rest of the bottle 10. The flip 22 is then pivoted about the hinge 19 opposite the mouth indent 70 to be stably placed in the open configuration.

As shown in fig. 3, when the flip 22 is in the open configuration, the projection 90 of the flip 22 moves away from obstructing or blocking the opening 34 in the base 20, thereby leaving the opening 34 unobstructed. Fig. 3 also shows a central portion 30, which may be dome-shaped, and a planar portion 62 disposed at least partially therearound, with the opening 34 extending therethrough. As shown in the illustrative embodiment of FIG. 3, the lower surface 74 of the mouth-shaped indent 70 extends between sections of the planar portion 62.

Fig. 4 shows a perspective cross-sectional view of a portion of the closure 18 in an inverted orientation. As shown in fig. 4, the base 20 includes: the inner skirt 26, the internal threads 32 and one or more retaining rings 44 are disposed thereon; outer skirt 28, planar portion 62 therebetween; and a dome-shaped central surface 30 having an opening 34 disposed therein. One or more radial stiffeners or stiffeners 76, shown in FIG. 4, are disposed between the outer skirt 28 and the inner skirt 26. As shown in the illustrative configuration of fig. 4 and 5, the base 20 includes an inner shaft 36 that extends upwardly away from the central domed surface 30 and terminates in a non-linear surface 38 (shown in fig. 5).

In one illustrative embodiment, the cover 18 includes a disk 42 (shown in fig. 4 and 6) having a plurality of openings therein through which the fluid 5 and air can flow. According to one method, a retaining ring 44 disposed on the inner wall of the inner skirt 26 captures the disk 42 in the middle. In another configuration (not shown), the disc 42 may be captured between a stationary ring and another structure, such as a portion or extension of the inner shaft 36. Fig. 4 shows a cross-section of a portion of the cover 18, wherein the disk 42 is captured between two retaining rings 44, thereby illustrating how the disk 42 and the base 20 form a mixing chamber 56. In one illustrative embodiment, the mixing chamber 56 is formed by the walls of the inner skirt 26, the central portion 30, the inner axle 36 of the base 20, and the disc 42.

Further, the planar portion 62 of the base 20 also engages the inner and outer skirts 28. As shown in fig. 1, the base 20 also has ribs 80 disposed on the portion of the base 20 (when the bottle is in the upright orientation) below the flip 22. These ribs provide a gripping surface so that if one wishes to remove the entire closure 18 from the container body 12, the user can more easily grasp the closure 18 to disengage the internal threads 32 of the base 20 from the external threads 16 of the neck 14. In other constructions, the ribs 80 may be removable from the closure 18.

Figures 5 and 9 illustrate an exemplary non-linear termination surface 38 of the inner shaft 36 of the base 20. In some embodiments, the non-linear termination surface 38 forms a passage opening for fluid and air to move between the mixing chamber 56 and the inner shaft 36. According to one approach, the non-linear termination surface 38 has a stepped configuration 64, as shown in fig. 8 and 9. In another approach, the non-linear termination surface 38 has a wavy, sinusoidal, or other arcuate configuration. In some configurations, the non-linear stop surface 38 may have a semi-circular recess cut into the wall of the inner shaft 36. Further, the recess or recesses may form one or more channels between the mixing chamber 56 and the inner shaft 36.

Further, the stepped configuration 64 shown in fig. 5 and 9 may include one or more raised teeth 68 and one or more deep grooves 64 extending from a midpoint thereof, or otherwise positioned. The stepped configuration 64 of the non-linear termination surface 38 of the inner shaft 36 cooperates with the surface of the disc to form fluid channels 58 having different widths and/or depths. As shown in FIG. 10, the non-linear terminal surface 39 may also have an undulating or arcuate configuration with a plurality of grooves or recesses 65 and rounded extensions 69. The wavy non-linear termination surface 39, which operates similarly to the stepped configuration discussed above, forms a channel 58 with the disk 42. In some configurations, the non-linear termination surface may have a combination of stepped portions, protrusions, angles, and/or curved sections, among other elements.

In fact, the non-linear termination surface 38 may take on a variety of configurations, such as the configurations shown in FIGS. 8-10 and 39-44. As described above, the non-linear surface 38 shown in FIGS. 5 and 9 has a stepped configuration forming a plurality of channels 58. Furthermore, in another configuration, the non-linear termination surface 39 shown in FIG. 10 has a wavy or sinusoidal configuration. Fig. 39 shows a non-linear termination surface 2238 having two different heights, as opposed to the three different heights illustrated in fig. 8 and 9. Fig. 40 shows a non-linear termination surface 2338 having two heights and an angled portion therebetween. Fig. 41 shows a non-linear termination surface 2438 having generally V-shaped valleys disposed between corners or protrusions having a triangular cross-section. FIG. 42 is similar to FIG. 39, showing a non-linear termination surface 2538 having two different heights, but the corners or projections of FIG. 41 have triangular or trapezoidal shapes, with more or less acute angles adjacent to a larger base. Fig. 43 shows a non-linear termination surface 2638 having a stepped configuration in which the width of the lowermost step is less than the width of the uppermost step. Finally, fig. 44 shows a non-linear termination surface 2738 having triangular corners or protrusions with U-shaped valleys therebetween. It should be noted that the features illustrated may be used as illustrated, or in combination with other exemplary features, including, for example, features illustrated in other figures. Alternatively, the ends of the shaft may be linear or flat, and the shaft may include other openings incorporated therein.

In addition to partially forming the mixing chamber 56, the disk 42 also defines a partial annular groove or opening 50 therein to allow fluid (and its component parts) to flow into the mixing chamber. The annular opening 50 may take on a variety of configurations, such as the configurations shown in fig. 7A, 7B, and 45A-45I. According to one approach, as shown in fig. 7A and 7B, the disc 52 includes four openings. In another embodiment, as shown in fig. 45A, the tray 1242 has two openings. In further examples, fig. 45B includes three annular openings 1250, while the example of fig. 45C includes five openings 1350. Fig. 45D shows an exemplary disc 1442 having six openings 1450, while fig. 45E shows an exemplary disc 1542 having seven annular openings 1550. The exemplary disc 1642 shown in fig. 45F includes eight annular openings 1650 and offset pinholes 1648, whereas the pinholes in fig. 45A-45E and 45G-45I are centrally disposed in the disc shown therein. Furthermore, the corners of the annular openings shown in FIGS. 7A, 7B, and 45A-45F are rounded without any sharp edges or pinch points, while the openings shown in FIGS. 45G-45I have less rounded openings 1750, 1850, and 1950. These features may be combined in various ways.

Fig. 47A-47I also illustrate some exemplary trays having various features that may be helpful in managing the flow of fluid from the bottle and through the cap. As noted above, bottles are often stored and/or used in a top-down position, such that slurry separated in the chamber may leak from the bottle, in part because it may not advance through an exceptionally long flow path or time to mix back into the fluid before being removed from the cap.

To facilitate the mixing of any separated slurry with the rest of the fluid, the tray may contain some additional features, such as additional openings provided inside its flange. In an illustrative embodiment, the openings are between the annular groove and the center of the disk, which may have a central pinhole as described above. One illustrative disk 2042 shown in fig. 47A includes an annular opening 2051 that is within the flange 2054, itself within a larger annular opening or groove 2050. In this manner, there is a smaller interior opening 2051 adjacent the interior wall of flange 2054, facilitating mixing of the fluid and any separate constituent elements thereof. Fig. 47B and 47C also illustrate exemplary trays 2142, 2242 having adjacent flanges 2154, 2254 and annular openings or slots 2150, 2250 with intermediate or interior openings 2151, 2251, although the openings are differently configured in shape and size than fig. 47A and each other. Further, fig. 47C lacks a central pinhole, while fig. 47A and 47B include a central opening in the tray shown therein. In addition to these configurations, the pinholes may also be arranged offset from the geometric center of the tray, as suggested previously.

Fig. 47D-47F show additional illustrative embodiments of a disk having posts extending therefrom to promote mixing of fluids as they move through the cover. Once mounted or secured to the remainder of the cap, the post typically extends toward the outlet or opening of the bottle. For example, the example disk 2342 (fig. 47D) includes an annular opening 2350 and a centrally disposed post 2353, which are relatively smooth on their sides. The disk 2442 shown in fig. 47E includes an annular opening 2450, a flange 2454, and a central deployment post 2453. While post 2353 has a rounded exterior, post 2453 has uneven sides with a generally X-shaped configuration in cross-section.

Although the post is shown in a central configuration, it may be in an off-center configuration and multiple posts may be contained in the tray. Further, the posts may have various surface textures and configurations. Indeed, depending on the fluid moving in the cap, a variety of differently configured posts may be included in the cap.

In some constructions, instead of a post, the disc may have another similar structure, such as a cone. Fig. 47I shows a central portion of the disc 2842, the disc 2842 having a cone-shaped extension 2857 with an opening 2848 extending therethrough. In addition, the disk 2842 also includes an annular opening 2851, a flange 2854, and an opening 2850.

Disk 2542 of FIG. 47F, similarly having a centrally disposed post 2553, has a generally X-shaped cross-section and an annular opening 2550. However, rather than discrete flanges, the disk 2542 has a continuous one flange or cylindrical wall 2555 extending from the disk 2542. Although the cylindrical wall 2555 is shown as being generally perpendicular to the disk, it may also extend at an angle from the disk, similar to the manner in which the flange is not perpendicular as shown in fig. 46B.

Fig. 48 shows the disk 2542 secured to the rest of the cover 2518. Further, the post 2553 is shown extending at least partially into the inner shaft 2536. In this manner, fluid must be forced through the annular opening 2550, across or around the cylindrical wall 2555, across or around the end of the inner shaft 2536, and through the shaft along the post 2553 toward the opening 2534. Such a configuration, with some degree of intertwining of the flow channels, may be particularly suitable for certain fluids having particular fluid properties.

Other modifications or combinations of the features described herein may be made. For example, fig. 47G shows a disk 2642 similar to disk 2142 of fig. 47B, however, flanges 2654 are not as long as shown in fig. 47B, such that there is more movement space or clearance for fluid between flanges 2654 of fig. 47G than flanges 2654 in fig. 47B. Further, fig. 47H shows that outer annular opening 2750 in disk 2742 is contiguous with opening 2751, with no flange disposed therebetween. Many of the various structural features of the tray may be combined or modified in various ways, including those described herein, to adapt the tray to the characteristics of the fluid being propelled from the bottle through its lid.

As described above, the mixing chamber 56 and the opening in the disc 42 formed by the disc 42 and the inner shaft 36 allow for precise dispensing and metering of the fluid 5 within the container. Thus, the geometry of the disc 42 helps to promote proper distribution of the fluid 5.

Fig. 7A shows a first side of the disk 42, with the flange 54 of the disk 42 extending downward when the jar is inverted, and the disk 42 facing the inner axle 36 when the disk 42 is mounted in place between the securing ring(s) of the closure 18. Although the flange 54 may extend orthogonally from the face of the disk 42 (as shown in fig. 7C-7E), the flange 54 may extend at an angle other than 90 ° from the disk 42. Turning briefly to fig. 46A and 46B, two illustrative flange configurations are shown. Fig. 46A shows the flange 54 extending at about 90 ° from the main body of the disc 42, whereas in fig. 46B, the flange 54' extends at an angle of less than 90 ° from the main body of the disc 42. Such an angled flange may affect the flow of product 5 into the mixing chamber 56 and may affect the mixing action in the chamber. While both flanges shown in fig. 46A and 46B help to mix as the product advances toward the outlet, the angle of flange 54' shown in fig. 46B may be less than 90 deg. depending on the fluid characteristics of the product. As described above, the central pinhole 48 is centrally disposed through the planar portion of the disk 42, partially surrounded by a plurality of slots or partial annular openings 50. The peripheral partial annular opening 50 is significantly larger than the central needle aperture and the majority of the fluid 5 flowing from the bottle 10 is propelled through the partial annular opening 50. In some embodiments, the diameter D1 of disc 42 is 20mm to 40mm, 25mm-35mm, or about 30-34 mm. In one exemplary configuration, the diameter D1 of disc 42 is approximately 31.9mm 0.1 mm. According to one method, the arcuate length of the annular groove is 10-15mm, or 11-14 mm. As shown in fig. 7B, the arcuate length a1 of each opening may be about 12.7 mm. Further, the annular opening 50 has an inner radius of curvature R1 at the inner edge of the opening and an outer radius of curvature R2 at the outer edge of the opening. In one illustrative method, R1 is about 6-10mm and R2 is about 10-15 mm. In another illustrative method, R1 is about 8 to 9mm and R2 is about 12 to 13 mm. In one illustrative embodiment, R1 is about 8.3mm and R2 is about 12.3 mm.

As shown in fig. 6 and 7A, the partial annular opening 50 is disposed adjacent the flange 54, and when the disk 42 is installed in the base 20, the flange 54 extends into the mixing chamber 56 such that the fluid 5 (including any constituent, such as slurry) cannot be propelled directly through the opening 50 into the inner shaft 36 to exit the bottle, rather, a portion of the fluid 5 propelled through the opening 50 must flow into the mixing chamber 56 before the fluid exits the bottle 10 (thereby promoting mixing of any constituent from which the fluid 5 is separated). In one illustrative method, the extension or flange 54 has a height h1 of about 2-5 mm. In another illustrative method, the height h1 is about 3-4 mm. In one exemplary embodiment, h1 is approximately 3.5 mm. Further, in operation, the length or height of the flange 54 may be related to the depth of the channel 58 formed by the non-linear termination surface 38, as having these similarly sized helps promote mixing by requiring fluid to flow around the flange 54, rather than directly through the annular opening 50 and through the fluid channel 58. In one illustrative approach, the height h2 of the disk 42 is approximately 3-7 mm. In another illustrative method, the height h2 of the disk 42 is approximately 4-6 mm. In another illustrative method, the height h2 of the disk 42 is about 4.8 mm.

As shown in fig. 7D, in some embodiments, the width w1 of the planar portion of disk 42 is about 0.75mm to about 3 mm. In one illustrative method, the width w1 of the disc 42 is approximately 1-2 mm. In one illustrative method, the width w1 of the disc 42 is about 1.3 mm. The width of the central pinhole opening 48, shown as d2 in fig. 2, is about 1-2 mm. In one illustrative approach, the width d2 of the pinhole of the disk 42 is about 1.5 mm.

As shown in fig. 7E, each of the partial annular openings 50 may have a beveled edge on the surface of the disk 42 facing the base 20. This orientation may facilitate the flow of fluid 5 (e.g., at least a portion of the fluid that is not retained within the inner shaft 36) back into the container body 12 when the bottle is placed in a cap-side-up (upright) configuration. In addition, the beveled edge also facilitates moving air back into the bottle to improve bottle or container body 12 spring back.

To facilitate proper distribution of the fluid, the geometry of the disk 42 regulates the flow of the fluid 5, including, for example, the size, shape, and angle of the flange 54. In addition to the geometry discussed above, there are sufficient openings in the disc 42 relative to the area of the disc 42 to promote adequate flow of the fluid 5 while preventing leakage of the closure 18. The opening 50 is of a particular size, shape and location to facilitate the flow of fluid, thereby allowing the bottle to be easily dispensed and quickly rebound. In one illustrative method, the entire area of the disk is about 800mm²The total area of the partial annular opening 50 and the central pinhole is approximately 211mm of this total area²Or about 26% of the total area of the disc. According to some methods, the total area of the openings of the disk will cover about 20-35% of the total area of the disk, and typically the area occupied by the partial annular openings will be much larger than the central pin holes.

In fig. 4, the flow of tomato paste during dispensing is shown as a dashed line. After dispensing, the flow of air into the bottle to replace the paste is shown as a thick solid line. The lighter solid lines show the flow of separated slurry from the stream 5, which flows into the mixing chamber 56 where it is mixed again into the stream 5.

In some illustrative methods, the cover 18 (e.g., the base 20, flip 22, and tray 42) is composed of a single material, such as polypropylene or other food grade plastic or polymer, or similar recyclable material. In operation, forming the lid 18 from a single material may increase the ease and likelihood of material recycling. According to some methods, a material having a particular surface tension may be selected. For example, the surface of the disk 42 (and potentially other interior surfaces of the closure) may be rougher or textured to provide flow resistance and help control the flow of the fluid being dispensed. As discussed below, the inner surface of the inner shaft 38 may also be textured to inhibit flow or may have a smooth surface to promote movement of fluid therein. A smooth surface may result in faster and/or more difficult to control fluid flow and may also result in leakage of the product or separated components of the product due to a reduction in surface tension. Surface treatment of the material or manner of formation of the element may also affect the surface tension of the element and help facilitate control of fluid flow. For example, portions of the flip cover 18 may form a roughened surface so that the flow of fluid 5 therethrough may be affected.

Turning briefly to fig. 38, two different exemplary finished surfaces 77 and 79 are shown. While a single interior wall 78 may have portions of a single texture or surfaces having different textures throughout its surface, the cover 2018 shown in fig. 38 has a first portion 2078 with a rougher texture and a second portion 2178 with a smoother texture. As mentioned above, the surface of the material forming the cap 18 may inhibit, slow or restrict the flow of the liquid 5 within the bottle. Whether a textured surface is included on a portion or the entire cap, such as an inner wall of the inner shaft, may depend on the type of fluid being advanced through the cap 2018.

As shown in fig. 6, a first side of the disc 42 (disposed adjacent the inner shaft 36 of the base 20 when installed) includes a rainbow or arcuate flange or extension 54 extending therefrom. When the disk 42 is installed in the base 20, an arcuate flange or extension 54 extends into the mixing chamber 56 and toward the base 20. The disc extension 54 facilitates mixing of the fluid 5 in the mixing chamber 56 by moving the fluid 5 around the extension 54 rather than directly into the fluid passage 58 from the partial annular opening 50.

As shown in FIG. 8, the base 20 at the opening 34 and the inner shaft 36 has internal tabs or ledges 60 on the interior surface adjacent the opening, wherein the inner diameter of the inner shaft decreases sharply. For example, the diameter of the inner shaft may decrease sharply at the ledge 60, such that the sharp edge helps to facilitate reducing tail formation of the product by retaining a portion of the product in the closure until manual pressure against the container body becomes great enough to overcome the tendency of fluid to be retained in the closure by the ledge. According to one method, the blocking sheet has sharp edges without burrs. In some configurations, the diameter of the opening into the container is smaller than the diameter of the inner shaft, and this reduction in size and the relatively sharp edges therebetween help to stop dispensing in a quick and clean manner. Although such a blocking tab does not prevent the product from flowing out of the opening of the closure, it reduces the amount released under a certain pressure by slowing down the flow rate. According to one method, the blocking tab is relatively small compared to the diameter of the shaft, and the opening into the container itself is between about 3.5mm and about 4.5mm, and in one illustrative embodiment about 4 mm.

As described above, the inner shaft 36 can help support the disk 42 when the disk is attached to the base 20. According to one method, an inner wall or inner wall 78 of the inner shaft 36 leaks the fluid 5 towards the opening 34. In one embodiment, the interior wall 78 forms at least one of a circular or parabolic shape. Fig. 11 shows an example shape of the inner wall 79, which narrows slightly near the exit of the inner shaft 36. Further, in some embodiments, the shaft 36 may again be flared adjacent the opening 34. By flaring a little where the opening meets the upper surface of the base, the opening allows the projection 90 to be more easily and quickly placed in the opening 34 when the flip 18 is closed. In another configuration shown in fig. 12, the inner wall 78 has a substantially vertical straight portion and then an angled portion to direct the fluid 5 toward the opening 34. Fig. 13 is similar to the inner shaft 36 of fig. 12, but further includes a diameter-wise sharp reduction in the stop tab 60 or the inner shaft 36 to assist in stopping the dispensing of the fluid 5, as described above. Additional examples of blocking tab configurations or internal projections around the opening are shown in fig. 14 and 15. Fig. 14 shows the opening 134 with the blocking tab 160 having an interior surface that is slightly downwardly inclined or directed toward the through opening without a horizontal ledge extending from the interior surface, whereas fig. 13, discussed above, includes a downwardly inclined portion but with a horizontal blocking tab 60 extending therefrom. Further, fig. 15 shows the opening 234 having a blocker plate 260 with an interior surface angled away from the through opening.

Fig. 16 and 17 show two options for the configuration of the dome or surface of the container outside the opening 34. For example, FIG. 16 shows a rounded edge where the central portion 30 meets the opening 34. Fig. 14 and 15, discussed previously, have angled recesses around the opening at this location. Further, fig. 17 shows that there is a recess 161 with an inclined wall surface between the central portion 30 and the opening 34.

The bottle 10 and closure 18 can be produced in a number of different ways. In one illustrative method, a method of manufacturing or producing a filled bottle for dispensing a fluid includes molding a container, such as a container body having a threaded neck, filling the container with a fluid, such as a thixotropic fluid, molding a closure having a base, a flip top, and a disc, and closing the filled container with the closure. Further, the bottles may be formed and filled on a flow line, or may be formed at one location and filled at another location.

According to one method, the cover and tray are molded separately and snapped together. In some constructions, the molded base has an inner skirt and an outer skirt, the inner skirt configured with base threads configured to engage threads of a neck of the container. In addition, the molded base may have one or more retaining rings and a central dome-shaped portion on the inner skirt (at a short distance from the threads) with an opening therein aligned with the inner shaft terminating in a non-planar end surface opposite the central dome-shaped portion. As described above, the opening in the base allows fluid to flow out therethrough without obstruction of the opening. In some configurations, the molded flip cap has an internal protrusion that is movable between a first position in which the protrusion blocks the opening of the base from fluid within the container body and a second position in which fluid is allowed to flow out through the opening of the base.

As described above, in some methods, the cover and the tray are molded separately and then secured to one another or snapped together. In such a configuration, the manufacturing method may further include an assembly step that orients the tray in a particular position relative to the remainder of the cover or base 20. By including one or more orientation steps prior to assembling the disc with the rest of the closure, the assembled closure is more likely to have a constant flow rate therein. Furthermore, in some configurations, by adjusting the relative positions of certain elements of the cap or disk, the flow rate can be adjusted for different fluids without changing the structure of the cap or disk. By one approach, visual indicia or indentation disposed on one or both of the lid or tray can be used to assist in positioning the tray and/or lid relative to each other.

This may depend in part on the configuration of its various elements. In one illustrative example, such as the base 20 of fig. 5, the non-linear termination surface 38 of the inner shaft 36 includes three cutouts, while the disk 42 of fig. 6 includes four flanges 54. The flow of fluid through the assembled closure may be affected by the orientation of the flange 54 relative to the cutout opening of the inner shaft 36. Thus, the two structural elements may be oriented relative to each other to promote increased fluid flow therebetween or to slow fluid flow by causing the fluid outlet to the bottle to take a longer path. In view of the interest in standardizing the flow path of the fluid or the flow rates of numerous closures, the method of manufacturing or assembling the closures and bottles may include orienting the disk relative to the remainder of the closure in a particular manner.

As mentioned above, the method of producing a filled bottle may comprise snapping the disc into the retaining ring of the closure. In some configurations, the molded disc includes a central pinhole and a partial annular groove disposed around the central pinhole. Once the disc is attached to the remainder of the closure 18, the disc 42, the central portion of the base 20, the inner skirt 26, and the inner shaft 36 of the base define a mixing chamber 56, with a plurality of fluid passages 58 formed by the inner shaft 36 and the non-planar end surfaces of the disc 42. A passage 58 formed between the end of the inner shaft 36 and the disc 42 allows fluid to be advanced from the mixing chamber 56 to the slide formed by the inner shaft 36 in communication with the opening 34.

The filled container or container body, in some configurations, is sealed from fluid therein by a gasket associated with the closure. For example, a liner, such as a liner of paperboard, plastic, and/or metal material, is associated with a portion of the securing ring, which seals the fluid 5 in the container when the closure 18 is threadably attached to the container body.

Further, in some methods, a method of manufacturing a cover includes forming a flip-top cover including a base and a flip-top lid in a mold. In some embodiments, the shaped base has: a dome-shaped wall having an opening therethrough and an inner shaft extending therefrom; an inner skirt with threads thereon; an outer skirt joined to the inner skirt by a planar portion and/or possible ribs; and a securing ring on the inner skirt. The inner shaft of the molded base generally extends inwardly from the dome-shaped wall and terminates at a non-planar end surface. The molded closure also has a flip top hingedly connected to the base, wherein the flip top has an internal protrusion and is movable from a first position in which the internal protrusion blocks the opening to a second position in which the internal protrusion does not block the opening of the base. In some configurations, the method of manufacturing the cover further comprises snapping the tray into a securing ring or protrusion of the base. In some embodiments, the disc has: a central pinhole; a local annular groove disposed around the central pinhole; and a flange extending toward the base and disposed between the inner shaft and the partial annular groove when installed. Once the disc and base are attached, a mixing chamber is formed between the disc, dome-shaped wall, inner skirt and inner shaft, with a plurality of fluid passages formed by the inner shaft and the non-planar end surfaces of the disc.

In some configurations, the cover is made of only two separate components, including the flip cover and the tray, wherein the flip cover includes a base and a flip cover formed as a single, unitary, one-piece structure, and wherein the two separate components (i.e., the flip cover and the tray) are made of the same material and are assembled. In operation, after the cover is molded and ejected from the mold, the tray can be mechanically assembled into the cover (either in the same mold as the base and flip cover or in a different location), for example, by snapping it into place in the base. In addition, the mechanism or another device may be used to attach the liner to the securing ring, which may help seal the fluid in the bottle. In some configurations, the base and flap are molded in the same mold as the tray; in other constructions, the tray is molded separately from the base and flap in the same mold. Furthermore, the base and the tray may be formed and assembled separately at additional stations. In other constructions, the entire cover (including the base, flip cover, and tray) may be molded or printed together.

As noted above, some modifications may be made to the concepts described herein while remaining consistent with these teachings. For example, fig. 18 and 19 show another embodiment of a disk having an annular opening. As shown, the disc 342 has a central portion 384 disposed at a vertical distance from a peripheral portion 386 having an annular opening 350 disposed therein. In such a configuration, the volume of the mixing chamber 356 may be designed to be somewhat independent of the discharge shaft or chamber formed by the inner shaft 356. In fact, the mixing chamber 356 is smaller than the other mixing chambers discussed above. To allow fluid 5 to flow from mixing chamber 356 to inner shaft 356 forming a discharge chamber, the radius of central portion 384 may be large enough compared to the radius of inner shaft 336 to provide clearance for fluid 5 to flow from mixing chamber 356 through an opening or fluid passage 358 formed between inner shaft 336 and mixing chamber 356, and/or opening 358 may extend to have a height or position that exceeds the vertical portion of disc 342, which disc 342 may be disposed adjacent inner shaft 336. In short, the opening between the mixing chamber 356 and the inner shaft 358 can be moved or sized to allow fluid flow even if the central portion 384 is not significantly larger than the inner shaft. Further, while the central portion 384 is shown in fig. 18 and 19 as lacking a central pinhole, in some configurations, the central portion 384 may include a vent formed via a pinhole or other structure. Further, the disc 342 may mate with the remainder of the cover in any manner, such as via a snap fit between portions of the base, including ribs and/or protrusions or other complementary geometries between the disc and the base. Fig. 20 and 21 illustrate another example of a disc 442 that lacks the central pinhole 48 in some other embodiments. Additionally, while fig. 18 and 19 do not include a flange similar to that described above, the vertical portion of the disc separates the central portion 384 and the peripheral portion 386, which operates similarly to the product being mixed therein.

Turning to fig. 22 and 23, another embodiment is shown which is a three-part solution with a flat disc 542 and an inner cover or inner cylindrical housing 596. By one approach, the inner cylindrical housing 596 includes a circular wall 592 having one or more openings 598 disposed therein. In this manner, the mixing chamber 556 is in fluid communication with an intermediate chamber 594 defined in part by the inner cylindrical housing 596. By one approach, the inner cylindrical housing 596 is placed in position around the inner shaft 536 and placed in position via a disc 542, the disc 542 being secured in place by a securing member 544, such as a ring. Further, the inner cylindrical housing 596 may also be securely attached to the central portion 530. When the inner cylindrical housing 596 is disposed in place about the inner shaft 536, fluid 5 is advanced from the bottle to the outlet or opening 534 through the annular opening 540, the opening 598 of the inner cover 592, and up through the inner opening 588 of the inner shaft 536 along the length of the inner shaft 536 and down the shaft to the outlet opening 534. As shown, the disk 542 includes an annular opening 540, but lacks a central pinhole because the inner cylindrical housing 596 lacks openings on its surface between the walls 592. In this manner, fluid 5 will travel and mix as it advances through the fluid passage of the three-part cap 518. In addition to mixing, this configuration may be particularly useful for larger containers because the downward force of the fluid is considerable when the container is inverted, as there may be a large amount of product placed over the cap.

In addition, although fig. 20-23 are not shown as including a flange extending from the disc, in some configurations, the disc may include a flange similar to that described above.

The outer shape of the central portion of the base may also have various configurations. As noted above, the central portion 30 of the base 20 may have a dome-shaped configuration, such as that contained in the tray 18 shown in fig. 24. Fig. 25 shows a partial cross-section of the outlet 34 of the dome-shaped central portion 30 of fig. 24. In addition, fig. 26 further illustrates the dome-shaped central portion in cross-section. While the domed central portion 30 of the base 20 provides an easy-to-wipe clean surface, other configurations having similar properties may also employ the teachings described herein. For example, fig. 27-29 illustrate another exemplary embodiment, the cover 618 having a central portion 630 with a generally volcano-shaped sloped wall and an opening 634 disposed in the center thereof. In addition, fig. 30-32 illustrate another embodiment, including a cover 718 having a swinging center portion 730 and an opening 734 therein, wherein several flat surfaces surround the outside of the opening 734. In addition, while the exemplary shapes shown in fig. 24-32 illustrate openings having exemplary blocking tabs, these different shapes may be combined with other opening shapes and aspects described herein.

As described above, the mixing chamber described herein allows for the separated slurry to be incorporated or mixed back into the fluid before the fluid and/or portions thereof are discharged from the opening of the container lid. By one approach, the desired size of the mixing chamber may depend in part on the viscosity or other fluid properties of the fluid or product in the container. By one approach, the size of the mixing chamber 56 is dependent in part on the size of the inner shaft 36, the position of the disc 42 being determined via the corresponding geometry of the base, and/or the configuration of the disc, as described above. Turning briefly to fig. 33 and 34, two differently sized mixing chambers 56 and 56' are shown. Although the assembly is similar, the wall forming the inner shaft 36 is longer in fig. 34 than the wall of the shaft 36 ' in fig. 33, and the corresponding geometry (e.g., the securing ring 44 ') is disposed at a greater distance relative to the central surface 30 ' of the base 20 ' than the corresponding geometry (e.g., the securing ring 44) is to the central surface 30 of the base 20 '. Although the relative dimensions of these components may vary, as shown, their function is still present; that is, the mixing chamber helps to prevent the separated slurry from leaking from the bottle separately from the rest of the fluid product 5.

As described above, the inner wall 78 of the inner shaft may have a cross-section that forms a different shape, e.g., circular or elliptical, etc. Further, the shape or configuration of the inner wall 78 formed along its length may take on a variety of configurations. For example, as shown in fig. 4, 14, and 15, the inner shaft 36, 136, 236 can have a substantially linear inner wall 78 along the height of the inner shaft 36. In other embodiments, the inner shaft 36 may have one or more non-linear inner walls 78. In one embodiment, fig. 35 shows an inner wall 878 of the inner shaft 836 that is angled toward the opening 834. According to one approach, the downward angle provides a cross-section having a V-shaped configuration. In another embodiment, fig. 36 shows that the inner wall 978 of the inner shaft 936 has a downward slope that is slightly non-linear. According to one approach, the downward slope provides a cross-section having a modified u-shape. In another embodiment, fig. 37 shows the inner shaft 1036 having an inner wall 1078, the inner wall 1078 having a stepped configuration narrowing in diameter in a stepped manner.

Those skilled in the art will recognize that a wide variety of other modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.