Container, closure and method of manufacture

Abstract

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 cap includes a flip-top, a base, and a disc, wherein the base and disc define a mixing chamber configured to facilitate mixing of any slurry or liquid separated from the fluid back into it. In certain configurations, the base has a central opening through which the fluid exits and an inner shaft with 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 includes a central opening, a plurality of partial annular openings through a planar surface of the disc, and a protrusion extending into the mixing chamber.

Description

[0001] This application is a divisional application of HJ Heinz Brand GmbH's invention application CN201980092488.6 (PCT / US2019 / 067485) entitled "Container, Closure and Method of Manufacturing", filed on December 19, 2019. Technical Field

[0002] This disclosure generally relates to containers for fluids. More particularly, this disclosure generally relates to containers with caps. Background Technology

[0003] Fluid containers can occasionally experience dispensing and leakage issues, especially during transport and / or when placed in certain configurations. Many bottled consumer products may have this drawback. For example, thixotropic fluids, such as ketchup or certain liquid soaps, are sometimes sold in bottles that use flexible plastic diaphragm valves with an "X" shaped slit. These bottles are sometimes used as inverted containers that rest on the caps when not in use, allowing gravity to hold the product in place near the valve.

[0004] One problem with this type of valve is that, in certain situations, product may leak through the valve when the bottle is not in use. Another problem is that product may be ejected from the opening at unintended high speeds during dispensing, increasing the risk of splashing. High-speed product ejection also makes proper metering difficult, as control over the product is often insufficient at high speeds. A third problem is that the valve may resist or prevent air inflow to maintain the internal volume after dispensing, resulting in subatmospheric pressure, i.e., a partial vacuum, inside the bottle. This can lead to panelization, i.e., warping, or other undesirable inward deflection of the container walls, which can cause both aesthetic and functional problems, as it may increase the manual pressure required to dispense the product and may result in response squeezing, i.e., uneven or inconsistent dispensing due to manual pressure applied to the outside of the container.

[0005] Another issue is that these membrane valves are typically made of silicon, while the rest of the cap is usually made of another material, such as polypropylene. Making the cap composed of multiple materials increases manufacturing complexity and cost, and may make recycling difficult and / or impractical, thus reducing the appeal of this approach for large-scale use.

[0006] Furthermore, these membrane valves and other similar solutions do not always adequately address the product separation problems that frequently occur in fluids, such as when slurries, water, or other relatively low-viscosity thin liquid components separate from the rest of the fluid, such as tomato sauce. This separation increases leakage, splashing, and causes the thin liquid component to separate and distribute from the rest of the product. Summary of the Invention

[0007] To overcome the shortcomings of the prior art, the present invention provides a cap for a container, the cap comprising a base, a flap, and a disc. The base has at least a central portion with an opening, an inner skirt, an outer skirt connected by a planar portion, threads and a retaining ring located on the inner skirt, and an inner shaft extending inward from the central portion and terminating at a non-planar end surface. The flap is hinged to the base, has a protrusion, and is movable between a first position where the protrusion obstructs the opening and a second position where the protrusion does not obstruct the opening. The disc is attached to the interior of the base and fixed about the inner shaft. A mixing chamber is defined by the disc, the central portion, the mixing chamber wall, and the inner shaft, wherein at least one fluid passage is formed by the non-planar end surface of the inner shaft and the disc, the at least one fluid passage allowing fluid to flow from the mixing chamber into the inner shaft; when the disc is attached to the base, the disc remains stationary relative to the base.

[0008] Furthermore, the present invention provides a method for manufacturing a cap, the method comprising the steps of: forming a flip cap in a mold, the flip cap comprising a base and a flip cap. The base has at least a central portion with an opening, an inner skirt, an outer skirt connected by a planar portion, threads and a retaining ring located on the inner skirt, and an inner shaft extending inward from the central portion and terminating at a non-planar end surface. The flip cap is hinged to the base, has an internal protrusion, and is movable between a first position where the protrusion obstructs the opening and a second position where the protrusion does not obstruct the opening. The method further comprises securing a disc to the base of the flip cap, such that the disc is positioned about the inner shaft; wherein the disc and the base together form a mixing chamber defined by the disc, the central portion, a mixing chamber wall, and the inner shaft, wherein at least one fluid passage is formed between the mixing chamber and the inner shaft via a non-planar end surface of the inner shaft; once the disc is attached to the base, the disc is stationary relative to the base.

[0009] Furthermore, the present invention provides a cap comprising a base, a flap, and a disc. The base has at least a central portion with an opening, an inner skirt, an outer skirt connected to the central portion, threads on the inner skirt, and an inner shaft extending inward from the central portion and terminating at a non-planar end surface. The flap is hinged to the base, has a protrusion, and is movable between a first position where the protrusion obstructs the opening and a second position where the protrusion does not obstruct the opening. The disc is attachable to the interior of the base and fixed about the inner shaft, the inner shaft supporting the disc when the disc is attached to the base. A mixing chamber is formed by the disc, the central portion, the mixing chamber wall, and the inner shaft; at least one fluid channel is formed between the mixing chamber wall and the space inside the inner shaft, the at least one fluid channel being partially formed by the inner shaft and the non-planar end surface; when the disc is attached to the base, the disc is stationary relative to the base.

[0010] Furthermore, the present invention provides a cap for a container, the cap comprising a base, a flap, and a disc. The base has at least a central wall with an opening, an inner skirt, an outer skirt connected to the inner skirt by a planar portion, threads, and an inner shaft extending inward from the central wall and terminating at a non-planar end surface. The flap is hinged to the base, has a protrusion, and is movable between a first position where the protrusion obstructs the opening and a second position where the protrusion does not obstruct the opening. The disc is attached to the interior of the base by snapping into it, the disc having one or more flanges extending from the disc toward the base, a centrally located post, and a plurality of openings therethrough. A mixing chamber is defined by the disc, the central wall, the inner skirt, and the inner shaft, wherein a plurality of fluid channels are formed by the non-planar end surface of the inner shaft and the disc.

[0011] Furthermore, the present invention provides a cap for a container, the cap comprising a base, a flap, and a disc. The base has at least a centrally located wall with an opening, an inner skirt, an outer skirt connected to the inner skirt by a planar portion, threads, and an inner shaft extending inward from the wall and terminating at a non-planar end surface. The flap is hinged to the base, has a protrusion, and is movable between a first position where the protrusion obstructs the opening and a second position where the protrusion does not obstruct the opening. The disc is connected to the interior of the base by snapping into it, the disc having a plurality of annular grooves and a plurality of intermediate openings therethrough, wherein the intermediate openings are located between the plurality of annular grooves and the center of the disc. A mixing chamber is defined by the disc, the wall, the inner skirt, and the inner shaft, wherein a plurality of fluid channels are formed by the non-planar end surface of the inner shaft and the disc. Attached Figure Description

[0012] This document discloses embodiments of systems, apparatus, and methods relating to containers, closures, and manufacturing methods. This description includes accompanying drawings, in which:

[0013] Figure 1A This is a perspective view of a bottle with a cap according to some embodiments.

[0014] Figure 1B yes Figure 1A A cross-sectional view of the bottle in an inverted position.

[0015] Figure 2 This is a perspective view of the cap and a portion of the bottle according to several embodiments.

[0016] Figure 3 yes Figure 2 A three-dimensional view of the cover under the open structure.

[0017] Figure 4 It is a three-dimensional cross-sectional view of a portion of the cover in an inverted orientation.

[0018] Figure 5 This is a perspective view of the bottom surface of a cover according to some embodiments, from which the disc is removed.

[0019] Figure 6 This is a perspective view of the bottom surface of the disk according to several embodiments.

[0020] Figure 7A and 7B These are top and bottom plan views of the disk according to several embodiments.

[0021] Figure 7C yes Figure 7A and 7B A bottom-view side view of the disk.

[0022] Figure 7D It is along Figure 7B The cross-sectional view of line DD.

[0023] Figure 7E It is along Figure 7B The cross-sectional view of line EE.

[0024] Figure 8 This is a three-dimensional cross-sectional view of the cover in a closed configuration according to several embodiments, with the disc removed therefrom.

[0025] Figure 9 This is a perspective cross-sectional view of a portion of the cover according to several embodiments, without a disc attached to the cover.

[0026] Figure 10 This is a perspective cross-sectional view of a portion of the cover according to several embodiments, without a disc attached to the cover.

[0027] Figure 11 This is a three-dimensional cross-sectional view of a portion of the cover according to several embodiments.

[0028] Figure 12 This is a cross-sectional view of a portion of the inner axis at the opening of the cover according to several embodiments.

[0029] Figure 13 This is a cross-sectional view of a portion of the inner axis at the opening of the cover according to several embodiments.

[0030] Figure 14 and 15 This is a partial cross-sectional view as part of an alternative embodiment.

[0031] Figure 16 and 17 This is a partial cross-sectional view of a cover according to a portion of several embodiments.

[0032] Figure 18 This is a three-dimensional cross-sectional view showing a portion of the cover of an alternative embodiment.

[0033] Figure 19 yes Figure 18 A cross-sectional view of an embodiment.

[0034] Figure 20 This is a three-dimensional cross-sectional view showing a portion of the cover of an alternative embodiment.

[0035] Figure 21 yes Figure 20 A cross-sectional view of an embodiment.

[0036] Figure 22 This is a three-dimensional cross-sectional view showing a portion of the cover of an alternative embodiment.

[0037] Figure 23 yes Figure 22 A cross-sectional view of an embodiment.

[0038] Figure 24 This is a side view of the lid in an open configuration according to several embodiments.

[0039] Figure 25 and 26 yes Figure 24 A partial cross-sectional view of the cover.

[0040] Figure 27 This is a side view of the lid in an open configuration according to several embodiments.

[0041] Figure 28 and 29 yes Figure 27 A partial cross-sectional view of the cover.

[0042] Figure 30 This is a side view of the lid in an open configuration according to several embodiments.

[0043] Figure 31 and 32 yes Figure 30 A partial cross-sectional view of the cover.

[0044] Figure 33 and 34 This is a cross-sectional view showing the alternative mixing chamber.

[0045] Figures 35-37 This is a partial cross-sectional view showing an alternative inner shaft according to several embodiments.

[0046] Figure 38 It is a cross-sectional view of the cover with magnified details to show the various finishing options for the inner shaft.

[0047] Figures 39-44 This is a partial perspective view, in which a portion is removed to show an alternative embodiment of the inner axis of the base.

[0048] Figure 45A-45I This is a top plan view of an alternative embodiment of the disk.

[0049] Figure 46A and 46B This is a cross-sectional view of an alternative embodiment of the disk.

[0050] Figure 47A-47I This is a perspective view of the bottom surface of an alternative embodiment of the disc.

[0051] Figure 48 This is a three-dimensional cross-sectional view of a portion of an alternative cover according to several embodiments.

[0052] For simplicity and clarity, all elements are shown in the figures, and these elements are not necessarily drawn to scale. For example, the size and / or relative position of some elements in the figures may be exaggerated relative to other elements to aid in understanding the various embodiments of the invention. Additionally, common but well-understood elements that are useful or necessary in commercially viable embodiments may be omitted to provide a less obstructive view of these different embodiments of the invention. Certain actions and / or steps may be described or depicted in a particular order of occurrence, but such specificity relative to the order is not actually required. The terms and expressions used herein have the ordinary technical meaning that those skilled in the art would assign to them, unless otherwise specified herein. Detailed Implementation

[0053] This document describes systems, apparatus, and methods for dispensing fluids, such as thixotropic fluids, from bottles. Some embodiments include a cap for such bottles. The cap may include a flipper, a base, and a disc, wherein the base and disc define a mixing chamber configured to facilitate mixing of fluids, such as mixing slurries or mixing liquids separated from the fluid and returning them therein. In some configurations, the base has a central opening through which fluid flows out, and also has 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 channels between the mixing chamber and the interior of the shaft. (In other configurations, the shaft may have a planar end surface opposite the opening, and the shaft may have a hole formed therein.) In some embodiments, the disc includes a central opening, a plurality of partially annular openings through the planar surface of the disc, and a protrusion extending into the mixing chamber. To exit the bottle, fluid advances from a reservoir or bottle body, through openings in the disc (e.g., partially annular openings or a central pinhole), and exits from the central opening of the base through a slide formed by the inner shaft. Fluid moves through these openings and channels by the user applying manual pressure to the bottle.

[0054] In some embodiments, the dispensing bottle includes a container body having an external thread on the neck that engages with an internal thread on a cap, the cap including a base and a flap. In one illustrative embodiment, the base of the cap has a skirt with base threads configured to engage with the external thread on the neck of the bottle. Furthermore, in some embodiments, the base includes one or more retaining elements, protrusions, or rings located on an inner surface of the base (such as the inner surface of the skirt), and a central portion having an opening aligned with an inner shaft, allowing fluid to flow out when the opening is unobstructed. According to one method, the inner shaft terminates on a non-planar end surface opposite the central portion. Additionally, the inner shaft may have a disc mounted adjacent to it.

[0055] As previously described, the cover has a flap, and in one illustrative configuration, the flap has an internal protrusion movable between a closed first position and an open second position, wherein the protrusion blocks an opening in the base, preventing or inhibiting fluid outflow from the container body in the first position, and allowing fluid to flow out through the opening in the base in the second position. Furthermore, in one illustrative embodiment, the disc is attached to the interior of the base by engaging with (some) retaining rings, the disc having a central pinhole and a partially annular groove surrounding the central pinhole. In an exemplary configuration, the mixing chamber is formed by the disc and the central portion of the base, as well as a skirt and an inner shaft. Additionally, in some configurations, multiple fluid channels are formed by the non-planar end surface of the inner shaft and the disc allowing fluid to flow from the mixing chamber to the inner shaft.

[0056] In some embodiments, when the bottle is in the inverted position such that the bottle opening is positioned below the body of the container, the cap in the closed position allows the thixotropic fluid to maintain a stable equilibrium within the bottle without leakage. In some embodiments, when the cap is in the open position, the cap is configured to control the distribution of the thixotropic fluid during pressure application to the container body, and the release of pressure on the container body causes the distribution to stop rapidly, for example, by allowing air to flow back into the container body, causing the bottle to spring back and reversing the flow of the thixotropic fluid in the internal channels. Furthermore, in an illustrative configuration, this does not require movement of the disc relative to the base. According to one method, springback is achieved by allowing air to rapidly enter the bottle to replace the distributed fluid volume, which allows the bottle to quickly return to its original shape.

[0057] In one illustrative method, before leaving the dispensing bottle via the central opening, at least a portion of the fluid is propelled downwards through a partial annular opening, through a mixing chamber, then inwards through a fluid channel defined between the non-planar ends of the disc and the inner shaft, and then downwards through the interior of the shaft. According to one method, thixotropic fluid disposed in the bottle can be expelled from the bottle before moving through the channel formed by the ends of the inner shaft and the disc and exiting from the central opening at the base, propelled through a partial annular groove in the disc and through the mixing chamber, where any separated slurry can be mixed into the fluid. Additionally, a portion of the fluid can also be propelled downwards through a small hole or pinhole in the disc and through the central opening at the base. As described above, in operation, the bottle is able to rapidly return to its shape after the pressure is released. Air can flow into the bottle through one or both of these pathways, for example, through a pinhole in the disc and / or through the annular opening, allowing air to flow into the bottle through the inner chamber, channel, pinhole, mixing chamber, and / or partial annular groove. Generally, air is drawn into the bottle when the pressure on the body or container of the bottle is released. Therefore, in short, air flows into the main cavity of the bottle through at least one central pinhole or local annular groove in the disc. Furthermore, once the disc is mounted onto the base of the cap, the disc remains stationary relative to the base according to a specific method.

[0058] In some embodiments, the cap, including the base, flap, and disc, is generally made of polypropylene, allowing the entire cap to be recycled as a unit. Furthermore, due to the absence of a silicone membrane, in some embodiments, the strength of the seal does not significantly decrease over time, and its performance shows almost no degradation. In some embodiments, the pressure required to dispense fluid from the bottle remains virtually unchanged throughout the bottle's entire lifespan.

[0059] As described herein, capping allows for better metering. It prevents product from being accidentally ejected from the bottle at high speed, which could result in a chaotic ejection, and prevents permanent collapse or other permanent inward deformation of the bottle. Furthermore, the capping design reduces splashing. Additionally, as described below, the mixing chamber can be configured to facilitate the cleaning of its external surfaces, for example, by having an outwardly convex or dome-shaped external surface.

[0060] According to one method, the outer, bottom (when the bottle is inverted) surface of the base, adjacent to a central opening through which fluid is dispensed, has an arcuate or dome-shaped central portion surrounded by a planar peripheral surface. In one example, the interior of the base has an inner shaft extending at least partially parallel to the skirt of the base. In some configurations, the base includes an inner baffle disposed adjacent to the central opening, wherein the inner diameter of the inner shaft decreases sharply. According to one method, the baffle has sharp edges without burrs. In some configurations, the inner diameter of the opening itself differs from that of the inner shaft wall. More particularly, in such configurations, the diameter of the opening entering the container is smaller than the diameter between the inner shaft walls; this reduction in size and the relatively sharp edges therebetween help to reduce product tail formation by retaining a portion of the product at the seal. Additionally, surface tension and the size of the opening also contribute to reducing product tail formation. While such a baffle does not prevent product from flowing out of the cap opening, it reduces the amount released under pressure by slowing the flow rate. According to one method, the diameter of the blocking tab is relatively small compared to the diameter of the shaft. In some configurations, the width of the inner cutting tab is approximately 1 mm, while the diameter of the opening into the container itself is approximately 3 mm to approximately 7 mm. In another configuration, the diameter of the opening is approximately 3.5 mm to approximately 4.5 mm. In yet another embodiment, the diameter of the opening is approximately 4 mm, while the diameter of the inner shaft is approximately 6 mm. Accordingly, in some configurations, the blocking tab has a width of approximately 1 mm.

[0061] While the blocking disc helps to quickly stop liquid dispensing, 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 construction of the opening in the disc facilitates flow monitoring and, depending on the viscosity and surface tension of the product, the geometry of the disc can be adjusted to accommodate different fluids.

[0062] At the upper end of the inner shaft, 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 structure forming multiple teeth and recesses. According to another construction, the non-planar end surface has wavy, sinusoidal, or other arcuate recesses.

[0063] As described above, the bottles and caps presented herein can be used for a variety of fluids. In one illustrative configuration, the bottle is filled with a thixotropic fluid, such as certain condiments, sauces, or certain consumer products, such as shampoos or shower gels. This application can be particularly advantageous because it allows consumers or users to easily and quickly dispense the desired amount of fluid without spilling or otherwise causing accidental liquid spillage. According to one method, a dispensing bottle with a cap can have a capacity of approximately 250 mL to approximately 1000 mL. Furthermore, various container configurations are envisioned, including some containers stored in an inverted configuration where the bottle rests on the cap. In one illustrative method, the diameter of the disc is between approximately 20 and approximately 40 mm, the height of the inner shaft is between approximately 4 and approximately 12 mm, and the diameter of the inner shaft is between approximately 3 and approximately 9 mm. In other configurations, the height of the inner shaft is approximately 5 to approximately 9 mm, and the diameter is approximately 3 to 5 mm.

[0064] As described above, the cap has a mixing chamber formed by a portion of a base to which a disc is fixed. According to one method, the mixing chamber includes multiple extensions from the disc. More specifically, in some configurations, the disc includes multiple extending flanges that extend downward from the bottom of the disc (when the bottle is inverted) into the mixing chamber. The mixing chamber described herein helps prevent leakage of the slurry from the dispensing bottle, in part by remixing the slurry separated from the thixotropic fluid into the remainder of the thixotropic fluid. According to one method, the mixing chamber prevents leakage of the separated slurry from the bottle by mixing it back into the liquid before it leaves the bottle neck. In some embodiments, the capacity of the mixing chamber is, or retains, 2 mL to 11 mL, 3 mL to 9 mL, or 5 to 7 mL, or about 6 mL. The disc extensions can aid in the 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.

[0065] According to one method, multiple retaining rings may be provided, and one of these retaining rings may have an associated bottle or cap liner that can seal the bottle after the cap is attached thereto. For example, a first retaining ring and a second retaining ring may be spaced apart from each other in the axial (vertical) direction, with the edge of the disc captured between them. The upper ring (when the bottle is inverted) may have an associated removable film or liner member that seals the opening at the bottle neck before use. The consumer can manually remove the liner member before dispensing the product.

[0066] The capped bottles described herein can be formed, filled, and sealed in high-speed, high-capacity, large-scale production operations or other types of operations. In one method, the manufacture of a dispensing bottle typically includes forming a squeezable, flexible bottle, for example by blow molding, injection molding, or other methods; forming a disc and cap having a base and a flip-top by injection molding or other methods; snapping the disc into the base; filling the container with a fluid (e.g., a thixotropic fluid); and securing the cap to the filled container. In some embodiments, the base has an inner skirt and an outer skirt, the inner skirt having internal base threads (wherein the base threads are configured to engage with threads outside the neck), an internal retaining ring, and a central dome-shaped portion having an opening aligned with an inner axis and terminating on a non-planar end surface opposite the central opening. The dome-shaped portion includes an opening that allows fluid to flow out when unobstructed, while the flap has an internal protrusion that moves between a first position and a second position. In the first position, the internal protrusion blocks the opening of the base, inhibiting or preventing fluid outflow, while in the second position, the internal protrusion allows fluid to flow out through the opening of the base. In some embodiments, the disc has a central pinhole and a local annular groove surrounding the central pinhole, wherein the disc, the central portion of the base, the inner skirt, and the outer surfaces of the inner shaft define a mixing chamber, and wherein a plurality of fluid channels are formed between the non-planar end surface of the inner shaft and the disc. In some configurations, the method further includes sealing the container with a removable gasket associated with the cap to seal the product within the body of the bottle. As discussed further below, the base and flap can be molded together with or separately from the disc.

[0067] In one illustrative configuration, the cap for a container includes a flap and a base, the base having at least a dome-shaped wall with an opening therethrough, an inner skirt, an outer skirt connected by a top planar portion, threads on the inner skirt, and one or more retaining rings, and an inner shaft extending inwardly from the dome-shaped wall. According to one method, the inner shaft terminates at a non-planar end surface. Furthermore, in such a configuration, the flap has a protrusion and is movable between a first position and a second position, in which the protrusion blocks the opening, and in the second position, the protrusion does not block the opening of the base. In some configurations, the cap has a disc attached to the interior of the base by engaging the disc with (some) retaining rings. In such a configuration, the disc has a central pinhole, a partial annular groove disposed around the central pinhole, and a flange extending toward the base, which is disposed between the inner shaft and the partial annular groove when the disc is attached to the base. Further, according to one method, the cap includes a mixing chamber defined by the disc, the dome-shaped wall, the inner skirt, and the inner shaft, wherein a plurality of fluid channels are formed by the non-planar end surfaces of the inner shaft and the disc.

[0068] In another method, a method of manufacturing a cap includes forming a flip cap in a mold, the flip cap having (a) a base having at least a dome-shaped wall with an opening therethrough, an inner skirt, an outer skirt connected by a planar portion, threads and a retaining ring on the inner skirt, and an inner shaft extending inward from the dome-shaped wall, the inner shaft terminating at a non-planar end surface, and (b) a flip cap hinged to the base, the flip cap having an internal protrusion and movable from a first position where the internal protrusion blocks the opening to a second position where the internal protrusion does not block the opening of the base. Further, in some methods, the method further includes engaging a disc in a retaining ring in the base of the flip cap, the disc having a central pinhole, a partially annular groove surrounding the central pinhole, and a flange extending toward the base, the flange being disposed between the inner shaft and the partially annular groove when the disc 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 a plurality of fluid channels are formed by the non-planar end surfaces of the inner shaft and the disc.

[0069] Furthermore, in some configurations, the method also includes forming the cap into two separate components, including a flip cap and a disc, wherein the flip cap includes a base and a flip cover formed as a single, integral, unitary, one-piece structure, and wherein the two separate components are made of the same material and are assembled at a mold or separation station.

[0070] Figure 1A and 1B The illustration shows a packaged food product including a bottle 10 containing a liquid food 5 such as ketchup, mayonnaise, barbecue sauce, mustard, or other products, with a cap 18 via an internal thread 32 (e.g., see...). Figure 4 It is attached to the container body 12 by engaging with the external thread 16 of the container body 12. For illustrative purposes, Figure 1A A portion of the cap 18 is transparently shown in the middle. Although Figure 1A The bottle is shown in an upright position, but in some embodiments, the bottle 10 is configured for inverted storage, resting on its cap, such as... Figure 1B As shown. Therefore, during storage and distribution, bottle 10 can position the cap 18 below the container body 12 of bottle 10 without the liquid 5 accidentally leaking from bottle 10.

[0071] like Figure 2 and Figure 3 As shown, the cap 18 includes a base 20 and a hinged cap or flip cap 22. To open the bottle 10 and allow liquid 5 to be easily dispensed from it, the user can flip the cap 22 from... Figure 2 The closing structure pivots to Figure 3The opening mechanism is as follows. For this purpose, the user or consumer can apply an upward force to the cap 22 by engaging the spout-shaped notch 70 defined by the upper surface 72 and the lower surface 74. According to one method, the user will manually grasp and pull upward on the upper surface 72, pulling it away from the base 20 and the rest of the bottle 10. The cap 22 then pivots about the hinge 19 opposite the spout-shaped notch 70 to securely hold itself in the opening mechanism.

[0072] like Figure 3 As shown, when the flip cover 22 is in the open configuration, the protrusion 90 of the flip cover 22 moves away from the opening 34 in the base 20, thereby making the opening 34 unobstructed. Figure 3 Also shown is a central portion 30 and a planar portion 62 disposed at least partially around it; the central portion 30 may be dome-shaped, with an opening 34 extending through it. Figure 3 As shown in the illustrative embodiment, the lower surface 74 of the mouth-shaped recess 70 extends between the segments of the planar portion 62.

[0073] Figure 4 A three-dimensional cross-sectional view of a portion of the cap 18 in an inverted orientation is shown. (See figure) Figure 4 As shown, the base 20 includes: an inner skirt 26, an internal thread 32 and one or more retaining rings 44 disposed thereon; an outer skirt 28, a planar portion 62 therebetween; and a dome-shaped central surface 30 having an opening 34 disposed therein. Figure 4 One or more radial stiffeners or reinforcing ribs 76, as shown, are arranged between the outer skirt 28 and the inner skirt 26. Figure 4 and Figure 5 As shown in the illustrative configuration, the base 20 includes an upwardly extending portion away from the central dome-shaped surface 30 and terminating at a non-linear surface 38 (e.g., Figure 5 The inner shaft 36 (as shown).

[0074] In one illustrative embodiment, the cover 18 includes a disc 42 (e.g. Figure 4 and 6 As shown), it has multiple openings through which fluid 5 and air can flow. According to one method, a retaining ring 44 disposed on the inner wall of the inner skirt 26 holds the disc 42 in the middle. In another configuration (not shown), the disc 42 may be held between the retaining ring and another structure, such as a portion or extension of the inner shaft 36. Figure 4 A cross-section of a portion of the cap 18 is shown, with the disc 42 engaged between two retaining rings 44, thus illustrating how the disc 42 and the base 20 form the 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 shaft 36 of the base 20, and the disc 42.

[0075] Furthermore, the planar portion 62 of the base 20 also engages with the inner and outer skirts 28. As shown in Figure 1, the base 20 also has ribs 80 provided on the portion of the base 20 (when the bottle is in an upright position) below the cap 22. These ribs provide gripping surfaces, making it easier for a user to grasp the cap 18 if someone wants to remove the entire cap 18 from the container body 12, disengaging the internal threads 32 of the base 20 from the external threads 16 of the neck 14. In other configurations, the ribs 80 can be removed from the cap 18.

[0076] Figure 5 and Figure 9 An exemplary nonlinear termination surface 38 of the inner shaft 36 of the base 20 is shown. In some embodiments, the nonlinear termination surface 38 forms a channel opening for fluid and air to move between the mixing chamber 56 and the inner shaft 36. According to one method, the nonlinear termination surface 38 has a stepped configuration 64, such as... Figure 8 and 9 As shown. In another method, the nonlinear termination surface 38 has a wavy, sinusoidal, or other arcuate configuration. In some configurations, the nonlinear termination surface 38 may have a semi-circular recess that cuts into the wall of the inner shaft 36. Furthermore, one or more recesses may form one or more channels between the mixing chamber 56 and the inner shaft 36.

[0077] Furthermore, in Figure 5 and Figure 9 The stepped configuration 64 shown may include one or more protruding teeth 68, and one or more deep grooves 64 extending from its midpoint or otherwise positioned. The stepped configuration 64 of the nonlinear termination surface 38 of the inner shaft 36 mates with the surface of the disk to form fluid channels 58 with different widths and / or depths. Figure 10 As shown, the nonlinear termination surface 39 can also have a wavy or arcuate structure, with multiple grooves or recesses 65 and rounded extensions 69. The wavy nonlinear termination surface 39 operates similarly to the stepped structure discussed above, forming a channel 58 with the disk 42. In some configurations, the nonlinear termination surface can have a combination of stepped portions, protrusions, angles and / or curved segments, as well as other elements.

[0078] In fact, the nonlinear termination surface 38 can be constructed in various ways, for example... Figure 8-10 And the construction shown in 39-44. As described above, Figure 5 and Figure 9 The nonlinear surface 38 shown has a stepped structure forming a plurality of channels 58. Furthermore, in another configuration, Figure 10 The nonlinear termination surface 39 shown has a wavy or sinusoidal structure. Figure 39 The nonlinear termination surface 2238 is shown, which has two different heights, and Figure 8 and Figure 9 The three different heights described in the text are opposite. Figure 40 The nonlinear termination surface 2338 is shown, having two heights and an angled portion therebetween. Figure 41 A nonlinear termination surface 2438 is shown, which has generally V-shaped valleys arranged between edges or protrusions with triangular cross sections. Figure 42 and Figure 39 Similarly, a nonlinear termination surface 2538 with two different heights is shown, but... Figure 41 The edges or protrusions have triangular or trapezoidal shapes, and the angles adjacent to the larger base are sharper or smaller. Figure 43 A nonlinear terminating surface 2638 with a stepped structure is shown, wherein the width of the lowest step is smaller than the width of the uppermost step. Finally, Figure 44 A non-linear termination surface 2738 is shown, having triangular edges or protrusions with U-shaped valleys in between. It should be noted that the illustrated features can be used as shown or in combination with other exemplary features, including, for example, those shown in other figures. Alternatively, the ends of the shaft can be linear or flat, and the shaft can include additional openings therein.

[0079] In addition to partially forming the mixing chamber 56, the disk 42 also defines a local annular groove or opening 50 therein to allow fluid (and its components) to flow into the mixing chamber. The annular opening 50 can take various configurations, for example, Figure 7A , 7B And the construction shown in 45A-45I. According to a method, such as Figure 7A and 7B As shown, disk 42 includes four openings. In another embodiment, as... Figure 45A As shown, disk 1142 has two openings. In another example, Figure 45B Includes three annular openings of 1250, while Figure 45C The example includes five openings of 1350. Figure 45D An exemplary disk 1442 with six openings 1450 is shown, while Figure 45E An exemplary disk 1542 with seven annular openings 1550 is shown. Figure 45F The exemplary disk 1642 shown includes eight annular openings 1650 and offset pinholes 1648, while Figures 45A-45E The pinhole in the 45G-45I is centrally located in the disc shown therein. Furthermore, Figure 7A , 7B The corners of the annular opening shown in 45A-45F are rounded, without any sharp edges or pinch points, while Figure 45G-45IThe openings shown have less-than-circular openings 1750, 1850, and 1950. These features can be combined in various ways.

[0080] Figure 47A-47I Exemplary discs with various features are also shown that could help manage the flow of fluid from the bottle and through the cap. As mentioned above, bottles are often stored and / or used with the top down, which can cause slurry that separates in the chamber to leak out of the bottle, partly because it may not have made progress through a particularly long flow path or time before it is mixed back into the fluid before being removed from the cap.

[0081] To facilitate mixing of any separated slurry with the rest of the fluid, the disc may include additional features, such as additional openings disposed within its flange. In one illustrative embodiment, these openings are located between an annular groove and the center of the disc, which, as mentioned above, may have a central pinhole. Figure 47A An illustrative disk 2042 shown includes an annular opening 2051 within a flange 2054, which itself is within a larger annular opening or groove 2050. In this way, the inner wall adjacent to the flange 2054 has a smaller internal opening 2051, which facilitates the mixing of the fluid and any of its separated components. Figure 47B and 47C Similarly shown are exemplary disks 2142, 2242 with adjacent flanges 2154, 2254 having intermediate or internal openings 2151, 2251 and annular openings or grooves 2150, 2250, although with Figure 47A Compared to each other, the shapes and sizes of the openings are different. Furthermore, Figure 47C The central pinhole is missing, and Figure 47A and 47B The plate shown includes a central opening. In addition to these constructions, the pinholes can also be arranged offset from the geometric center of the plate, as previously suggested.

[0082] Figure 47D-47F Additional illustrative embodiments of a disc with columns extending therefrom are shown to facilitate mixing of fluids as they move through the cap. Once mounted or secured to the remainder of the cap, the columns typically extend toward the bottle's outlet or opening. For example, exemplary disc 2342 ( Figure 47D It includes an annular opening 2350 and a centrally positioned column 2353, the sides of which are relatively smooth. Figure 47E The disk 2442 shown includes an annular opening 2450, a flange 2454, and a centrally positioned post 2453. The post 2453 has a rounded exterior, uneven sides, and a generally X-shaped cross-section.

[0083] Although the pillars are shown as centrally positioned, they can also be positioned off-center, and multiple pillars can be included in the dish. Furthermore, the pillars can have various surface textures and constructions. In fact, depending on the fluid moving within the lid, pillars with various different constructions can be included in the lid.

[0084] In some constructions, instead of columns, disks can have another similar structure, such as cones. Figure 47I The central portion of disk 2842 is shown, which has a conical extension 2857 with an opening 2848 extending therethrough. Furthermore, disk 2842 also includes an annular opening 2851, a flange 2854, and an opening 2850.

[0085] Figure 47F The disk 2542, similarly, has a centrally positioned column 2553, a generally X-shaped cross-section, and an annular opening 2550. However, the disk 2542 has a continuous flange or cylindrical wall 2555 extending from the disk 2542, rather than discrete flanges. Although the cylindrical wall 2555 is shown as generally perpendicular to the disk, it may also extend at an angle from the disk, similar to... Figure 46B The flange shown is not perpendicular.

[0086] Figure 48 The disc 2542 is shown to be secured to the remainder of the cover 2518. Furthermore, the column 2553 is shown to extend at least partially into the inner shaft 2536. In this way, fluid must pass through the annular opening 2550, across or around the cylindrical wall 2555, across or around the end of the inner shaft 2536, and be propelled along the shaft 2553 towards the opening 2534. Such a configuration, with a degree of winding flow channel, may be particularly suitable for certain fluids with specific fluid properties.

[0087] Other modifications or combinations can be made to the features described herein. For example, Figure 47G It shows the relationship with Figure 47B The disc 2142 is similar to the disc 2642; however, the flange 2654 is not like... Figure 47B As shown in the figure, so that with Figure 47B Compared to flange 2654, the fluid in Figure 47G There is more room or gap between the flanges 2654. Furthermore, Figure 47H In the illustrated disc 2742, the outer annular opening 2750 is adjacent to the opening 2751, and no flange is provided between them. Many of the various structural features of the disc can be combined or modified in various ways, including those described herein, to adapt the disc to the characteristics of fluid propelled from the bottle through its cap.

[0088] As described above, the mixing chamber 56 and the opening formed by the disk 42 and the inner shaft 36 in the disk 42 allow for precise dispensing and metering of the fluid 5 within the container. Therefore, the geometry of the disk 42 helps to facilitate the proper dispensing of the fluid 5.

[0089] Figure 7A The first side of disc 42 is shown. When the bottle is inverted, the flange 54 of disc 42 extends downward, and when disc 42 is installed in place between (some) retaining rings of cap 18, disc 42 faces the inner axis 36. Although the flange 54 can extend orthogonally from the face of disc 42 (e.g., Figures 7C-7E (as shown in the diagram), but flange 54 can also extend from disk 42 at angles other than 90°. Briefly turn to Figure 46A and 46B The figure shows two illustrative flange constructions. Figure 46A It is shown that flange 54 extends from the body of disk 42 at approximately 90°, while Figure 46B In this configuration, the flange 54' extends from the body of the disk 42 at an angle of less than 90°. This angled flange may affect the flow of product 5 into the mixing chamber 56 and may influence the mixing process within the chamber. Although Figure 46A and 46B Both flanges shown help to mix the product as it moves toward the outlet, but depending on the product's fluid properties, Figure 46B The angle of the flange 54' shown can be less than 90°. As described above, the central pinhole 48 is disposed through the center of the planar portion of the disc 42 and is partially surrounded by a plurality of grooves or partial annular openings 50. The peripheral partial annular openings 50 are significantly larger than the central pinhole, and most of the fluid 5 flowing out of the bottle 10 is propelled through the partial annular openings 50. In some embodiments, the diameter D1 of the disc 42 is 20 mm to 40 mm, 25 mm to 35 mm, or about 30 to 34 mm. In an exemplary configuration, the diameter D1 of the disc 42 is about 31.9 mm ± 0.1 mm. According to one method, the arc length of the annular groove is 10 to 15 mm, or 11 to 14 mm. Figure 7B As shown, the arc length A1 of each opening can be approximately 12.7 mm. Furthermore, the annular opening 50 has an inner radius of curvature R1 at its inner edge and an outer radius of curvature R2 at its outer edge. In one illustrative method, R1 is approximately 6-10 mm and R2 is approximately 10-15 mm. In another illustrative method, R1 is approximately 8-9 mm and R2 is approximately 12-13 mm. In one illustrative embodiment, R1 is approximately 8.3 mm and R2 is approximately 12.3 mm.

[0090] like Figure 6 and 7AAs shown, the partial annular opening 50 is configured adjacent to the flange 54. When the disc 42 is mounted in the base 20, the flange 54 extends into the mixing chamber 56, such that the fluid 5 (including any components, such as slurry) cannot be directly propelled through the opening 50 into the inner shaft 36 to leave the bottle. Instead, a portion of the fluid 5 propelled through the opening 50 must flow into the mixing chamber 56 before leaving the bottle 10 (thus promoting mixing of any components of the fluid 5 separated from it). In one illustrative method, the extension or flange 54 has a height h1 of approximately 2-5 mm. In another illustrative method, the height h1 is approximately 3-4 mm. In an exemplary embodiment, h1 is approximately 3.5 mm. Furthermore, in operation, the length or height of the flange 54 can be correlated with the depth of the channel 58 formed by the non-linear termination surface 38, as having these with similar dimensions helps to promote mixing by requiring the fluid to flow around the flange 54 rather than directly through the annular opening 50 and through the fluid channel 58. In one illustrative method, the height h2 of the disc 42 is approximately 3-7 mm. In another illustrative method, the height h2 of disk 42 is approximately 4-6 mm. In yet another illustrative method, the height h2 of disk 42 is approximately 4.8 mm.

[0091] like Figure 7D As shown, in some embodiments, the width w1 of the planar portion of disk 42 is from about 0.75 mm to about 3 mm. In one illustrative method, the width w1 of disk 42 is about 1-2 mm. In another illustrative method, the width w1 of disk 42 is about 1.3 mm. The width of the central pinhole opening 48 is as follows... Figure 2 The value shown is d2, which is approximately 1-2 mm. In one illustrative method, the width d2 of the pinhole in disc 42 is approximately 1.5 mm.

[0092] like Figure 7E As shown, each of the partial annular openings 50 may have a beveled edge on the surface of the disc 42 facing the base 20. When the bottle is placed in a configuration with the cap side up (upright), this orientation can facilitate the flow of fluid 5 (e.g., at least a portion of the fluid not retained in the inner shaft 36) back into the container body 12. Furthermore, the beveled edge also facilitates the retraction of air back into the bottle to improve the resilience of the bottle or container body 12.

[0093] To facilitate proper fluid distribution, the geometry of the disc 42 modulates the flow of fluid 5, including, for example, the size, shape, and angle of the flange 54. In addition to the geometry discussed above, the disc 42 has sufficient openings relative to its area to promote adequate flow of fluid 5 while preventing leakage from the cap 18. The openings 50 have specific sizes, shapes, and positions to facilitate fluid flow, thereby making the bottle easy to dispense and quick to return. In one illustrative approach, the total area of ​​the disc is approximately 800 mm².2 The total area of ​​the local annular opening 50 and the central pinhole is approximately 211 mm². 2 This is approximately 26% of the total area of ​​the disk. According to some methods, the total area of ​​the openings in the disk will cover about 20-35% of the total area of ​​the disk. Generally speaking, the area occupied by the local annular opening is much larger than that of the central pinhole.

[0094] exist Figure 4 In the diagram, the flow of tomato paste during dispensing is shown as a dashed line. After dispensing, the flow of air entering the bottle to replace the tomato paste is shown as a thick solid line. A lighter solid line indicates the flow of slurry separated from fluid 5, which flows into mixing chamber 56 and is then mixed back into fluid 5.

[0095] In some illustrative methods, the cap 18 (e.g., base 20, flap 22, and disc 42) is composed of a single material, such as polypropylene or other food-grade plastics or polymers, or similar recyclable materials. In operation, making the cap 18 from a single material increases the ease and possibility of material recycling. According to some methods, materials with specific surface tensions can be selected. For example, the surface of disc 42 (and other potential inner surfaces of the cap) can 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 can also be textured to inhibit flow, or it can have a smooth surface to facilitate fluid movement therein. Smooth surfaces may result in faster and / or more difficult-to-control fluid flow, and may also lead to leakage of the product or its separated components due to reduced surface tension. The surface treatment of the material or the way the element is formed can also affect the surface tension of the element and help facilitate control of fluid flow. For example, some portions of the flap 18 can be formed with rough surfaces that can affect the flow of fluid 5 through it.

[0096] Briefly switch to Figure 38 Two different exemplary finished surfaces 77 and 79 are shown. While a single inner wall 78 may have a single texture over its entire surface or portions thereof with different textures, Figure 38 The cap 2018 shown has a first portion 2078 with a coarser texture and a second portion 2178 with a smoother texture. As described above, the surface of the material forming the cap 18 can inhibit, slow down, or restrict the flow of liquid 5 within the bottle. Whether a textured surface is included on part or the entire cap, such as the inner wall of the inner shaft, depends on the type of fluid being propelled through the cap 2018.

[0097] like Figure 6As shown, the first side of the disc 42 (arranged adjacent to the inner shaft 36 of the base 20 during installation) includes a rainbow-shaped or arcuate flange or extension 54 extending therefrom. When the disc 42 is mounted in the base 20, the arcuate flange or extension 54 extends into the mixing chamber 56 and toward the base 20. The disc extension 54 promotes mixing of the fluid 5 in the mixing chamber 56 by allowing the fluid 5 to move around the extension 54 rather than directly entering the fluid passage 58 from the partially annular opening 50.

[0098] like Figure 8 As shown, the base 20 at the opening 34 and the inner shaft 36 has an inner stop or flange 60 on the inner surface adjacent to 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 flange 60, such that the sharp edge helps to reduce product tail formation by retaining part of the product in the cap until the manual pressure on the container body becomes sufficient to overcome the tendency of fluid to be retained in the cap by the flange. According to one method, the stop has a sharp edge without burrs. In some configurations, the diameter of the opening into the container is smaller than the diameter of the inner shaft; this reduction in size and the relatively sharp edges therebetween help to stop dispensing in a quick and clean manner. While such a stop does not prevent product from flowing out of the opening of the cap, it reduces the amount released at a given pressure by slowing the flow rate. According to one method, the stop is relatively small compared to the diameter of the shaft, while the opening into the container itself is between about 3.5 mm and about 4.5 mm, and about 4 mm in one illustrative embodiment.

[0099] As described above, when the disc is attached to the base 20, the inner shaft 36 can help support the disc 42. According to one method, the inner wall or internal wall 78 of the inner shaft 36 allows fluid 5 to leak into the opening 34. In one embodiment, the internal wall 78 is formed in at least one of a circular or parabolic shape. Figure 11 An example shape of the inner wall 79 is shown, which narrows slightly near the exit of the inner shaft 36. Furthermore, in some embodiments, the shaft 36 may widen again adjacent to the opening 34. By widening slightly at the junction of the opening and the upper surface of the base, the opening allows the protrusion 90 to be placed more easily and quickly into the opening 34 when the flap 18 is closed. Figure 12 In another configuration shown, the inner wall 78 has a generally vertical straight portion, followed by an angled portion that directs the fluid 5 to the opening 34. Figure 13 and Figure 12 Similar to the inner shaft 36, but further including a blocking tab 60 or a sharp reduction in the diameter of the inner shaft 36 to assist in stopping the distribution of fluid 5, as described above. Additional examples of blocking tab constructions or inner protrusions around the opening are shown in... Figure 14 and Figure 15 As shown in the image. Figure 14An opening 134 with a blocking tab 160 is shown, the inner surface of which is slightly inclined downwards or toward the through opening, without any horizontal protrusions extending from the inner surface, as discussed earlier. Figure 13 It includes a downward-sloping section, but with a horizontal blocking piece 60 extending from it. Furthermore, Figure 15 An opening 234 with a blocking tab 260 is shown, the blocking tab having an inner surface angled away from the through opening.

[0100] Figure 16 and Figure 17 Two options for the construction of the surface of the dome or container outside the opening 34 are shown. For example, Figure 16 The rounded edge at the junction of the central portion 30 and the opening 34 is shown. (Previously discussed...) Figure 14 and 15 There is an angled indentation around the opening at this location. Furthermore, Figure 17 A recess 161 with an inclined wall surface is shown between the central portion 30 and the opening 34.

[0101] Bottle 10 and cap 18 can be produced in many different ways. In one illustrative method, the manufacture or production of a filled bottle for dispensing fluid includes molding a container, such as a container body with a threaded neck, filling the container with a fluid, such as a thixotropic fluid, molding a cap having a base, a flap, and a disc, and sealing the filled container with the cap. Furthermore, the bottle can be formed and filled on an assembly line, or it can be formed at one location and filled at another.

[0102] According to one method, the cap and disc are separately molded and snapped together. In some configurations, the molded base has an inner skirt and an outer skirt, with a base thread configured to engage with a threaded neck of the container. Furthermore, 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 thread), having an opening aligned with an inner axis terminating on a non-planar end surface opposite the central dome-shaped portion. As described above, the opening in the base allows fluid to flow out unobstructed. In some configurations, the molded cap has an internal protrusion movable between a first position and a second position, wherein the protrusion in the first position blocks the opening of the base, inhibiting fluid flow out of the container, while the second position allows fluid to flow out through the opening of the base.

[0103] As described above, in some methods, the cap and disc are molded separately and then fixed to each other or snapped together. In such a construction, the manufacturing method may also include an assembly step that orients the disc in a specific position relative to the cap or the remainder of the base 20. By including one or more orientation steps before assembling the disc with the remainder of the cap, the assembled cap is more likely to have a constant flow rate therein. Furthermore, in some constructions, the flow rate can be adjusted for different fluids by adjusting the relative positions of certain elements of the cap or disc without changing the structure of the cap or disc. By one method, visual markings or recessed notches arranged on one or both of the cap or disc can be used to help position the disc and / or cap relative to each other.

[0104] This may depend in part on the construction of its various components. In an illustrative example, such as Figure 5 The base 20 and the nonlinear termination surface 38 of the inner shaft 36 include three cuts, while Figure 6 The disc 42 includes four flanges 54. Fluid flow through the assembled cap may be affected by the orientation of the flanges 54 relative to the slit openings of the inner shaft 36. Therefore, the two structural elements can be oriented relative to each other to promote increased fluid flow between them, or to slow fluid flow by making the fluid take a longer path to the bottle's outlet. Given the interest in regulating fluid paths or standardizing flow rates across numerous caps, methods of manufacturing or assembling the cap and bottle may include orienting the disc relative to the remainder of the cap in a specific manner.

[0105] As described above, a method of producing a filled bottle may include inserting a disc into a retaining ring of a cap. In some configurations, the molded disc includes a central pinhole and a partially annular groove surrounding the central pinhole. Once the disc is attached to the remainder of the cap 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 multiple fluid channels 58 formed by the non-planar end surfaces of the inner shaft 36 and the disc 42. The channels 58 formed between the end of the inner shaft 36 and the disc 42 allow fluid to advance from the mixing chamber 56 into a chute formed by the inner shaft 36 that communicates with an opening 34.

[0106] In some configurations, the filled container or container body is sealed with fluid by a gasket associated with a cap. For example, the gasket, such as a gasket made of cardboard, plastic, and / or metal, is associated with a retaining ring and seals the fluid 5 within the container when the cap 18 is threaded onto the container body.

[0107] Furthermore, in some methods, the method of manufacturing the cap includes forming a flip-top cap comprising a base and a flap in a mold. In some embodiments, the formed 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 connected to the inner skirt by a planar portion and / or possible reinforcing ribs; and a retaining ring on the inner skirt. The inner shaft of the molded base generally extends inward from the dome-shaped wall and terminates at a non-planar end surface. Additionally, the formed cap also has a flap hingedly connected to the base, wherein the flap has an internal protrusion and is movable from a first position where the internal protrusion blocks the opening to a second position where the internal protrusion does not block the base opening. In some configurations, the method of manufacturing the cap further includes engaging a disc into the retaining ring or protrusion of the base. In some embodiments, the disc has: a central pinhole; a partial 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 during installation. Once the disk and base are attached, a mixing chamber is formed between the disk, the dome-shaped wall, the inner skirt, and the inner shaft, with multiple fluid channels formed by the non-planar end surfaces of the inner shaft and the disk.

[0108] In some configurations, the cap is made from only two separate components, including a flip cap and a disc, wherein the flip cap comprises a base and a flip cap formed as a single, integral, unitary, one-piece structure, and wherein the two separate components (i.e., the flip cap and the disc) are made of the same material and are assembled. In operation, after the cap is molded and ejected from the mold, a mechanism can be used to assemble the disc into the cap (which may be formed in the same mold as the base and flip cap, or in a different location), for example, by snapping it into place in the base. Furthermore, this mechanism or another device can be used to attach a gasket to a retaining ring, which can facilitate sealing the fluid in the bottle. In some configurations, the base and flip cap are formed in the same mold as the disc; in other configurations, the disc is formed independently in the same mold as the base and flip cap. Additionally, the base and disc can be formed and assembled separately at a separate station. In other configurations, the entire cap (including the base, flip cap, and disc) can be molded or printed together.

[0109] As mentioned above, some adjustments can be made to the concepts presented in this article while maintaining consistency with these teachings. For example, Figure 18 and Figure 19Another embodiment of a disc with an annular opening is shown. As shown, disc 342 has a central portion 384 positioned vertically relative to a peripheral portion 386, the peripheral portion having an annular opening 350 disposed therein. In such a configuration, the volume of mixing chamber 356 can be designed to be somewhat independent of the discharge shaft or chamber formed by inner shaft 356. In fact, this mixing chamber 356 is smaller than some of the other mixing chambers discussed above. To allow fluid 5 to flow from mixing chamber 356 to inner shaft 336 forming the discharge chamber, the radius of the central portion 384 can be sufficiently large compared to the radius of inner shaft 336 to provide clearance for fluid 5 from mixing chamber 356 through an opening or fluid channel 358 formed between inner shaft 336 and mixing chamber 356, and / or the opening 358 can extend to have a height or position exceeding the vertical portion of disc 342, disc 342 may be positioned adjacent to inner shaft 336. In short, even if the central portion 384 is not significantly larger than the inner shaft, the opening between the mixing chamber 356 and the inner shaft 336 can be moved or sized to allow fluid flow. Furthermore, although the central portion 384 is... Figure 18 and Figure 19 The central portion 384 is shown without a central pinhole, but in some configurations, the central portion 384 may include an vent formed via the pinhole or other structures. Furthermore, the disc 342 may engage with the rest of the cover in any manner, such as via engagement between portions of the base, including ribs and / or protrusions or other complementary geometries between the disc and the base. Figure 20 and 21 Another example of disk 442 is shown, which lacks the central pinhole 48 found in some other embodiments. Additionally, although... Figure 18 and Figure 19 Excluding flanges similar to those described above, the vertical portion of the disc separates the central portion 384 and the peripheral portion 386, and the operation of this vertical portion is similar to that of the mixed products.

[0110] Turn Figure 22 and 23Another embodiment is shown, which is a three-part configuration with a flat disc 542 and an inner cover or inner cylindrical housing 596. In one manner, the inner cylindrical housing 596 includes a circular wall 592 with one or more openings 598. In this way, a mixing chamber 556 is in fluid communication with an intermediate chamber 594 partially defined by the inner cylindrical housing 596. The inner cylindrical housing 596 is arranged around an inner axis 536 and positioned via the disc 542, which is secured in place by a fixing member 544, such as a ring. Furthermore, the inner cylindrical housing 596 can also be securely attached to a central portion 530. When the inner cylindrical shell 596 is positioned around the inner shaft 536, fluid 5 is propelled from the bottle to the outlet or opening 534 through the annular opening 540, the opening 598 of the inner cap 592, and upward along the length of the inner shaft 536 through the internal opening 588 of the inner shaft 536, and downward along the axial direction to the outlet opening 534. As shown, the disc 542 includes the annular opening 540 but lacks a central pinhole because the inner cylindrical shell 596 lacks openings between the walls 592 on its surface. In this way, the fluid 5 travels and mixes as it is propelled through the fluid channels of the three-part cap 518. In addition to mixing, this configuration may be particularly useful for larger containers because, when the container is inverted, the downward force of the fluid is considerable due to the potential large amount of product placed above the cap.

[0111] In addition, although Figure 20-23 The flange extending from the disk is not shown, but in some configurations the disk may include a flange similar to that described above.

[0112] The external shape of the central portion of the base can also have various configurations. As mentioned above, the central portion 30 of the base 20 can have a dome-shaped configuration, such as including... Figure 24 The structure of disk 18 shown. Figure 25 It shows Figure 24 A portion of the cross-section of the outlet 34 of the central dome-shaped portion 30. Furthermore, Figure 26 The dome-shaped central portion is further shown in cross-section. While the dome-shaped central portion 30 of the base 20 provides a surface that is easy to wipe clean, other constructions with similar properties can also utilize the teachings described herein. For example, Figure 27-29 Another exemplary embodiment is shown, in which the cover 618 has a central portion 630 with sloping walls in a generally volcano-shaped shape and an opening 634 disposed at its center. Furthermore, Figure 30-32 Another embodiment is shown, including a cover 718 having a swinging central portion 730 and an opening 734 therein, wherein several flat surfaces surround the exterior of the opening 734. Furthermore, although... Figure 24-32The exemplary shapes shown illustrate openings with exemplary blocking tabs, but these different shapes can be combined with other opening shapes and aspects described herein.

[0113] As described above, the mixing chamber described herein allows for the incorporation or mixing back of separated slurry into the fluid before the fluid and / or a portion thereof exits from the opening in the container lid. By one method, 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 method, the size of the mixing chamber 56 depends in part on the size of the inner shaft 36, the corresponding geometry of the base, and / or the construction of the disk, which determines the position of the disk 42, as described above. Briefly go to Figure 33 and 34 The figure shows two mixing chambers 56 and 56' of different sizes. Although the components are similar, the walls forming the inner shaft 36 are... Figure 34 China and Belgium Figure 33 The wall length of the shaft 36' in the middle, and the corresponding geometry (e.g., retaining ring 44) is set at a greater distance from the central surface 30' of the base 20 compared to the central surface 30' of the base 20. Although the relative dimensions of these components can be changed, as shown, their function remains; that is, the mixing chamber helps prevent the separated slurry from leaking out of the bottle from the rest of the fluid product 5.

[0114] As described above, the inner wall 78 of the inner shaft can have a cross-section forming different shapes, such as circular or elliptical. Furthermore, the shape or structure formed by the inner wall 78 along its length can adopt various configurations. For example, as... Figure 4 , 14 As shown in Figure 15, the inner shafts 36, 136, and 236 may have generally linear inner walls 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, Figure 35 The inner wall 878 of the inner shaft 836 is shown, which is angled toward the opening 834. According to one method, the downward angle provides a cross-section with a V-shaped configuration. In another embodiment, Figure 36 The inner wall 978 of the inner shaft 936 is shown to have a downward slope, which is slightly non-linear. According to one method, the downward slope provides a cross-section with a modified U-shape. In another embodiment, Figure 37 An inner shaft 1036 with an inner wall 1078 is shown, the inner wall 1078 having a stepped structure that narrows the diameter in a stepped manner.

[0115] Those skilled in the art will recognize that various other modifications, alterations, and combinations can be made to the above embodiments without departing from the scope of the invention, and such modifications, alterations, and combinations should be considered within the scope of the concept of the invention.

Claims

1. A closure for a container, the closure comprising: a base having at least: a central portion having an opening therethrough; an inner skirt; an outer skirt connected by a planar portion; threads and a retaining ring on the inner skirt; and an inner shaft suspended inwardly from the central portion, the inner shaft terminating at a non-planar end surface; a flip lid hingedly connected to the base, the flip lid 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 obstruct the opening of the base; and a disc attached to the interior of the base, the disc being secured around the inner shaft; and a mixing chamber defined by the disc, the central portion, a mixing chamber wall, and the inner shaft, wherein at least one fluid passageway is formed between the disc and the inner shaft by the non-planar end surface of the inner shaft, wherein the at least one fluid passageway allows fluid to flow from the mixing chamber into the inner shaft; wherein the disc is stationary relative to the base when the disc is attached to the base.

2. The closure of claim 1, wherein The mixing chamber has a capacity of 7 mL to 11 mL, and wherein the disc is attached to the base via a snap-in fit.

3. The closure of claim 1 wherein, The non-planar end surface of the inner shaft terminates opposite the central portion includes a stepped structure.

4. The closure of claim 1 wherein, The non-planar end surface of the inner shaft terminates opposite the central portion includes a portion having at least some curved surface forming one or more indentations.

5. The closure of claim 1 wherein, The disc has a diameter of less than 40 mm.

6. The closure of claim 1 wherein, Both the flip lid and the disc are composed of a single food grade plastic.

7. The closure of claim 1 wherein, The closure includes only two separate components, the base and flip lid are a single, unitary, one-piece, integral structure, and the disc is separately molded.

8. The closure of claim 1 wherein, The inner shaft supports the disc when the disc is attached to the inner shaft.

9. The closure of claim 1 wherein, The mixing chamber wall is formed by a flange extending from the disc.

10. A method of manufacturing a closure, the method comprising: forming a flip lid in a mold, the flip lid comprising: a base having at least: a central portion having an opening therethrough; an inner skirt; an outer skirt connected by a planar portion; threads and a retaining ring on the inner skirt; and an inner shaft suspended inwardly from the central portion, the inner shaft terminating at a non-planar end surface, and a flip lid hingedly connected to the base, the flip lid 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 obstruct the opening of the base; and securing a disc to the base of the flip lid, the disc being positioned around the inner shaft; wherein the disc and the base form a mixing chamber defined by the disc, the central portion, a mixing chamber wall, and the inner shaft, wherein at least one fluid passageway is formed between the mixing chamber and the inner shaft via the non-planar end surface of the inner shaft; wherein the disc is stationary relative to the base once the disc is attached to the base.

11. The method of claim 10, wherein, The closure is made of only two separate pieces, including the flip cap and the disc, and the flip cap includes the base and the flip cap formed as a single, unitary, one-piece, integral structure, and wherein the two separate pieces are made of the same material and are assembled.

12. The method of claim 10, wherein, The disc is snapped into the flip cap.

13. A closure, comprising: a base having at least: a central portion having an opening therethrough; an inner skirt; an outer skirt connected by the central portion; threads on the inner skirt; and an inner shaft depending inwardly from the central portion, the inner shaft terminating at a non-planar end surface; a flip cap hingedly connected to the base, the flip cap 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 obstruct the opening of the base; and a disc attachable to the interior of the base, the disc being secured about the inner shaft, wherein the inner shaft supports the disc when the disc is attached to the base; a mixing chamber formed by the disc, the central portion, the mixing chamber wall, and the inner shaft; and at least one fluid passageway formed between the mixing chamber wall and the space interior to the inner shaft, wherein the at least one fluid passageway is partially formed by the inner shaft and the non-planar end surface; wherein the disc is stationary relative to the base when the disc is attached to the base.

14. The closure of claim 13, wherein The non-planar end surface of the inner shaft terminating opposite the central portion includes a stepped structure.

15. The closure of claim 13, wherein The mixing chamber wall is a flange extending from the disc.

16. The closure of claim 15, wherein The mixing chamber wall is a substantially circular wall depending from the central portion of the base.

17. The closure of claim 13, wherein At least a portion of the non-planar end surface of the inner shaft is spaced apart from the disc to form the at least one fluid passageway therebetween.

18. The closure of claim 13, wherein The base and the disc form a tortuous fluid flow path to the opening into the central portion.

19. The closure of claim 13, wherein The disc engages at least a portion of the non-planar end surface of the inner shaft.

20. A closure for a container, the closure comprising: a base having at least: a central wall having an opening therethrough; an inner skirt; an outer skirt connected to the inner skirt by a planar portion; threads; and an inner shaft depending inwardly from the central wall, the inner shaft terminating at a non-planar end surface; a flip cap hingedly connected to the base, the flip cap 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 obstruct the opening of the base; and a disc attached to the interior of the base by snapping the disc into the base, the disc having one or more flanges extending from the disc toward the base, a centrally disposed post, and a plurality of openings therethrough; and a mixing chamber defined by the disc, the central wall, the inner skirt, and the inner shaft, wherein a plurality of fluid passageways are formed by the non-planar end surface of the inner shaft and the disc.

21. A closure for a container, the closure comprising: a base having at least: a central wall having an opening therethrough; an inner skirt; an outer skirt connected to the inner skirt by a planar portion; threads; and an inner shaft depending inwardly from the central wall, the inner shaft terminating at a non-planar end surface; a flip lid hingedly connected to the base, the flip lid having a protrusion and movable between a first position in which the protrusion blocks the opening and a second position in which the protrusion does not obstruct the opening of the base; and a disc connected inside the base by snapping the disc into the base, the disc 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 disc; and a mixing chamber defined by the disc, the central wall, the inner skirt, and the inner shaft, wherein a plurality of fluid channels are formed by the non-planar end surface of the inner shaft and the disc.

22. The closure of claim 21, wherein The disc further comprises one or more flanges extending towards the central wall of the base.

23. The closure of claim 22, wherein The one or more flanges are disposed between the plurality of annular grooves and the plurality of intermediate openings on the disc.

24. The closure of claim 21, wherein The disc is fixed relative to the base once connected to the base.

25. The closure of claim 21, wherein The central wall forming the opening comprises an inwardly protruding blocking piece.

26. The closure of claim 21, wherein An outer surface of the central wall has an outer central recess having a sloped wall towards the opening of the central wall.

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