FOAMING BOTTOM-DISPENSING CONTAINERS
20250380841 ยท 2025-12-18
Inventors
- Thierry Christian Francis Dagnelie (Waterloo, BE)
- Vincent Hubert Monique De Wilde (Holsbeek, BE)
- Paulus Antonius Augustinus Hoefte (Astene, BE)
Cpc classification
International classification
Abstract
The need for a foaming bottom-dispensing package that dispenses liquid compositions in a foamed state from the bottom of the package, while being able to be kept for long durations in a bottom-dispensing orientation and without the need to invert the container for the air reservoir to be replenished, while also being resistant to leakage, even when there is no closing cap, is met by incorporating a foamer body into the base of the bottom-dispensing package.
Claims
1. A bottom-dispensing foam discharge package comprising: a. a resiliently squeezable container for housing a liquid composition, the resiliently squeezable container comprising a container wall; b. a void volume; c. a base operably connected to the resiliently squeezable container, wherein the base comprises a base orifice; and d. a foamer body, wherein the foamer body comprises: i. a mixing chamber; ii. at least one liquid inlet; iii. at least one air inlet, wherein the at least one air inlet comprises an air inlet valve, wherein the air inlet valve is a one-way valve which allows ingress of air into the mixing chamber from the void volume through the air inlet, and the air inlet valve opens at a pressure differential of from about 1.0 to about 25 mbar, measured at about 20 C.; and iv. a foam outlet operably connected to the base orifice, wherein the foam outlet comprises a foam-dispensing valve for dispensing the foam from the mixing chamber through the foam outlet, and the foam-dispensing valve opens to dispense foam at a pressure differential of from about 25 to about 250 mbar, measured at about 20 C.
2. The bottom-dispensing foam discharge package according to claim 1, wherein the foam-dispensing valve is a two-way valve.
3. The bottom-dispensing foam discharge package according to claim 1, wherein the foam-dispensing valve opens at a pressure differential of from about 25 mbar to about 150 mbar, measured at about 20 C.
4. The bottom-dispensing foam discharge package according to claim 3, wherein the foam-dispensing valve opens at a pressure differential of from about 25 mbar to about 100 mbar, measured at about 20 C.
5. The bottom-dispensing foam discharge package according to claim 1, wherein the air inlet valve opens at a pressure differential of from about 5.0 to about 25 mbar, measured at about 20 C.
6. The bottom-dispensing foam discharge package according to claim 5, wherein the air inlet valve opens at a pressure differential of from about 10 to about 25 mbar, measured at about 20 C.
7. The bottom-dispensing foam discharge package according to claim 1, wherein the air inlet valve is operably connected to the void volume via a dip-tube.
8. The bottom-dispensing foam discharge package according to claim 1, wherein the liquid inlet has a total surface area of from about 1.0 mm.sup.2 to about 50 mm.sup.2, wherein the total surface area is measured as a sum of cross-sectional areas of all of the liquid inlets.
9. The bottom-dispensing foam discharge package according to claim 8, wherein the total surface area of the liquid inlet is from about 1.0 mm.sup.2 to about 25 mm.sup.2.
10. The bottom-dispensing foam discharge package according to claim 1, wherein the air inlet has a total surface area of from about 1.0 mm.sup.2 to about 50 mm.sup.2, wherein the total surface area is measured as a sum of cross-sectional areas of all of the air inlets.
11. The bottom-dispensing foam discharge package according to claim 10, wherein the total surface area of the air inlet is from about 1.0 mm.sup.2 to about 25 mm.sup.2.
12. The bottom-dispensing foam discharge package according to claim 1, wherein the foamer body comprises an upper cavity and a lower cavity, wherein the upper cavity and the lower cavity are connected by a diffusing orifice.
13. The bottom-dispensing foam discharge package according to claim 1, wherein the foam outlet comprises at least one mesh, wherein a nominal sieve opening and typical wire diameter are as defined in in ASTM E11-22.
14. The bottom-dispensing foam discharge package according to claim 1, wherein the resiliently squeezable container contains the liquid composition, wherein the liquid composition partially fills the container in order to create the void volume.
15. The bottom-dispensing foam discharge package according to claim 1, wherein prior to initial use, the void volume forms from about 1.0% to about 25% by volume of the container.
16. A bottom-dispensing foam discharge package comprising: a. a resiliently squeezable container for housing a liquid composition, the resiliently squeezable container comprising a container wall; b. a void volume; c. a base operably connected to the resiliently squeezable container, wherein the base comprises a base orifice; and d. a foamer body, wherein the foamer body comprises: i. a mixing chamber; ii. at least one liquid inlet; iii. at least one air inlet, wherein the at least one air inlet comprises an air inlet valve, wherein the air inlet valve is a one-way valve which allows ingress of air into the mixing chamber from the void volume through the air inlet; and iv. a foam outlet operably connected to the base orifice, wherein the foam outlet comprises a foam-dispensing valve for dispensing the foam from the mixing chamber through the foam outlet; wherein a ratio of a total surface area of the air inlet to a total surface area of the liquid inlet is from about 1:1 to about 1:15.
17. The bottom-dispensing foam discharge package according to claim 16, wherein the ratio of the total surface area of the air inlet to the total surface area of the liquid inlet is from about 1:1.15 to about 1:10.
18. A bottom-dispensing foam discharge package comprising: a. a resiliently squeezable container for housing a liquid composition, the resiliently squeezable container comprising a container wall; b. a void volume; c. a base operably connected to the resiliently squeezable container, wherein the base comprises a base orifice; and d. a foamer body, wherein the foamer body comprises: i. a mixing chamber; ii. at least one liquid inlet; iii. at least one air inlet, wherein the at least one air inlet comprises an air inlet valve, wherein the air inlet valve is a one-way valve which allows ingress of air into the mixing chamber from the void volume through the air inlet; and iv. a foam outlet operably connected to the base orifice, wherein the foam outlet comprises a foam-dispensing valve for dispensing the foam from the mixing chamber through the foam outlet.
19. The bottom-dispensing foam discharge package according to claim 18, wherein the air inlet valve is a one-way valve selected from: a duckbill valve, an umbrella valve, a flapper valve, a ball valve, or a degassing valve.
20. The bottom-dispensing foam discharge package according to claim 18, wherein the mixing chamber comprises at least two cavities, the at least two cavities comprising an upper cavity and a lower cavity, wherein the upper cavity and the lower cavity are connected by a diffusing orifice.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0011]
[0012]
[0013]
[0014]
[0015]
[0016]
[0017]
[0018]
[0019]
[0020]
[0021]
[0022]
[0023] The foaming body (40) is connected to a dip-tube (60). The inset to
DETAILED DESCRIPTION OF THE INVENTION
[0024] Incorporating a foamer body, as described herein, into the base of a bottom dispensing package, results in a bottom-dispensing package that dispenses varying amounts of liquid compositions in a foamed state from the bottom of the package in a controlled manner, while being able to be kept for long durations in a bottom-dispensing orientation and without the need to invert the container for the air reservoir to be replenished, while also being resistant to leakage, even when there is no closing cap. Additionally, the foaming bottom-dispensing containers described herein can be maintained in their bottom-dispensing orientation while minimizing the amount of the liquid composition that is dispensed in a non-foamed state. This is because the entry of the liquid into the mixing chamber, before the entry of the air from the void volume, is significantly reduced, in comparison to prior foam dispensing packages, such as those described in US20020153389A. Moreover, the design of the foamer body ensures that air is drawn through the foamer body upon release of the squeezing force applied during dispensing. This both reduces leakage while the package is being stored, and reduces the amount of unfoamed liquid that is dispensed during subsequent use, since less liquid remains in the foamer body. This is in contrast to prior art foaming packages such as WO9114648A1, in which air is drawn through the dip-tube directly from the atmosphere, when the squeezing pressure is removed.
[0025] By resiliently squeezable, what is meant is that the container wall (11) exhibits a degree of flexibility sufficient to permit deformation in response to manual forces applied to the outer surface of the container wall (11) and a degree of resilience sufficient to return automatically to its undeformed condition when said manually applied forces are removed from the outer surface of the container wall (11). By the terms a and an when describing a particular element, we herein mean at least one of that particular element. The term dose as used herein is defined as the measured amount of liquid to be delivered by the package. The dose begins when the liquid first exits the base orifice (21) and ends once the flow of said liquid stops. By substantially independently from pressure as used herein it is meant that pressure causes less than 10% variation from the target measured dose. By substantially constant liquid output or dosage as used herein it is meant that variation from the target measured dose is less than 10%. By shear thinning as used herein it is meant that the liquid referred to is non-Newtonian and preferably has a viscosity that changes with changes in shear rate. By drip-free as used herein it is meant that no visible residue is left proximal to the nozzle of the cap following dosing and/or that no liquid exits the resilient container without squeezing.
[0026] A preferred field of use is that of dosage devices for domestic or household use, containing detergents such as hard surface cleaning compositions, liquid laundry detergent compositions, or other cleaning preparations, and the like. A particularly preferred field of use is hard surface cleaning, especially manual dishwashing. For such applications, the resiliently squeezable container (10) can have an overflow volume, as measured using the method described herein, of from 0.1 litres to 5 litres, preferably from 0.2 litres to 1.5 litres, more preferably from 0.25 litres to 0.75 litres. The volume of liquid dosed for each squeeze of the package (1) is typically from 1 ml to 50 ml, preferably from 2 ml to 30 ml, more preferably 3 ml to 20 ml.
Bottom-Dispensing Package:
[0027] The invention is directed to a package (1) for repeatedly dosing a quantity of liquid. The package (1) comprises a resiliently squeezable container (10), and a base (20) operably connected to said container (10).
[0028] Bottom-dispensing packages (1) have several advantages over other packaging types. The package (1) does not need to be inverted, requiring fewer user motions for dispensing and providing greater positioning and dispensing control than for packages that dispense from orifices in the top of the package. In addition, there is no need to wait for the liquid contained within to reach the orifice before dispensing, especially when the amount of composition remaining within the package is low. Thus bottom-dispensing packages simplify activities such as hand dishwashing, where repeated dosing of detergent composition is required.
[0029] A significant advantage of the present bottom dispensing package (1) is its non-pressurized nature. That is, the liquid contained within the resiliently squeezable container is not maintained under a pressurised gas or similar means. By eliminating the need for pressurized components, the bottom dispensing package (1) can be manufactured at a relatively lower cost compared to pressurized alternatives. Furthermore, the absence of pressurization in the package (1) results in enhanced flow rates during extended periods of use. The liquid can be dispensed smoothly and consistently, maintaining its desired properties without experiencing a decline in performance over time. This ensures a reliable and satisfying user experience.
Resiliently Squeezable Container:
[0030] The resiliently squeezable container (10) is preferably a bottle. The resiliently squeezable container (10) comprises a container wall (11).
[0031] The resiliently squeezable container (10) can comprise a container opening (12), wherein the container opening (12) is positioned at a lower portion or at the bottom of the container (10).
[0032] The resiliently squeezable container (10) can have an internal volume, for the liquid contained therein, of from 0.1 litres to 5.0 litres, preferably from 0.2 litres to 1.5 litres, more preferably from 0.25 litres to 0.75 litres.
[0033] That container (10) can have a height of from 75 mm to 300 mm, preferably from 100 ml to 270 ml, more preferably from 150 mm to 225 mm, wherein the height of the container is measured from the inner-surface of the orifice (21) which is within the bottom-dispensing package (1), to the top of the container (10) or, if a cap (90) is present, to the top of the cap (90).
[0034] The container wall (11) can have a thickness of from 0.25 mm to 8.0 mm, preferably from 0.5 mm to 6.0 mm, more preferably from 1.0 to 4.0 mm.
[0035] The top of the container (10), distal from the base (20), can be closed. Alternatively, the container can comprise a cap (90), the cap (90) preferably being detachable. If present, the cap (90) can be comprised on the top of the container, distal from the base (20). Such caps (90) can be sized to provide easy refilling of the container (10) without the need to remove the base (20). The cap (90) can be a screw-on cap, or a push-fit cap or other form of cap which sealingly engages with the container (10).
[0036] Especially, but not only, when the container wall (11) is at least partially made from an elastomer, the container wall (11) can be very flexible. As such, if needed, the cap (90) can comprise an attachment ring which is fixedly attached to the container wall (11), for instance via gluing or welding. Alternatively, the container wall (11) can be moulded on to the cap (90), or vice-versa. The cap (90) can be permanently attached to the enclosure, for instance, via a string or plastic chord, or may be fully detachable. The cap (90), and if present its attachment ring is preferably rigid.
[0037] The interior (14) or exterior surface (15) of the resiliently squeezable container (10) can comprise at least one, preferably multiple, circumferentially oriented grooves (80). Such grooves (80) on the interior surface result in greater flexibility and spring-back of the container while ensuring that the exterior surface (14) can be left smooth or textured as desired. In addition, the exterior surface (14) of the container (10) remains easy to clean. The at least one groove (80) is preferably essentially horizontally oriented. As such, the groove (80) can have a spiral form or can be one or more horizontal groove (80). Multiple horizontal grooves (80) are preferred.
[0038] The at least one circumferentially oriented groove (80) can extend over at least 70%, preferably at least 80%, more preferably at least 95%, most preferably 100% of the circumferential length of the interior surface (15) of the container wall (11) where the at least one circumferentially oriented groove (80) is positioned. The interior surface (15) of the container wall (11) preferably comprises multiple circumferentially oriented grooves (80). The circumferentially oriented grooves (80) can be present over a groove zone (4) which extends over at least 25%, preferably at least 50%, more preferably at least 75% of the height of the container wall (11).
[0039] Where the circumferentially oriented grooves (80) are present, the grooves (80) can be spaced out such that the pitch (81) is from less than 1 mm to 15 mm, preferably from 2 mm to 12 mm, more preferably from 2.5 mm to 10 mm, wherein the pitch (81) is defined as the distance between two adjacent peaks (82) of the circumferentially oriented grooves (80) on the interior surface (15) of the resiliently squeezable container.
[0040] If grooves (80) are present, the wall thickness is measured as the distance between the exterior surface (14) and the groove top (82), measured perpendicular to the exterior surface (14) of the container wall (11).
[0041] The exterior surface (14) of the container wall (11) can comprise further grooves or ribs. However, the exterior surface is preferably essentially free of such further grooves or ribs, with the possible exception of such further grooves and ribs which form part of a mark, such as a trademark, ingredients, or the like.
[0042] The container wall (11) can have a wider portion (2), such that at least part of the exterior surface of the container (10) has a convex shape. For good gripping and dispensing, the wider portion (2) preferably has a radius of from 25 mm to 120 mm, preferably from 40 mm to 100 mm, more preferably from 50 mm to 80 mm. Where the cross-section of the wider portion (2) of the container wall (11) is non-circular, such as oval, the radius is calculated based on a circular cross-section having the same cross-sectional area. The radius of the wider portion (2) is calculated where the cross-sectional area is a maximum.
[0043] The container wall (11) can have a narrow portion (3), such that at least part of the exterior surface of the container wall (11) has a concave shape which is narrower that the adjacent parts of the container (10). The narrow portion (3) is preferably situated adjacent to the wider portion (2) of the container wall (11), and in particular, adjacent to where the container wall (11) would typically be gripped and squeezed. In such embodiments, the narrow portion (3) and the wider portion (2) are connected together by a point of inflexion. The narrow portion (3) preferably has a diameter of from 30 mm to 65 mm, preferably from 35 mm to 55 mm, more preferably from 40 mm to 50 mm. Where the cross-section of the narrow portion (3) of the container wall (11) is non-circular, such as oval, the radius is calculated based on a circular cross-section having the same cross-sectional area. The radius of the narrow portion (3) is calculated where the cross-sectional area is a minimum. The ratio of the diameter of the wider portion (2) to the narrow portion (3) is preferably from 1.1:1 to 3:1, more preferably from 1.2:1 to 2.0:1, and most preferably from 1.3:1 to 1.7:1. The diameter of the wider portion (2) is measured where the diameter is largest, while the diameter of the narrow portion (3) is measured where the narrow portion is narrowest. For containers having a non-circular horizontal cross-section, the diameter is defined as the diameter of the circle having the same cross-sectional area. While the variation in the diameter appears relatively small, it corresponds to the ratio of the cross-sectional area of the wider portion (2) to the narrow portion (3) being preferably from 1.21:1 to 9.0:1, more preferably from 1.44:1 to 4.0:1, and most preferably from 1.69:1 to 2.89:1.
[0044] The container wall (11) has both a wider portion (2) and a narrow portion (3), more preferably wherein the narrow portion (3) is above the wider portion (2). Such containers (10) provide improved spring-back to the original shape once the squeezing pressure has been removed. In addition, by squeezing on the narrow portion (3) of the container wall (11), accurate dosing of smaller amounts of the composition, contained therein, can be achieved. By squeezing on the wider portion (2) of the container wall (11), accurate dosing of large amounts of the composition, contained therein, can be achieved.
[0045] The wider portion (2) and preferably both the wider portion (2) and the narrow portion (3) have either a circular or oval cross section, with a circular cross section being preferred. It has been found that such cross-sections result in improved spring-back of the container wall (11) back to the original shape, after the squeezing pressure has been removed. This is in contrast to stiffer bottom-dispensing containers such as those made from polyethylene terephthalate (PET), polyethylene, polypropylene, and the like, where an essentially flat front panel and preferably also a back panel are more desired.
[0046] Resin materials suitable for use in making the resiliently squeezable container (10), especially the container walls (11), can be selected from the group consisting of: polyethylene terephthalate (PET), polypropylene (PP), low-density polyethylene (LDPE), high-density polyethylene (HDPE) and mixtures thereof, preferably polyethylene terephthalate (PET), or high-density polyethylene (HDPE), more preferably polyethylene terephthalate (PET). Such materials are particularly suitable when forming the container (10) using an injection stretch blow-moulding process.
[0047] The resiliently squeezable container (10) formed from such resins can be made using any suitable process, though blow-moulding (BM) processes, and especially extrusion blow moulding or injection stretch blow-moulding (ISBM) processes are preferred, with injection stretch blow-moulding (ISBM) processes being most preferred.
[0048] Further details on extrusion blow-moulding can be obtained in general packaging textbook, for example in The Wiley Encyclopaedia of Packaging Technology, referred to above (in particular pages 83-86). Extrusion blow-moulding may be used to obtain laminated or co-extruded containers with multiple layers for aesthetic or improved physical (barrier) properties. More information on injection stretch blow-moulding processes can be obtained from general textbooks, for example The Wiley Encyclopaedia of Packaging Technology, Second Edition (1997), published by Wiley-Interscience Publication (in particular see pages 87-89).
[0049] The present package (1) can be foreseen to be durable so that it can be repeatedly refilled and re-used. Materials such as polyethylene terephthalate (PET), polyethylene, polypropylene, and the like, are prone to strain-hardening and cracking after repeated use, especially when at the thickness to provide the desired spring-back after use. Therefore, the container wall (11) of use in the present invention can be at least partially made from, for example, an elastomer, preferably wherein the elastomer is selected from the group consisting of: thermoplastic elastomer, silicone rubber, rubber, or a combination thereof, with thermoplastic elastomers and/or silicone rubber being preferred and thermoplastic elastomers being particularly preferred. The container wall (11) is preferably fully made from the elastomer, with the exception of any components that are necessary for connecting the optional cap (90) and/or base (20).
[0050] Elastomers are polymers with viscoelasticity, generally having low Young's modulus and high yield strain compared with other materials. Elastomers are amorphous polymers existing above their glass transition temperature, so that considerable segmental motion is possible. As such, they are relatively soft and deformable at ambient temperatures, for instance 21 C.
[0051] Thermoplastic elastomers (TPE) are copolymers or a physical mix of polymers, such as a plastic and a rubber, which comprises materials with both thermoplastic and elastomeric properties. Thermoplastic elastomers are relatively easy to manufacture, for example, by injection molding. Thermoplastic elastomers show advantages typical of both rubbery materials and plastic materials. The principal difference between thermoset elastomers and thermoplastic elastomers is the type of crosslinking bond in their structures. The crosslink in thermoset polymers is a covalent bond, such as created during a vulcanization process. In contrast, the crosslink in thermoplastic elastomer polymers is physical, reversible, typically comprising entanglements, a weaker dipole or hydrogen bond or a difference in material phase such as crystalline regions. For example, one of the constituent polymers, or segments of the constituent polymer has a melting or glass transition temperature well above room temperature. Examples of suitable thermoplastic elastomers, methods of making them, and methods of processing that, can be found in Handbook of Thermoplastic Elastomers, December 2007, Drobny, ISBN 9780815515494.
[0052] Thermoplastic elastomers include reactor-made thermoplastic elastomers, such as styrene block copolymers (SBC), thermoplastic polyether block amides (TPA), thermoplastic polyurethane elastomer (TPU) and thermoplastic copolyester elastomer (TCA). Reactor-made thermoplastic elastomers are implemented in one polymer that is formed through a reaction process which results in polymer segments that provide the thermoplastic properties and polymer segments that provide the elastomeric properties. Other thermoplastic elastomers comprise a blend of polymers, such as homopolymers and/or copolymers, that give rise to crystalline domains where blocks from the polymer co-crystallizes with blocks in adjacent chains, such as in copolyester rubbers. Depending on the block length, the domains are generally more stable than the latter owing to the higher crystal melting point. That crystal melting point determines the processing temperatures needed to shape the material, as well as the ultimate service use temperatures of the resultant thermoplastic elastomer. Such materials include Hytrel, a polyester-polyether copolymer and Pebax, a nylon or polyamide-polyether copolymer. Reactor-made thermoplastic elastomers are preferred, especially thermoplastic polyurethane elastomers (TPUs).
[0053] Thermoplastic elastomers, often referred to as thermoplastic olefins are typically derived from polyolefins and are also preferred due to their improved recyclability. The thermoplastic elastomer can contain further ingredients such as plasticizers, fillers, compatibilizers, and the like.
[0054] Silicone rubbers are elastomers composed of silicone. Silicone rubbers are often one- or two-component polymers, and may comprise fillers to improve properties or reduce cost. Silicone rubber is generally non-reactive, stable, and resistant to extreme environments and a wide range of temperatures, while still maintaining their properties. Due to these properties and case of manufacturing and shaping, silicone rubber can be found in a wide variety of products, including voltage line insulators; automotive applications; cooking, baking, and food storage products; apparel such as undergarments, sportswear, and footwear; electronics; medical devices and implants; and in home repair and hardware, in products such as silicone sealants. Silicone is typically a highly adhesive gel or liquid, which is converted to silicone rubber by curing, such as through vulcanisation (condensation curing), catalysed curing, or peroxide curing. This is normally carried out in a two-stage process at the point of manufacture into the desired shape, and then in a prolonged post-cure process. The curing process can be accelerated by adding heat or pressure.
[0055] Suitable rubbers can be either naturally derived, or synthetically derived. Naturally derived rubber comprises suitable polymers derived from natural sources, most often isoprene with minor impurities of other organic compounds. Natural rubber is typically harvested in the form of latex. The latex is then refined into rubber ready for commercial processing. Synthetically derived rubber is an artificial elastomer, derived from petroleum byproducts, which is crosslinked via vulcanisation. Rubber can be used either alone or in combination with other materials.
[0056] The elastomer can have a Shore A (Type A) hardness of from 0 to 80, preferably 5 to 60, more preferably 10 to 40. The Shore A hardness can be measured using the method described in ISO 868:2003 (last reviewed and confirmed in 2018). The elastomer can have a tensile elongation (break), measured in the flow direction at a stretch rate of 200 mm/min at 23 C. using the method described in ISO 37:2017 (last reviewed and confirmed in 2022), of from 200% to 1000%, preferably from 250% to 750%, more preferably from 300% to 700%. The elongation at break is a characteristic value that describes the maximum percentage elongation that a tensile specimen experiences at the moment of break. It therefore describes the deformability of a material under tensile load. The elastomer can have a compression set, measured at 23 C. over 72 hours using the method described in ISO 815-1:2019, of less than 50%, preferably less than 35%, more preferably less than 20%. The compression set measures the ability of the elastomer to withstand hardening and retain their elastic properties at ambient temperatures after prolonged compression. As such, the compression set provides an indication of the ability of the elastomer to withstand physical or chemical changes which prevent the elastomer from returning to its original dimensions after release of the deforming force, or lose too much of its elasticity.
[0057] Durable container walls (11) or even the resiliently squeezable container (10) itself can be made using any suitable moulding process, such as injection moulding, rotational moulding or compression moulding.
[0058] Injection moulding is a method to obtain moulded products by injecting plastic materials molten by heat into a mould, and then cooling and solidifying them. The method is suitable for the mass production of products with complicated shapes. With injection moulding, the elastomer is first melted down so that it can be put into the injection unit. The injection unit can be a plunger, an extruder or similar. The injection unit is typically heated to above the melt temperature of the elastomer. The melted elastomer is then injected into the mould. Once injected, it can be vulcanized or cooled so that it forms the shape of the mold, creating an elastomer molded part. For thermoplastic elastomers, cooling is typically sufficient.
[0059] With transfer moulding, the elastomer is heated and not the mould. The liquid elastomer remains in a melted state until the moulding process begins. An injector, such as a plunger, pushes the elastomer into the closed mould where it forms the shape after being cooled or vulcanized. Once cooled, the mould can be opened to release the container.
[0060] Compression moulding is a method of moulding in which the moulding material, generally preheated, is first placed in an open, heated mould cavity. The mould is closed with a top force or plug member, pressure is applied to force the material into contact with all mould surfaces, while heat and pressure are maintained until the moulding material has cured. Where the process employs thermosetting resins, for instance in a partially cured stage, either in the form of granules, putty-like masses, or preforms, the process is essentially a vulcanisation process. For improved strength or resiliency, fibres can be added to the moulding material. Advanced composite thermoplastics can also be compression molded with unidirectional tapes, woven fabrics, randomly oriented fiber mat or chopped strand. The elastomer may be loaded into the mould either in the form of pellets or sheet, or the mould may be loaded from a plasticating extruder. Materials are heated above their melting points, formed and cooled. The more evenly the feed material is distributed over the mold surface, the less flow orientation occurs during the compression stage. Compression moulding can also be used to produce sandwich structures that incorporate a core material such as a honeycomb or polymer foam into the resiliently squeezable container (10).
Void Volume:
[0061] The void volume (13) is a space comprised within the package (1) and more preferably within the resiliently squeezable container (10), comprising a gas, preferably air. If the liquid composition contained within the resiliently squeezable container (10) is susceptible to microbial contamination or oxidisation, the void volume (13) can be initially filled with an inert gas, such as nitrogen. During use, the volume of gas contained within the void volume (13) increases as air is entrained into the container (10).
[0062] When the container (10) is squeezed, the internal pressure generated within the container (10) results in the void volume (13) being deformed, reducing the volume of the void volume (13), which results in at least part of the air contained within the void volume (13) being expelled through the air inlet (42) and air inlet valve (43) and into the mixing chamber (46).
[0063] The void volume (13) can be formed by partially filling the container (10), to leave a space at the top of the container (10). Prior to initial use, the void volume (13) can form from 1.0% to 25%, preferably from 4.0% to 20%, more preferably from 8.0% to 15% by volume of the container (10). As the liquid composition contained within the container (10) is dispensed, the void volume (13) increases.
[0064] The void volume (13) is operably connected to the air inlet valve (43), preferably via a dip-tube (60).
[0065] Alternatively, or in addition, the void volume (13) can be a separate compartment (16) comprised within the container (10). Where the void volume (13) is a separate compartment (16), at least part of the separate compartment (16) is flexible. For instance, the void volume (13) can comprise a flexible panel (17). The flexible panel (17) can be elastic. Alternatively, the flexible panel can comprise a spring element (18), such as a plastic hinge. The separate compartment (16) can alternatively be a flexible bulb or balloon.
[0066] The void volume (13) can further comprise a void volume inlet valve (19), wherein the void volume inlet valve (43) is a one-way valve which allows ingress of air into the void volume (13) from the exterior atmosphere, especially when the void volume (13) is a separate compartment (16). The void volume inlet valve (43) can be any suitable one-way valve. Suitable one-way valves include: duckbill valves, umbrella valves, flapper valves, ball valves, degassing valves, and spring-loaded valves, as described herein. The opening pressure differential of the void volume inlet valve (19) is preferably less than the opening pressure differential of the foam-dispensing valve (50) in the reverse direction. That is, less than the opening pressure required to open foam-dispensing valve (50) and allow ingress of air from the exterior atmosphere, into the mixing chamber (46).
Base:
[0067] The package comprises a base (20) operably connected to the container (10). The base (20) comprises a base orifice (21) which is operably connected to the foamer body (40). The base (20) typically comprises or consists of a base housing (29), as exemplified in
[0068] The base (20) can comprise a closure (not shown) which is at least partially detachable, more preferably fully removable from the base (20). When the package is more resistant to leakage due to changes in pressure during use, transport and storage, the cap is preferably not scalingly engaged to the orifice (21). Preferably, the base (20) does not comprise a closure or the base (20) comprises a closure which is fully detachable and can be removed and discarded prior to first use. The base (20) can also comprise a sticker covering the orifice (21) as additional protection against leakage during transport.
[0069] The base (20) can comprise a bottom surface which can optionally be adapted for resting the package (1) on a flat surface. The base (20) can comprise a base wall (22), at least partially, preferably fully connected to the periphery of the bottom surface and extending from said periphery of the bottom surface to a base wall rim (23), such that the bottom-dispensing package (1) can rest on the base wall rim (23). Such a base wall (22) can further comprise an exterior base wall surface (24) and an interior base wall surface (25).
[0070] When the resiliently squeezable container is made from an elastomer, the bottom dispensing package (1) of the present invention is less prone to leakage due to pressure changes during storage and transport, for instance, from variations in temperature. However, leakage can also be due to transient liquid pressure increases from impact, such as if the package is dropped or placed on a surface with sufficient force. Such transient liquid pressure increases, also referred to as hydraulic hammer pressure, inside the container can momentarily force open the valve causing liquid to leak out. At least part of the base (20) can be made from an elastomer, in order to reduce leakage due to transient liquid pressure increases from impact. By making at least part of the base (20) from an elastomer, at least part of the aforementioned transient liquid pressure increases (hydraulic hammer pressure), is absorbed. The base housing (29) is preferably at least partially made from an elastomer. By making part of the base, and especially part of the base housing (29) from an elastomer results in less leakage due to transient liquid pressure increases from impacts. The base wall (22) can comprise an elastomer. For instance, the base wall (22) can be moulded from a hard plastic such as polypropylene and an elastomeric lip, comprising the base-wall rim (23) can be over-moulded onto the base wall (22). More preferably, the base wall (22) is made from an elastomer.
[0071] The elastomer used in the base (20) can have a Shore A (Type A) hardness of from 0 to 80, preferably 5 to 60, more preferably 10 to 40. The Shore A hardness can be measured using the method described in ISO 868:2003 (last reviewed and confirmed in 2018). The elastomer can have a tensile elongation (break), measured in the flow direction at a stretch rate of 200 mm/min at 23 C. using the method described in ISO 37:2017 (last reviewed and confirmed in 2022), of from 200% to 1000%, preferably from 250% to 750%, more preferably from 300% to 700%. The elongation at break is a characteristic value that describes the maximum percentage elongation that a tensile specimen experiences at the moment of break. It therefore describes the deformability of a material under tensile load. The elastomer can have a compression set, measured at 23 C. over 72 hours using the method described in ISO 815-1:2019, of less than 50%, preferably less than 35%, more preferably less than 20%. The compression set measures the ability of the elastomer to withstand hardening and retain their elastic properties at ambient temperatures after prolonged compression. As such, the compression set provides an indication of the ability of the elastomer to withstand physical or chemical changes which prevent the elastomer from returning to its original dimensions after release of the deforming force, or lose too much of its elasticity.
[0072] The body of the base (20) and the resiliently squeezable container (10) can be co-moulded together, especially where they are made from the same elastomer. In such embodiments, the resiliently squeezable container (10) and the base (20) are essentially a single element.
Foamer Body:
[0073] The foamer body (40) comprises: a mixing chamber (46), at least one liquid inlet (41), and at least one air inlet (42). The air inlet valve (43) is a one-way valve which allows ingress of air into the mixing chamber (46) from the void volume (13) through the air inlet (42). The foam outlet (44) is operably connected to the base orifice (21). The foam outlet (44) comprises a foam-dispensing valve (50) for dispensing the foam from the mixing chamber (46) through the foam outlet (44).
[0074] The at least one liquid inlet (41) allows ingress of liquid (100) into the mixing chamber (46) from the container (10). The liquid inlets (41) can have any suitable form. Preferably, the liquid inlets (41) can be in the form of slit-like openings in the foamer body (40), more preferably with the long axis of the slit-like opening oriented horizontally. The foamer body (40) can comprise from one to five, preferably from one to three liquid inlets (41) in the foamer body (40).
[0075] Preferably, the total surface area of the liquid inlet (41) to the mixing chamber (46) is from 1.0 mm.sup.2 to 75 mm.sup.2, preferably from 1.5 mm.sup.2 to 50 mm.sup.2, more preferably from 3.0 mm.sup.2 to 30 mm.sup.2. The total surface area is measured as the cross-sectional area and is the measured as the sum of the cross-sectional areas of all of the liquid inlets (41) to the mixing chamber (46).
[0076] The foamer body (40) can comprise at least one wall (45). To reduce leakage, the foamer body (40) can comprise an inner wall (45a) and an outer wall (45b), positioned as a siphon, with the inner wall (45a) forming the wall of the mixing chamber (46). In such a foamer body (40), the at least one liquid inlet (41) in the inner wall (45a) are preferably positioned higher than the at least one liquid inlet (41) in the outer wall (45b) of the foamer body (40). Preferably, the total surface area of the liquid inlet (41) in the outer wall (45b) is from 1.0 mm.sup.2 to 75 mm.sup.2, preferably from 1.5 mm.sup.2 to 50 mm.sup.2, more preferably from 3.0 mm.sup.2 to 30 mm.sup.2. The total surface area is measured as the cross-sectional area and is the measured as the sum of the cross-sectional areas of all of the liquid inlets (41) in the outer wall (45b).
[0077] The mixing chamber (46) can be any suitable shape, with circular or oval cross-sections being preferred. The mixing chamber (46) can be sized according to the desired amount of foam to be dispensed. The mixing chamber (46) can have a volume of from 50 mm.sup.3 to 2,500 mm.sup.3, preferably from 100 mm.sup.3 to 1,500 mm.sup.3, more preferably from 150 mm.sup.3 to 1,250 mm.sup.3. The volume of the mixing chamber (46) is the space in the mixing chamber (46) between the liquid inlet (41), the air inlet (42) or air inlet valve (43), whichever is closest to the mixing chamber (46), and the foam-dispensing valve (50).
[0078] The mixing chamber (46) can comprise at least two cavities, with an upper cavity (46a) and a lower cavity (46b), wherein the upper cavity (46a) and the lower cavity (46b) are connected by a diffusing orifice (47). Preferably, the liquid inlet (41) and air inlet (42) allow ingress of liquid (100) and air into the upper cavity (46a). As the liquid (100) and air pass through the diffusing orifice (47), mixing of the liquid (100) and air is improved, resulting in improved foaming.
[0079] The upper cavity (46a) can have a volume of from 20 mm.sup.3 to 950 mm.sup.3, preferably from 40 mm.sup.3 to 550 mm.sup.3, more preferably from 60 mm.sup.3 to 475 mm.sup.3. The volume of the upper cavity (46a) is the space in the mixing chamber (46) between the liquid inlet (41), the air inlet (42) or air inlet valve (43), whichever is closest to the mixing chamber (46), and the mid-point of the diffusing orifice (47).
[0080] The lower cavity (46b) can have a volume of from 50 mm.sup.3 to 1550 mm.sup.3, preferably from 60 mm.sup.3 to 950 mm.sup.3, more preferably from 90 mm.sup.3 to 775 mm.sup.3. The volume of the lower cavity (46b) is the space in the mixing chamber (46) between the mid-point of the diffusing orifice (47) and the foam-dispensing valve (50).
[0081] The at least one air inlet (42) comprises: an air inlet valve (43), wherein the air inlet valve (43) is a one-way valve which allows ingress of air from the void volume (13) through the air inlet (42), into the mixing chamber (46).
[0082] Preferably, the total surface area of the air inlet (42) is from 1.0 mm.sup.2 to 75 mm.sup.2, preferably from 3.0 mm.sup.2 to 50 mm.sup.2, more preferably from 5.0 mm.sup.2 to 30 mm.sup.2. The total surface area is measured as the cross-sectional area and is the measured as the sum of the cross-sectional areas of all of the air inlets (42).
[0083] For a more jet-like foam, a lower ratio of the total surface area of the air inlet (42) to the total surface area of the liquid inlet (41) is needed. For such foams, the ratio of the total surface area of the air inlet (42) to the total surface area of the liquid inlet (41) can be from 1:2.5 to 1:15, preferably from 1:2.5 to 1:10, more preferably from 1:2.5 to 1:7.5. In contrast, a more mousse-like foam comprising a higher proportion of liquid composition is achieved when the ratio of the total surface area of the air inlet (42) to the total surface area of the liquid inlet (41) is from 1:0.4 to 1:2.4, preferably from 1:0.6 to 1:2.4, more preferably from 1:0.75 to 1:1.5.
[0084] The air inlet valve (43) is preferably positioned on or near the foamer body (40). When the air inlet (42) comprises a dip-tube (60), the air inlet valve (43) can alternatively be positioned at or near the end of the dip-tube (60) distal from the foamer body (40). The air inlet valve (43) is opened by exerting pressure on the container (10), such as by gripping and squeezing the container. The air inlet valve (43) opens at a pressure differential of from 1.0 to 25 mbar, preferably from 5.0 to 25 mbar, more preferably from 10 to 25 mbar, measured at 20 C. A challenge for traditional foam dispensing packages is that if the user squeezes slowly, liquid with little foam is typically dispensed. While higher applied pressures result in improved foaming, the bottom-dispensing foam discharge package (1) of the present invention can also dispense relatively good foam at lower applied pressures, with less non-foamed liquid being dispensed, especially when the air inlet valve (43) opens at a pressure differential which is less than the a pressure differential required to open the foam-dispensing valve (50).
[0085] The air inlet valve (43) is preferably a one-way valve. Suitable one-way valves can be selected from: duckbill valves, umbrella valves, flapper valves, ball valves, degassing valves, and spring-loaded valves. Less preferably, the air inlet valve (43) can be a slit-valve. When the air inlet valve (43) is a slit-valve, the opening pressure differential of the slit-valve in the direction from the mixing chamber (46) to the void volume (13) is greater than the opening pressure differential of the foam-dispensing valve (50) in the inverse direction. That is, greater than the opening pressure required to open the foam-dispensing valve (50) and allow ingress of air from the exterior atmosphere, into the mixing chamber (46).
[0086] Duckbill valves are typically one-piece, elastomeric components that act as backflow prevention devices or one-way valves or check valves. They have elastomeric lips in the shape of a duckbill which prevent backflow and allow forward flow. The main advantage of duckbill valves over other types of one-way valves is that duckbill valves are self-contained, in that the critical sealing function is an integral part of the one-piece elastomeric component as opposed to valves where a sealing element has to engage with a smooth seat surface to form a seal. Therefore, duckbill valves are easily incorporated and assembled into a wide variety of devices without the hassle or problems associated with the surface finish quality of mating seats and/or complex assembly processes. Duckbill valves can be supplied by Minivalve (Netherlands).
[0087] Umbrella valves and Belleville valves are elastomeric valve components that have a diaphragm shaped scaling disk (umbrella shape). These elastomeric components are used as sealing elements in backflow prevention devices or one-way valves or check valves, in vent valves or pressure relief valves and in metering valves. When mounted in a seat, the convex diaphragm flattens out against the valve seat and absorbs a certain amount of seat irregularities and creates a certain sealing force. The umbrella valve will allow forward flow once the head pressure creates enough force to lift the convex diaphragm from the seat and so it will allow flow at a predetermined pressure in one way and prevent back flow immediately in the opposite way. Umbrella valves can be supplied by Minivalve (Netherlands).
[0088] Degassing valves can typically be found on bags of coffee and allow gases that are generated by the roasted beans to escape from the bag. When used in the present invention, the degassing valve is inversely mounted so that air can pass into the package (1) through the one-way vent (70) but not pass out of the package. Degassing valves are well known and typically comprise a cap, an elastic disc, a viscous layer, a plate usually made from polyethylene, and a paper filter. The elastic disc, such as a rubber diaphragm, is enclosed in the valve, and the side positioned on the exterior side of the container (10) or cap (70) has a viscous layer of sealant liquid that maintains surface tension against the valve. Once the pressure differential from the resiliently squeezable container (10) elastically returning to its original shape exceeds the surface tension, the elastic disc is released and air is able to ingress into the container (10). Suitable degassing valves are provided by EPAC Flexibles (Ghana), MTPak (China), WIPF Doypak (Turkey), and the like. Since the degassing valve is inversely mounted to the container (10) or cap (70), the valve is preferably protected by an air-permeable cover.
[0089] Spring loaded valves comprise a spring which holds a closure means such as a ball or pin in place. As such, an opposing pressure differential is required to open the valve. The spring can be metal or another elastic material such as a suitable plastic or rubber.
[0090] The liquid composition (100) can be provided via the liquid inlet (41) and air via the air inlet (42) such that the volumetric ratio of air entering via the air inlet (42) to liquid composition entering via the liquid inlet (41) is from 1:1 to 50:1, preferably from 2:1 to 25:1, more preferably from 5:1 to 15:1.
[0091] The foam outlet (44) is operably connected to the base orifice (21). The foam outlet (44) and the base orifice (21) can be the same, especially when at least part of the foamer body (40) and base housing (29) are moulded as a single piece.
[0092] The foam-dispensing valve (50) can be a slit-valve. As shown by
[0093] When the foam-dispensing valve (50) is a one-way valve, foam is dispensed and no air is entrained back into the foamer body (40). For such embodiments, a small amount of liquid is dispensed prior to the foam during subsequent use.
[0094] The foam-dispensing valve (50) preferably opens to dispense foam at a pressure differential of from 25 to 250 mbar, preferably from 25 mbar to mbar 150 mbar, more preferably from 25 mbar to 100 mbar, measured at 20 C. Where the foam-dispensing valve (50) is a two-way valve, the foam-dispensing valve (50) preferably opens to allow the ingress of air at a pressure differential of from 10 mbar to 250 mbar, preferably from 15 mbar to 150 mbar, more preferably from 25 mbar to 100 mbar, measured at 20 C.
[0095] The foam-dispensing valve (50) defines a dispensing orifice (53) that is reactably openable when the pressure on the valve interior side (51) exceeds the pressure on the valve exterior side (52).
[0096] The foam-dispensing valve (50) is preferably a flexible, elastomeric, resilient, 2-way bi-directional, self-closing, slit-type valve, and can be mounted in the foaming body (40), between the foaming body (40) and base orifice (21), or within the base orifice (21). The valve (50) has slit or slits (55) which define the dispensing orifice (53). For example, the dispensing orifice (53) may be formed from one slit (55) or two or more intersecting slits (55), that may open to permit dispensing of liquid therethrough in response to an increased pressure inside the container (10), such as for example, when the container (10) is squeezed. The foam-dispensing valve (50) is typically designed so as to reactably close the dispensing orifice (53) and stop the flow of liquid therethrough upon a reduction of the pressure differential across the valve (50). The amount of pressure needed to keep the foam-dispensing valve (50) in the closed position will partially depend on the internal resistance force of the foam-dispensing valve (50). The internal resistance force refers to a pre-determined resistance threshold, which leads to the opening pressure (or cracking-pressure) required for deformation/opening of the valve (50). In other words, the foam-dispensing valve (50) will not tend to resist deformation/opening so that it remains closed under pressure of the steady state liquid bearing against the interior side (51) of the foam-dispensing valve (50). The amount of pressure needed to deform/open the valve (opening pressure) must overcome this internal resistance force. This internal resistance force should not be too low so as to cause liquid leakage or too high to make dispensing a dose of liquid difficult.
[0097] Accordingly, the foam-dispensing valve (50) preferably has an opening pressure that is at least 10 mbar, preferably at least 25 mbar, more preferably less than 250 mbar, even more preferably less than 150 mbar, most preferably less than 75 mbar. Preferably, the dispensing orifice (53) is designed to be in the open position when a pressure difference of at least 10 mbar, preferably at least 25 mbar exists between the valve interior side (51) in relation to the valve on the exterior side (52). Preferably the force exerted on the valve interior side (51) that is required in order to open the dispensing orifice (53) is at least 10 mbar, preferably at least 25 mbar. The foam-dispensing valve (50) preferably opens at a pressure differential of from 10 to 250 mbar, preferably from 15 to 150 mbar, more preferably from 25 to 75 mbar, measured at 20 C.
[0098] Preferably the valve (50) has a surface area of between 0.1 cm.sup.2 and 10 cm.sup.2, more preferably between 0.3 cm.sup.2 and 5 cm.sup.2, most preferably between 0.5 cm.sup.2 and 2 cm.sup.2. Preferably the valve (50) has a height of between 1 mm and 10 mm, more preferably between 2 mm and 5 mm. Other dimensions could be used so long as they allow for the dispensing orifice (53) to remain in the fully closed position at rest.
[0099] As shown in
[0100] With continued reference to
[0101] The foam-dispensing valve (50) is typically designed to close the base orifice (21) and stop the flow of liquid through the base orifice (21) upon a reduction of the pressure differential across the foam-dispensing valve (50).
[0102] Especially where the container (10) comprises a low viscosity liquid, the use of a foam-dispensing valve (50) which opens at a relatively low-pressure differential helps to avoid spurting of the composition through the foam-dispensing valve (50).
[0103] Moreover, the use of a foam-dispensing valve (50) which opens at such low-pressure differentials also means that a smaller pressure differential is required to draw air through the valve (50) once the squeezing has been removed, so that the container (10) can return to its original shape. This is particularly important for packages (1) which comprise a more elastic container (10) since an insufficient pressure differential across the valve (50) means that not enough air is drawn through the valve (50) and into the container (10) for the container (10) to revert back to its undeformed shape.
[0104] The opening pressure differential (in mbar) is typically measured using a water column, to which the slit-valve has been sealingly attached to the bottom of the water-column, then measuring the water-height required to open the slit valve, at the target temperature. The opening pressure differential is typically available from the valve manufacture, including on technical literature provided for the valve.
[0105] Preferably the foam-dispensing valve (50) is not contacting the surface on which the base (20) of the bottom-dispensing package (1) is standing when at rest, nor contacting the surface to be cleaned upon dosing. Heretofore the valve (50) is augmented into the base (20), preferably being positioned at least 1 mm from the resting surface, more preferably at least 5 mm, even more preferably at least 1 cm. By positioning the valve (50) above rather than in contact with the surface there is less risk of capillary seeping through the valve (50) leading to surface contamination and potentially surface damage upon storage of the package (1).
[0106] As shown in
[0107] As shown in
[0108] The foam-dispensing valve (50) is normally in the closed position and can withstand the pressure of the liquid inside the container (10) so that the liquid will not leak out unless the container (10) is squeezed.
[0109] Especially where the bottom-dispensing package (1) comprises a low viscosity liquid, the use of a slit valve as the foam-dispensing valve (50) which opens at a relatively low-pressure differential helps to avoid spurting of the composition out of the foam outlet (44).
[0110] The foam-dispensing valve (50) is preferably molded as a unitary structure from materials which are flexible, pliable, clastic and resilient. Suitable materials include, such as for example, thermosetting polymers, including silicone rubber (available as D.C. 99-595-HC from Dow Corning Corp., USA; WACKER 3003-40 Silicone Rubber Material from Wacker Silicone Co.) preferably having a hardness ration of 40 Shore A, linear low-density polyethylene (LLDPE), low density polyethylene (LDPE), LLDPE/LDPE blends, acetate, acetal, ultra-high-molecular weight polyethylene (UHMW), polyester, urethane, ethylene-vinyl-acetate (EVA), polypropylene, high density polyethylene or thermoplastic elastomer (TPE). The valve (50) can also be formed from other materials such as thermoplastic propylene, ethylene and styrene, including their halogenated counterparts. Suitable valves are commercially available such as from the APTAR Company including the SimpliSqueeze valve line up.
[0111] The foam outlet (44) can comprise at least one mesh (49). Suitable mesh (49) can be woven or nonwoven, with woven preferred. The mesh (49) can be fabricated from any suitable material, including wire and/or plastic. Suitable plastic mesh (49) can be fabricated from nylon, polyethylene terephthalate (PET), polyethylene, polypropylene, and mixtures thereof. The mesh (49) and base (20) are preferably compatible in a recycle stream. The mesh (49) can have a nominal sieve opening of from 36 microns to 400 microns, preferably from 50 microns to 280 microns, more preferably from 80 microns to 200 microns. The mesh (49) can have a typical wire diameter of from 30 microns to 250 microns, preferably from 36 microns to 180 microns, more preferably from 56 microns to 140 microns. The nominal sieve opening and typical wire diameter are as defined in in ASTM E11-22. Within the above ranges of nominal sieve opening and typical wire diameter, improved foaming is achieved, while minimising the manual squeezing pressure that is required to be applied to the container in order to provide the foam.
[0112] The mesh (49) can be positioned adjacent to the foam-dispensing valve (50). The mesh (49) can be positioned above or below the foam-dispensing valve (50). When the mesh (49) is positioned above the foam-dispensing valve (50), a higher velocity foam is achievable, resulting in a narrow jet-like stream of foam. This is because the foam is formed before building up pressure sufficiently to open the foam-dispensing valve (50). In contrast, when the mesh (49) is positioned below the foam-dispensing valve (50), a wider, lower velocity stream of foam is achieved. The mesh (49) preferably covers the entire top or bottom surface of the foam-dispensing valve (50).
Liquid Composition:
[0113] The liquid cleaning composition preferably is a liquid hand dishwashing detergent composition. The liquid hand-dishwashing detergent composition preferably is an aqueous cleaning composition, comprising from 50% to 90%, preferably from 60% to 75%, by weight of the total composition of water.
[0114] The liquid cleaning composition can have a pH of from 5 to 12, preferably from 7.5 to 10, as measured as a 10% solution in distilled water at 20 C. The pH of the composition can be adjusted using pH modifying ingredients known in the art.
[0115] The liquid composition (100) is formulated to be foaming. Since the bottom dispensing container (1) is less prone to leakage, the bottom dispensing container (1) is particularly suited for containing a liquid composition (100), especially liquid detergent composition (100), having a viscosity of from 1.0 mPa.Math.s to 100 mPa.Math.s, preferably from 5.0 mPa.Math.s to 75 mPa.Math.s, most preferably from 10 mPa.Math.s to 50 mPa.Math.s, measured at a shear rate of 10 s-1. Such low viscosity liquid compositions are more readily foaming. The composition (100) can be Newtonian or non-Newtonian, preferably Newtonian.
[0116] Preferably, the liquid composition (100) has a density between 0.5 g/mL and 2 g/mL, more preferably between 0.8 g/mL and 1.5 g/mL, most preferably between 1 g/mL and 1.2 g/mL.
[0117] The liquid composition (100), especially when formulated as a hand dishwashing composition, can comprise from 5% to 50%, preferably from 8% to 45%, most preferably from 15% to 40%, by weight of the total composition of a surfactant system. Most suitable surfactants for use in hand dishwashing formulations include anionic surfactants, amphoteric surfactants, zwitterionic surfactants and nonionic surfactants.
[0118] Most suitable anionic surfactant include alkyl sulfated anionic surfactant, more preferably alkyl sulfated anionic surfactant selected from the group consisting of: alkyl sulfate, alkyl alkoxy sulfate, and mixtures thereof. Preferred alkyl alkoxy sulfates are alkyl ethoxy sulfates. More preferred anionic surfactants are an alkyl ethoxy sulfate or a mixed alkyl sulfate-alkyl ethoxy sulfate anionic surfactant system, with a mol average ethoxylation degree of less than 5, preferably less than 3, more preferably less than 2 and more than 0.5. Alternatively, the alkyl sulfated anionic surfactant can be free of alkoxylation. The mol average ethoxylation degree is calculated as the mole average degree of ethoxylation for the alkyl ethoxy sulfate blend or, if alkyl sulfate is present, for the mixed alkyl sulfate-alkyl ethoxy sulfate anionic surfactant system.
[0119] Preferably the unalkoxylated alkyl sulfate, alkyl ethoxy sulfate, or mixed alkyl sulfate-alkyl ethoxy sulfate, anionic surfactant has a weight average level of branching of from 5% to 60%, preferably from 10% to 50%, more preferably from 20% to 40%. The weight average branching degree is calculated as the weight average degree of branching for the alkyl ethoxy sulfate blend or, if alkyl sulfate is present, for the mixed alkyl sulfate-alkyl ethoxy sulfate anionic surfactant system. Alternatively, the alkyl sulfated anionic surfactant can be free of branching, e.g. linear. The alkyl sulfate anionic surfactant can be a primary or a secondary alkyl sulfated anionic surfactant comprising on average from 8 to 18, preferably from 10 to 14 mores preferably from 12 to 14, most preferably from 12 to 13 carbon atoms within the alkyl chain.
[0120] Suitable examples of commercially available alkyl sulfate anionic surfactants include those derived from alcohols sold under the Neodol brand-name by Shell, or the Lial, Isalchem, and Safol brand-names by Sasol, or some of the natural alcohols produced by The Procter & Gamble Chemicals company.
[0121] The surfactant system may comprise further or alternative anionic surfactant, including sulfonate such as HLAS, or sulfosuccinate anionic surfactants.
[0122] A suitable amphoteric surfactant is an amine oxide surfactant. Preferably, the amine oxide surfactant is selected from the group consisting of: alkyl dimethyl amine oxide, alkyl amido propyl dimethyl amine oxide, and mixtures thereof. Alkyl dimethyl amine oxides are preferred, such as C8-18 alkyl dimethyl amine oxides, or C10-16 alkyl dimethyl amine oxides (such as coco dimethyl amine oxide). Suitable alkyl dimethyl amine oxides include C10 alkyl dimethyl amine oxide surfactant, C10-12 alkyl dimethyl amine oxide surfactant, C12-C14 alkyl dimethyl amine oxide surfactant, and mixtures thereof. C12-C14 alkyl dimethyl amine oxide are particularly preferred.
[0123] Suitable zwitterionic surfactants include betaine surfactants. Such betaine surfactants includes alkyl betaines, alkylamidobetaine, amidazoliniumbetaine, sulfobetaine (INCI Sultaines) as well as the phosphobetaine. The most preferred zwitterionic surfactant is cocoamidopropylbetaine.
[0124] Suitable nonionic surfactants include alkoxylated alcohol nonionic surfactants, alkyl polyglucoside nonionic surfactants, and mixtures thereof. Preferably, the alkoxylated non-ionic surfactant is a linear or branched, primary or secondary alkyl alkoxylated non-ionic surfactant, preferably an alkyl ethoxylated non-ionic surfactant, preferably comprising on average from 9 to 15, preferably from 10 to 14 carbon atoms in its alkyl chain and on average from 5 to 12, preferably from 6 to 10, most preferably from 7 to 8, units of ethylene oxide per mole of alcohol. The alkyl chain may be derived from a natural alcohol, as commercially available from the Procter and Gamble company, or could be synthetically derived such as those derived through an OXO, guerbet or Ziegler process. The compositions can comprise alkyl polyglucoside (APG) surfactant, to improve sudsing beyond that of comparative nonionic surfactants such as alkyl ethoxylated surfactants. Preferably, the alkyl polyglucoside surfactant has an average alkyl carbon chain length between 8 and 16, preferably between 10 and 14, most preferably between 12 and 14, alternatively between 8 and 10, with an average degree of polymerization of between 0.5 and 2.5 preferably between 1 and 2, most preferably between 1.2 and 1.6. C8-C16 alkyl polyglucosides are commercially available from several suppliers (e.g., Simusol surfactants from Seppic Corporation; and Glucopon surfactants from BASF Corporation).
[0125] The liquid hand dishwashing detergent composition herein may optionally comprise a number of other adjunct ingredients such as builders (e.g., preferably citrate), chelants (e.g., preferably GLDA), conditioning polymers, cleaning polymers including polyalkoxylated polyalkylene imines, surface modifying polymers, soil flocculating polymers, sudsing polymers including EO-PO-EO triblock copolymers, grease cleaning amines including cyclic polyamines, structurants, emollients, humectants, skin rejuvenating actives, enzymes, carboxylic acids, scrubbing particles, bleach and bleach activators, perfumes, malodor control agents, pigments, dyes, opacifiers, beads, pearlescent particles, microcapsules, organic solvents, inorganic cations such as alkaline earth metals such as Ca/Mg-ions, antibacterial agents, preservatives, anti-oxidants, viscosity adjusters (e.g., salt such as NaCl, and other mono-, di- and trivalent salts) and pH adjusters and buffering means (e.g. carboxylic acids such as citric acid, HCl, NaOH, KOH, alkanolamines, phosphoric and sulfonic acids, carbonates such as sodium carbonates, bicarbonates, sesquicarbonates, borates, silicates, phosphates, imidazole and alike).
Viscosity
[0126] The viscosity of the liquid detergent compositions is measured using a DHR-1 rotational rheometer from TA instrument, using a cone-plate geometry of 40 mm diameter, 2.008 angle with truncation gap of 56 m. Unless otherwise mentioned, the viscosity is measured at a shear rate of 10 s.sup.1.
Example
[0127] A bottom-dispensing foam discharge package was made, having a container, a base and a foamer body comprised within the base. The foamer body comprised an outer wall and an inner wall, with a mixing chamber having a single cavity comprised within the inner wall. The outer wall of the foamer body comprised three liquid inlets in the form of horizontally oriented slits in the same horizontal plane. The inner wall comprised three liquid inlets (41) in the form of rectangular openings, distributed equidistantly in a horizontal plane which is vertically above the liquid inlets in the outer wall. The foamer body further comprised an air inlet which provided a connection from the bottom portion of the container to the mixing chamber via a dip-tube. The container was filled with the detergent composition comprising 18.4% of surfactant and 6% of glycol ether solvent. The package was then positioned in a bottom-dispensing orientation, such that the dip-tube fluidly connects the void volume to the mixing chamber via the air inlet.
[0128] The air-inlet did not comprise a one-way valve. As such, the package was a comparative bottom-dispensing foam discharge package.
[0129] A second bottom-dispensing foam discharge package was made, having all the features of the comparative package, further comprising a duck-bill valve positioned at the air inlet to the mixing chamber.
[0130] The comparative and inventive bottom-dispensing foam discharge packages were held 5 cm over a sponge and squeezed in a consistent manner, providing a similar depth of squeezing over a similar timescale, and the foam discharged from the packages on to the sponge were visually compared. The comparison was repeated three times to ensure consistency in the comparison.
[0131] The one-way valves of use in the present invention, provide an opening pressure and subsequently allows the transmission of air through the air inlet at a constant pressure. As a result, the inventive bottom-dispensing foam discharge package, comprising such valves, was found to produce a much more consistent foam which piled up to produce a mousse-like foam. The comparative bottom-dispensing foam discharge package produced less foam, which was more spread out and comprised more liquid, due to the lack of opening pressure and greater pressure variations at the air inlet during use.
[0132] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as 40 mm is intended to mean about 40 mm.
[0133] Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
[0134] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.