The present invention relates generally to a flow regulator and particularly to a regulator for a dispensing closure orifice.

There are a variety of circumstances in which regulation of a flowable product is dispensed from a closure is desirable or required. For example self-closing valves are well known as are certain forms of baffles, weirs and the like to regulate/restrict flow. The present invention seeks to provide improvements in or relating to the dispensing of a flowable product from a closure or the like.

According to an aspect of the present invention there is provided a flow regulator insert for a dispensing closure, the insert comprising an inlet and an outlet, and a flow path through which flowable product can flow from the inlet to the outlet, the insert comprising a baffle within the flow path for regulating product flow.

According to a further aspect of the present invention there is provided a flow regulator for a dispensing closure, the regulator comprising an inlet and an outlet, and a flow path through which flowable product can flow from the inlet to the outlet, the insert comprising a baffle within the flow path for regulating product flow.

The baffle may cause a non-rectilinear flow path. In some embodiments a baffle is provided at the inlet and/or outlet; alternatively or additionally a baffle within the flow path i.e. spaced from the inlet/outlet may be provided. The baffle may be arranged†o cause the flow path†o include at least one generally orthogonal turn.

The inlet may include one or more lateral entry orifices.

According to a further aspect of the present invention there is provided a flow regulator for a dispensing closure orifice, comprising an orifice arrangement and an upstream baffle arrangement, the orifice arrangement includes one or more orifices and the baffle arrangement includes one or more corresponding baffle members, in which the or each orifice is substantially the same shape as, and substantially in register with, the or each respective baffle member.

This aspect of the present invention therefore provides orifice and baffle arrangement which are at least in part "negative images" of each other. For example, when viewed in plan, with the orifices and baffles arranged serially they are aligned but spaced from each other to define a flow path.

According to an alternative aspect there is provided a flow regulator for a dispensing closure orifice, comprising an orifice arrangement including one or more orifices and an upstream baffle arrangement including one or more baffle members, the arrangements being spaced by a gap to define one or more windows which provide a flow path through the regulator.

The flow path may include an entry path part and an exit path part, and in which the window /s provide a flow path part which is generally perpendicular to the entry and exit path parts.

Arrangements of this sort can be configured to force flowable product to make two (or more) 90° turns. In aspects of the invention the orifices and baffle members may be a generally truncated triangle shape. In one embodiment the configuration is reminiscent of the trefoil radiation symbol.

One or more orifices may be provided in the orifice arrangement and an equal or different number of baffle members may be provided in the baffle arrangement. For example in some embodiments there are three respective baffle members.

The regulator may be a flow restrictor. Other forms of flow regulation may alternatively or additionally be provided by the regulator.

According to a further aspect there is provided a flip-top dispensing closure having a flow regulator as described herein.

The closure may include a spout and the regulator may be provided in the spout.

The regulator may be formed as an integral part of a closure, for example by being integrally moulded therewith.

Alternatively the regulator may be formed as in insert which is attached or attachable to a closure.

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

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

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

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

Accordingly, it may desirable to have a dispensing closure which can be produced with an orifice with a standard shape and size but which also can be adapted to meet the requirements of the particular customer and/or product. According†o a further aspect of the present invention there is provided an insert for a dispensing closure of the type having a housing with engagement means adapted to receive a valved dispensing body, the insert comprising a single-piece, valveless, orifice-defining body having standardised insert engagement means adapted to engage the housing engagement means and thereby to be received directly into the closure housing in use.

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

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

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

In one embodiment, the insert engaging means may include a bead projecting radially outward from an exterior wall for snap-fitting the insert into the dispensing closure. The bead for snap-fitting may be arranged so that it seals against the dispensing closure so that the product only passes through the orifice of the insert and not around the sides. Alternatively and/or additionally, the insert could be glued, welded and/or retained in the closure by other means.

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

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

The orifice/s of the insert may have a regular geometric shape or an irregular geometric shape.

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

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

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

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

Furthermore, in some aspects and embodiments the dispensing closures manufactured for use with the present invention may also be used with silicon valves without any changes since the means for retaining the silicon valves in place in the closures could be the same as the means for retaining the inserts. Accordingly, standardisation of the dispensing closure is attained; this minimises costs. The insert could also be described as a dispensing closure orifice reduction insert.

Different aspects of the invention may be used separately or together.

Further particular and preferred aspects of the present invention are set out in the accompanying independent and dependent claims. Features of the dependent claims may be combined with the features of the independent claims as appropriate, and in combination other than those explicitly set out in the claims. The present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a perspective new of a flow regulator formed according to the present invention;

Figure 2 is a plan view of the regulator of Figure 1 ;

Figure 3 is an underplan view of the regulator of Figure 1 ;

Figure 4 is a further perspective view of the regulator of Figure 1 ;

Figure 5 is a further perspective view of the regulator of Figure 1 ;

Figure 6 is a side view of the regulator of Figure 1 ;

Figure 7 is a further underplan view of the regulator of Figure 1 ;

Figure 8 is a further plan view of the regulator of Figure 1 ;

Figure 9 is a section of the regulator of Figure 8 taken along line A-A;

Figure 10 is a perspective view of a dispensing closure formed according to the present invention and shown in a closed position;

Figure 1 1 is an underplan view of the closure of Figure 10;

Figure 12 is a perspective view of the closure of Figures 10 and 1 1 shown in an open position;

Figure 13 is a plan view of the closure of Figure 12;

Figure 14 is a section of a dispensing closure fitted with an insert formed in accordance with the present invention;

Figure 15 is a magnified view of the region A of Figure 14;

Figure 16 is a plan view of a regulator insert formed according to an alternative embodiment;

Figure 1 7 is a side view of the regulator of Figure 16;

Figure 18 is an underplan view of the regulator of Figure 16;

Figure 19 is a top perspective view of the regulator of Figure 16;

Figure 20 is a bottom perspective view of the regulator of Figure 16; Figure 21 is a section of the regulator of Figure 16 illustrated with the flow path therethrough;

Figure 22 is a plan view of a regulator insert formed according to an alternative embodiment;

Figure 23 is a side view of the regulator of Figure 22;

Figure 24 is an underplan view of the regulator of Figure 22;

Figure 25 is a top perspective view of the regulator of Figure 22;

Figure 26 is a bottom perspective view of the regulator of Figure 22;

Figure 27 is a section of the regulator of Figure 22 illustrated with the flow path therethrough;

Figure 28 is a top perspective view of a regulator formed according to an alternative embodiment;

Figure 29 is a plan view of the regulator of Figure 28;

Figure 30 is a side perspective view of the regulator of Figure 28;

Figure 31 is a bottom perspective view of the regulator of Figure 28;

Figure 32 is a section of the regulator of Figure 28 illustrated with the flow path therethrough; and

Figure 33 is a cut away sectional view of the regulator of Figure 28 illustrated with the flow path therethrough.

Referring first to Figures 1 to 9, a flow regulating insert 10, consists in this embodiment of a moulded single-piece article. The insert 10 includes a cylindrical portion 12 in the form of a circular wall which provides a surface for assembly machinery to handle the insert 10.

At one end of the portion 12 an outer body 14 is provided. This outer body has an outer radial surface upon which a sealing bead 1 6 is provided. This sealing bead 16 projects radially outwardly in the form of an annular bulge. At the upper end of the outer body 14 a stop 18 and an inner sealing bead 24 are provided. The functions of these two features will be described below.

At the free end of the cylindrical wall 12 a baffle arrangement is provided in the form of three baffle members 5 which together define an inlet 6 shaped like a trefoil symbol.

The other end of the wall includes an aperture arrangement in the form of three generally triangular apertures 7 which are equally spaced circumferentially in an aperture plate 8.

The apertures 7 are aligned with and in register with the baffle members so that in many ways the baffle arrangement and aperture arrangement are "negative images" of each other. The aperture plate 8 and baffle members 5 are spaced along the wall by a gap which, as shown best in Figure 9, creates flow windows 9.

In use, product flows through the insert by first arriving at the baffle members, from where it must flow around them and through the windows 9. From here the flow path continues through the apertures. This means that two 90 degree turns are included in the flow path.

Variation in the regulation provided by the insert may be provided in a number of ways, including by varying the number and/or size of the apertures and corresponding baffle members, and/or by varying the gap between the baffle and the aperture plate.

Figures 10 to 13 show a closure 30 formed according to the present invention. The closure 30 comprises a base 35 and a lid 40 which are connected to each other by a hinge 37. The closure base 35 has a central spout 36 which is provided with the insert 10 of Figures 1 to 9. A snap-fit seal is achieved between the insert sealing bead 16 and a corresponding projection (not shown) on the surface of the inner radial wall of the dispensing closure spout 36

The stop 18 helps locate the insert 10 in relation to the closure such that when the insert 10 is pushed into the closure it limits how far the insert may be moved relative to the closure spout. This limitation is caused by the upper end of the stop 18 abutting the underside of the closure spout upper wall 34.

The underside of the lid includes an outer sealing ring which seal around the spout, and an inner sealing spigot which seals into the spout.

In other embodiments (not shown) the apertures and baffle members are formed as an integral part of the closure. It is also possible, for example, for the regulation features to be sequentially moulded into a closure, which could allow for use of different materials.

Figure 14 and 15 show a cross-sectional side view of an insert 1 10 in place in a dispensing closure 130 to illustrate one system of connecting inserts formed according to the present invention into a closure. The lid 140 of the closure is also shown. A snap-fit seal is achieved between a sealing bead 1 16 and a corresponding projection 131 on the surface of the inner radial wall 132 of the dispensing closure 130.

Further, it is seen that the surface of the inner radial wall 132 of the closure is formed so as to help retain the insert 1 10 in place. This is achieved by the inner radial wall 132 having a reduced diameter at the lower end such that the insert 1 10 has to be forced past this reduced diameter before reaching the section of the closure which has a slightly greater diameter. The diameter of the section of the closure 130, which is slightly reduced in diameter, is less than the maximum diameter of the insert (as measured in the plane of the annular sealing bead 1 16).

The stop 1 18 helps locate the insert 1 10 in relation to the closure 130 such that when the insert 1 10 is pushed into the closure 130 it limits how far the insert may be moved relative to the closure. This limitation is caused by the upper end of the stop 1 18 abutting the underside 134 of the closure 130. A seal between the upper end of the stop 1 18 and the underside 134 of the closure 130 may also be achieved. The inner sealing bead 124 provides a seal between the insert 1 10 and the underside of the upper radial wall of the closure 130. This seal is in addition to the one provided by the interaction, or interference, of the sealing bead 1 16 and inner radial wall 132 of the closure 130. This additional seal helps prevent product contained in the container (not shown) from leaking around the outside of the insert 1 10.

The lid 140 has two depending annular projections 142, 144. These projections also aid in sealing the combination of insert, closure and lid to prevent accidental and unwanted leakage of product from the associated container. The outer annular projection 142 presses against an inner radial surface, which defines the orifice of the closure 130. An interference fit between these two surfaces is thus achieved. The lower end of this projection 142 also presses against the top of the inner sealing bead 124, so that at this location, the insert, the closure and the lid all meet to provide a seal. The inner projection 144 presses against the upper surface of the insert 1 10 radially outside of the insert's orifice 122. This interaction provides a seal between the lid 140 and the insert 1 10 so that product contained in the associated container (not shown) cannot leak out when the lid 140 is in the closed position. Referring now†o Figures 16†o 21 there is shown a flow regulating insert 210 formed according to an alternative embodiment.

The insert 210 is generally similar to the insert 10. However, in this embodiment the inlet side is provided with multiple, in this embodiment three, holes 207. The holes 207 extend up into the insert body until they reach the underside of a baffle plate 204 that defines a single circular outlet hole 206 at its centre.

The apertures 207 therefore allow product to flow into the bottom of the body; thereafter the plate 204 in combination with the lower body plate 202, which effectively define lateral flow ports 201 , diverts the flow generally orthogonally into a central chamber 203 of the body for subsequent release through the outlet hole 206.

Referring now to Figures 22 to 27 there is shown a flow regulating insert 310 formed according to an alternative embodiment.

The insert 310 is generally similar to the insert 210. However, in this embodiment the inlet side is provided with a single circular central hole 307. The hole 307 extends up into the insert body until it reaches the underside of a baffle plate 304 that is formed as a central hub from which three radial spokes 350 extend. Three outlet apertures 355 are defined between the spokes 350.

The aperture 307 allows product to flow into the bottom of the body; thereafter the plate 304 in combination with the upper surface of the lower body plate 302, which effectively define lateral flow ports 301 , divert the flow generally orthogonally for release through the apertures 355. Referring now†o Figures 28†o 33 there is shown a flow regulating insert 410 formed according to an alternative embodiment.

The insert 410 is generally similar to the inserts 10, 210 and 310. However, in this embodiment the "bottom", "product side" wall 402 does not contain any apertures. Instead, the body sidewall 412 includes one or more lateral apertures 460. A central baffle wall 465 extends from the wall 402.

The apertures 460 extend radially inwards towards the centre of the insert body, where they encounter the wall 465.

Above the apertures 460 the upper half of the body comprises a single, central orifice 406 defined by a plate 404. Accordingly the flow path starts at the entrance to the apertures 460 and extends, between the upper surface of the wall 402 and the lower surface of the plate 404 until the wall 465 is reached. The wall 465 forces a generally orthogonal flow redirection up into the aperture 406 for release. Although illustrative embodiments of the invention have been disclosed in detail herein, with reference to the accompanying drawings, it is understood that the invention is not limited to the precise embodiments shown and that various changes and modifications can be effected therein by one skilled in the art without departing from the scope of the invention as defined by the appended claims and their equivalents.