Synthetic closure

Abstract

By achieving an extruded, foamed core formed from plastic material peripherally surrounded and integrally bonded with a plurality of cooperating synthetic, plastic, extruded, outer layers, a unique, multi-component, multi-layer synthetic closure is provided which may be employed as a bottle closure or stopper for any desired product, whether the product is a liquid, a viscous material, or a solid distributed in a bottle or container and dispensed through the open portal of the container neck. The present invention achieves a mass producible, resilient, synthetic bottle closure which is employable for any desired bottle, including wine. By employing the present invention, a multi-component or multi-layer synthetic closure is attained which possesses physical properties substantially equal to or better than the physical properties found in cork material, which has caused such cork material to be the principal closure material for wine bottles.

Having described my invention, what I claim is new and desire to secure by Letters Patent is:  
     
         1 . A stopper or closure for a product retaining container constructed for being inserted and securely retained in a portal forming neck of the container, said stopper/closure comprising: 
 A. an elongated, cylindrically shaped core member formed from foamed plastic material;    B. at first layer or skin member 
 a. peripherally surrounding and intimately bonded to the cylindrical surface of the core member, and  
 b. comprising at least one plastic material selected from the group consisting of polyethylenes, metallocene catalyst polyethylenes, polybutanes, polybutylenes, polyurethanes, silicones, vinyl-based resins, thermoplastic elastomers, polyesters, ethylenic acrylic copolymers, ethylene-vinyl-acetate copolymers, ethylene-methyl-acrylate copolymers, thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluorelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof, ethylene-butyl-acrylate copolymers, ethylene-propylene-rubber, styrene butadiene rubber, ethylene-ethyl-acrylic copolymers, ionomers, polypropylenes, and copolymers of polypropylene and copolymerizable ethylenically unsaturated comonomers, foamable or non-foamable thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluoroelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof; and  
   C. a second layer or skin member 
 a. peripherally surrounding and intimately bonded to the cylindrical surface of the first layer/skin member, and  
 b. comprising at least one plastic material selected from the group consisting of polyethylenes, metallocene catalyst polyethylenes, polybutanes, polybutylenes, polyurethanes, silicones, vinyl-based resins, thermoplastic elastomers, polyesters, ethylenic acrylic copolymers, ethylene-vinyl-acetate copolymers, ethylene-methyl-acrylate copolymers, thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluorelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof, ethylene-butyl-acrylate copolymers, ethylene-propylene-rubber, styrene butadiene rubber, ethylene-ethyl-acrylic copolymers, ionomers, polypropylenes, and copolymers of polypropylene and copolymerizable ethylenically unsaturated comonomers, foamable or non-foamable thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluoroelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof;  
 whereby a multi-layer/multi-component synthetic closure is attained which is capable of completely sealing any desired product in a container, retaining the product in the container for any desired length of time without any degradation of the product or degradation of the closure.  
   
     
     
         2 . The synthetic closure/stopper defined in  claim 1 , wherein the cylindrically shaped core member is further defined as comprising substantially flat terminating surfaces forming the opposed ends of said cylindrically shaped core member, said first layer/skin member is further defined as enveloping substantially the entire cylindrical surface f the core member, and the second layer/skin member is further defined as enveloping substantially the entire cylindrical surface of the first layer/skin member.  
     
     
         3 . The synthetic closure/stopper defined in  claim 1 , wherein the plastic material forming the core member is further defined as comprising medium density or low density, closed cell, foamed plastic comprising one or more selected from the group consisting of inert polymers, homopolymers, and copolymers.  
     
     
         4 . The synthetic closure/stopper defined in  claim 3 , wherein said closed cell foam plastic material is further defined as comprising at least one selected from the group consisting of polyethylenes, metallocene catalyst polyethylenes, polybutanes, polybutylenes, polyurethanes, silicones, vinyl-based resins, thermoplastic elastomers, polyesters, ethylenic acrylic copolymers, ethylene-vinyl-acetate copolymers, ethylene-methyl-acrylate copolymers, ethylene-butyl-acrylate copolymers, ethylene-propylene-rubber, styrene butadiene rubber, ethylene-ethyl-acrylic copolymers, ionomers, polypropylenes, and copolymers of polypropylene and copolymerizable ethylenically unsaturated comonomers, as well as ethylenic acrylic copolymers, ethylene-vinyl-acetate copolymers, ethylene-methyl-acrylate copolymers, thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluorelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof, ethylene-butyl-acrylate copolymers, ethylene-propylene-rubber, styrene butadiene rubber, ethylene-ethyl-acrylic copolymers.  
     
     
         5 . The synthetic closure/stopper defined in  claim 3 , wherein said closed cell, foamed plastic material is further defined as comprising one or more polyethylenes selected from the group consisting of high density, medium density, low density, linear low density, ultra high density, and medium low density.  
     
     
         6 . The synthetic closure/stopper defined in  claim 1 , wherein said core member is further defined as comprising a density ranging between about 100 kg/m 3  to 500 kg/m 3 .  
     
     
         7 . The synthetic closure/stopper defined in  claim 6 , wherein said core member further comprises a density ranging between about 200 kg/m 3  to 350 kg/m 3 .  
     
     
         8 . The synthetic closure/stopper defined in  claim 6 , wherein said core member is further defined as comprising closed cells having an average cell size ranging from between about 0.02 millimeters to 0.50 millimeters and a cell density ranging between about 8,000 cells/cm 3  to 25,000,000 cells/cm 3 .  
     
     
         9 . The synthetic closure/stopper defined in  claim 8 , wherein said core member is further defined as comprising cell size ranging between about 0.05 mm and 0.1 mm and a cell density ranging between about 1,000,000 cells/cm 3  to 8,000,000 cells/cm 3 .  
     
     
         10 . The synthetic closure/stopper defined in  claim 1 , wherein said first layer/skin member and said second layer/skin member are further defined as comprising one selected from the group consisting of foamed plastics and non-foamed plastics.  
     
     
         11 . The synthetic closure/stopper defined in  claim 10 , wherein said first layer/skin member and said second layer/skin member each comprise one selected from the group consisting of polyether-type polyurethanes, thermoplastic polyolefins, thermoplastic polyvulcanizates, flexible polyolefins, and blends thereof.  
     
     
         12 . The synthetic closure/stopper defined in  claim 11 , wherein said first layer/skin member and said second layer/skin member each further comprise between about 10% and 90% by weight based upon the weight of the entire composition of a thermoplastic olefin and between about 10% and 90% by weight based upon the weight of the entire composition of a thermoplastic vulcanizate.  
     
     
         13 . The synthetic closure/stopper defined in  claim 1 , wherein said core member is formed by injection molding.  
     
     
         14 . The synthetic closure/stopper defined in  claim 13 , wherein said first layer/skin member and said second layer/skin member are formed in an injection molding die during the formation process for the core member.  
     
     
         15 . The synthetic closure/stopper defined in  claim 1 , wherein said second layer/skin member further comprises at least one additive selected from the group consisting of lubricating agents, slip-enhancing compounds, antimicrobial agents, antibacterial agents, and oxygen scavenging compounds.  
     
     
         16 . The synthetic closure/stopper defined in  claim 1 , wherein said first layer/skin member is further defined as comprising a thickness ranging between about 0.05 mm and 5 mm.  
     
     
         17 . The synthetic closure/stopper defined in  claim 16 , wherein said first layer/skin member is further defined as comprising a thickness ranging between about 0.1 mm and 2 mm.  
     
     
         18 . The synthetic closure/stopper defined in  claim 1 , wherein said first layer/skin member is further defined as comprising a tough, score and mar resistant surface and a density ranging between about 300 kg/m 3  and 1,500 kg/m 3 .  
     
     
         19 . The synthetic closure/stopper defined in  claim 18 , wherein the density of the first layer/skin member is further defined as comprising between about 750 kg/m 3  and 1,000 kg/m 3 .  
     
     
         20 . The synthetic closure/stopper defined in  claim 1 , wherein said second layer/skin member is further defined as comprising a thickness ranging between about 0.002 mm and 2.5 mm.  
     
     
         21 . The synthetic closure/stopper defined in  claim 1 , wherein said second layer/skin member comprises a density ranging between about 100 kg/m 3  and 1,000 kg/m 3 .  
     
     
         22 . The synthetic closure/stopper defined in  claim 1  wherein said core member and said first layer/skin member and said second layer/skin member are further defined as being formed by extrusion.  
     
     
         23 . The synthetic closure/stopper defined in  claim 22 , wherein said core member, said first layer/skin member and said second layer/skin member are further defined as being extruded simultaneously.  
     
     
         24 . The synthetic closure/stopper defined in  claim 22 , wherein said core member is further defined as being extruded separately and subsequent thereto said first layer/skin member is formed in extrusion equipment peripherally surrounding and enveloping the preformed core member, and said second layer/skin member is formed in extrusion equipment peripherally surrounding and enveloping the preformed first layer/skin member.  
     
     
         25 . The synthetic closure/stopper defined in  claim 22 , wherein said extrusion process is further defined as incorporating one or more blowing agents selected from the group consisting of carbon dioxide, sulphur dioxide, nitrogen, carbon, water, air nitrogen, helium, and argon, Azodicarbonamic Azodiisobutyro-Nitride, Benzenesulfonhydrazide, 4,4-Oxybenzene Sulfonylsemi-carbazide, p-Toluene Sulfonylsemi-carbazide, Barium Azodicarboxlyate, N,N′-Dimethyl-N,N′-Dinitrosoterephthalamide, Trihydrazinotriazine, Aliphatic Hydrocarbons having 1-9 carbon atoms, Halogenated Aliphatic Hydrocarbons having 1-9 carbon atoms, Aliphatic Hydrocarbons having 1-9 carbon atoms, Aliphatic alcohols having 1-3 carbon atoms and partially Hydrogenated Chlorocarbon and Chlorofluorocarbons.  
     
     
         26 . The synthetic closure/stopper defined in  claim 25 , wherein said blowing agent is further defined as comprising between about 0.005% and 10% by weight of the weight of the plastic material and comprises an inert blowing agent selected from the group consisting of nitrogen, carbon dioxide, sulphur dioxide, water, air, nitrogen, helium, and argon.  
     
     
         27 . The synthetic closure/stopper defined in  claim 23 , wherein a nucleating agent is employed in the extrusion process and said nucleating agent is selected from the group consisting of calcium silicate, talc, clay, titanium oxide, silica, barium sulfate, diamatious earth, and mixtures of citric acid and sodium bicarbonate.  
     
     
         28 . The synthetic closure/stopper defined in  claim 27 , wherein said nucleating agent is further defined as comprising between about 0.1 and 5 parts by weight for every 100 parts by weight of the plastic material.  
     
     
         29 . The synthetic closure/stopper defined in  claim 1 , wherein one selected from the group consisting of said first layer/skin member and said second layer/skin member is further defined as comprising indicia formed on the outer surface thereof.  
     
     
         30 . The synthetic closure/stopper defined in  claim 29 , wherein said indicia comprises one or more selected from the group consisting of letters, symbols, colors, graphics, and wood tones.  
     
     
         31 . A stopper or closure for a product retaining container constructed for being inserted and securely retained in a portal forming neck of the container, said stopper/closure comprising: 
 A. an elongated, solid cylindrically shaped member dimensioned for insertion in the neck of the fluid product retaining container for closing and sealing the fluid product in the container;    B. comprising at least four components concentrically mounted to each other and integrally bonded together in the manner which prevents passage of the fluid therebetween;    C. said first component comprising an elongated, solid, cylindrically shaped core member formed from extruded foamed plastic material comprising a density ranging between about 100 kg/m 3  to 500 kg/m 3  and constructed for sealing the fluid product retained in the container and preventing transfer of the fluid product from the container prior to removal;    D. said second component 
 a. peripherally surrounding the cylindrical surface of the first component, and  
 b. comprising a plastic material in peripheral surrounding, intimate, bonded engagement with the cylindrical surface of the first component and comprising at least one selected from the group consisting of polyethylenes, metallocene catalyst polyethylenes, polybutanes, polybutylenes, polyurethanes, silicones, vinyl-based resins, thermoplastic elastomers, polyesters, ethylenic acrylic copolymers, ethylene-vinyl-acetate copolymers, ethylene-methyl-acrylate copolymers, thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluorelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof, ethylene-butyl-acrylate copolymers, ethylene-propylene-rubber, styrene butadiene rubber, ethylene-ethyl-acrylic copolymers, ionomers, poly-propylenes, and copolymers of polypropylene and copolymerizable ethylenically unsaturated comonomers, foamable or non-foamable thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluoroelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof;  
   E. a third component 
 a. peripherally surrounding the cylindrical surface of the second component, and  
 b. comprising a plastic material in peripheral surrounding, intimate, bonded engagement with the cylindrical surface of the second component and comprising at least one selected from the group consisting of polyethylenes, metallocene catalyst polyethylenes, polybutanes, polybutylenes, polyurethanes, silicones, vinyl-based resins, thermoplastic elastomers, polyesters, ethylenic acrylic copolymers, ethylene-vinyl-acetate copolymers, ethylene-methyl-acrylate copolymers, thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluorelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof, ethylene-butyl-acrylate copolymers, ethylene-propylene-rubber, styrene butadiene rubber, ethylene-ethyl-acrylic copolymers, ionomers, poly-propylenes, and copolymers of polypropylene and copolymerizable ethylenically unsaturated comonomers, foamable or non-foamable thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluoroelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof; and  
   F. a fourth component 
 a. peripherally surrounding the cylindrical surface of the third component,  
 b. comprising a plastic material in peripheral surrounding intimate bonded engagement with the cylindrical surface of the third component and comprising at least one selected from the group consisting of polyethylenes, metallocene catalyst polyethylenes, polybutanes, polybutylenes, polyurethanes, silicones, vinyl-based resins, thermoplastic elastomers, polyesters, ethylenic acrylic copolymers, ethylene-vinyl-acetate copolymers, ethylene-methyl-acrylate copolymers, thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluorelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof, ethylene-butyl-acrylate copolymers, ethylene-propylene-rubber, styrene butadiene rubber, ethylene-ethyl-acrylic copolymers, ionomers, poly-propylenes, and copolymers of polypropylene and copolymerizable ethylenically unsaturated comonomers, foamable or non-foamable thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluoroelastomers, fluoropolymers, polyethylenes, teflons, and blends thereof; and  
 c. having an exposed surface constructed for frictionally engaging a surface of the portal formed in the neck of the container and being securely engaged therewith until forcibly removed therefrom, sealing the fluid product in the container and resisting all forces generated by the fluid product when retained in said container;  
 whereby a multi-layer/multi-component synthetic closure is attained which is capable of completely sealing any desired fluid product in a container, retaining the product in the container for any desired length of time without any degradation of the fluid product or degradation of the closure.  
   
     
     
         32 . The synthetic closure/stopper defined in  claim 31 , wherein the plastic material forming the core member is defined as comprising medium density or low density, closed cell, foamed plastic comprising one or more selected from the group consisting of inert polymers, homopolymers, and copolymers.  
     
     
         33 . The synthetic closure/stopper defined in  claim 32 , wherein said closed cell foam plastic material is further defined as comprising at least one selected from the group consisting of polyethylenes, metallocene catalyst polyethylenes, polybutanes, polybutylenes, polyurethanes, silicones, vinyl-based resins, thermoplastic elastomers, polyesters, ethylenic acrylic copolymers, ethylene-vinyl-acetate copolymers, ethylene-methyl-acrylate copolymers, ethylene-butyl-acrylate copolymers, ethylene-propylene-rubber, styrene butadiene rubber, ethylene-ethyl-acrylic copolymers, ionomers, polypropylenes, and copolymers of polypropylene and copolymerizable ethylenically unsaturated comonomers as well as ethylenic acrylic copolymers, ethylene-vinyl-acetate copolymers, ethylene-methyl-acrylate copolymers, thermoplastic polyurethanes, thermoplastic olefins, thermoplastic vulcanizates, flexible polyolefins, fluorelastomers, fluoropolymers, polyethylenes, teflons, ethylene-butyl-acrylate copolymers, ethylene-propylene-rubber, styrene butadiene rubber, ethylene-ethyl-acrylic copolymers and blends thereof.  
     
     
         34 . The synthetic closure/stopper defined in  claim 32 , wherein said closed cell, foamed plastic material is further defined as comprising one or more polyethylenes selected from the group consisting of high density, medium density, low density, linear low density, ultra high density, and medium low density.  
     
     
         35 . The synthetic closure/stopper defined in  claim 31 , wherein each of said second, third, and fourth components are further defined as comprising one selected from the group consisting of foamed plastics and non-foamed plastics.  
     
     
         36 . The synthetic closure/stopper defined in  claim 35 , wherein said second, third, and fourth components each comprise one selected from the group consisting of polyether-type polyurethanes, thermoplastic polyolefins, thermoplastic polyvulcanizates, flexible polyolefins, and blends thereof.  
     
     
         37 . The synthetic closure/stopper defined in  claim 36 , wherein said second, third and fourth components are each comprises between about 10% and 90% by weight based upon the weight of the entire composition of a thermoplastic olefin and between about 10% and 90% by weight based upon the weight of the entire composition of a thermoplastic vulcanizate.  
     
     
         38 . The synthetic closure/stopper defined in  claim 31 , wherein said third and fourth components are each further defined as comprising a thickness ranging between about 0.002 mm and 2.5 mm.  
     
     
         39 . The synthetic closure/stopper defined in  claim 31 , wherein said third and fourth components are each further defined as comprising a density ranging between about 100 kg/m 3  and 1,000 kg/m 3 .  
     
     
         40 . The synthetic closure/stopper defined in  claim 31 , wherein said fourth component comprises an outer layer surface consisting of at least one selected from the group consisting of holes, dimples, fish scales, and shark skin appearance.  
     
     
         41 . The synthetic closure defined in  claim 40 , wherein said fourth component is further defined as being formed by one surface treatment selected from the group consisting of embossing and melt fracture.  
     
     
         42 . The synthetic closure defined in  claim 31 , wherein the outer surface of the fourth component is embossed by passing the synthetic closure through a plurality of rotating wheels having a desired surface configuration to be formed on the closure.