Semisolid product dispensing head

Abstract

A method of making a head for a semisolid product dispenser, such as a gel deodorant dispenser, comprises the steps of: providing a piece of porous media having a desired shape with a perimeter and openings through the media in the area inside of the perimeter, compressing at least the portion of the media inside of the perimeter between two parts of a hard tool so as to crush the media, thereby reducing the size of the openings, and affixing the porous media to a head frame to form the semisolid product dispenser head. Preferably the porous media is affixed to the head frame by an insert injection molding process, and the media is crushed in the same mold tool as is used to mold the head frame. A preferred porous media is made of two layers of extruded strands of polymer, where the strands in one layer are generally parallel to one another but are non-parallel to the strands in the adjoining layer, the strands are bonded at crossover points between the layers and have openings defined by spaces between the strands in one layer superimposed over spaces between strands in the adjoining layer. Preferably the head of the semisolid product dispenser is made by ultrasonically welding the head frame to a transfer member using a combination of double shear and energy-directing ultrasonic weld joints, coupled with a positive stop.

1 - 43 . (canceled)  
     
     
         44 . A method of making a semisolid product dispenser comprising the steps of: 
 a) providing a head frame with a top end and a sidewall depending from the top end;    b) providing a body member that mates with the head frame, defining a semisolid product holding and distribution space between the top end and the body member;    c) providing mating ultrasonic weld joint surfaces on the head frame and the body member that provide a weld joint and a positive stop; and    d) ultrasonically welding the body member and head frame together.    
     
     
         45 . The method of  claim 44  wherein the weld joint comprises a double shear joint.  
     
     
         46 . The method of  claim 45  wherein the weld joint further comprise an energy-directing point.  
     
     
         47 . The method of  claim 44  wherein the weld joint comprises a tongue and groove weld joint with double shear welds and an energy-directing weld point.  
     
     
         48 . The method of  claim 44  wherein the weld joint comprises at least one vent to allow escape of air otherwise trapped between the weld joint surfaces.  
     
     
         49 . The method of  claim 47  wherein the tongue is on the transfer member and the groove is on the head frame.  
     
     
         50 . The method of  claim 44  wherein the step of providing a head frame comprises injection molding thermoplastic material in the form of the head frame.  
     
     
         51 . The method of  claim 50  wherein a sheet of porous material is insert molded at the top end of the head frame as the head frame is molded.  
     
     
         52 - 55 . (canceled)  
     
     
         56 . A method of making a head for a semisolid deodorant dispenser comprising the steps of: 
 a) providing a piece of generally flat porous media having a perimeter;    b) forming the porous media into a dome shape; and    c) attaching the perimeter to a head frame having a central opening there through such that the dome shape of the media is retained, the media and the dome shape formed being rigid enough such that even though the media is supported only by its edges, the dome does not collapse when the head is pressed against underarm skin with normal user force sufficient to spread semisolid deodorant forced through the media across the skin.    
     
     
         57 . The method of  claim 56  wherein the perimeter of the media is secured to the head frame by being insert molded into the head frame as the head frame is formed.  
     
     
         58 . The method of  claim 56  wherein openings through the porous media in a band around the perimeter are blocked such that flow of deodorant through the media only occurs in the area interior of said band.  
     
     
         59 . The method of  claim 58  wherein the band of blocked openings has an outer edge sealed to the head frame and an inner edge not sealed to the frame, such that as semisolid deodorant is forced through the media a user is able to see a demarcation between where the semisolid deodorant is forced through the media and semisolid deodorant cannot be forced through said blocked openings, that demarcation being inside of the edge of the central opening of the head frame.  
     
     
         60 . The method of  claim 56  wherein the porous media is heat molded to the head frame.  
     
     
         61 . The method of  claim 56  wherein the media is formed into a dome shape between two halves of a mold tool, one half having a concave shape and the other half having a convex shape.  
     
     
         62 - 68 . (canceled)  
     
     
         69 . The method of  claim 44  wherein the body member comprises a transfer member.  
     
     
         70 . (canceled)