Apparatus and Method of Making an Aerosol Dispenser

Abstract

A method and apparatus of making an aerosol container. A polymeric container may be provided. The container may have a closed end bottom and a neck longitudinally opposed to the closed end bottom. The container has an internal container volume. A valve and a bag may be provided and a portion of the valve and the bag may be disposed within the container. The bag has a first bag volume. A portion of the at least one of the neck and the bag may contact a portion of the valve to form a temporary seal. Propellant may be introduced into the container. The bag may be collapsed from the first bag volume to a second bag volume. The pressure of the propellant and the pressure within the bag equilibrate. The valve may be joined to the container and the propellant may be sealed within the container.

What is claimed is: 
     
         1 . A method of making an aerosol container comprising:
 providing a polymeric container having a closed end bottom and a neck longitudinally opposed to the closed end bottom, wherein the neck defines an opening, and wherein the container has an internal container volume;   providing a valve and a bag, wherein at least a portion of the valve and the bag are disposed in the opening of the neck, wherein the bag has a first bag volume;   contacting a portion of at least one of the neck and the bag to a portion of the valve to form a temporary seal;   introducing a propellant into the container;   collapsing the bag from the first bag volume to a second bag volume, and wherein the second bag volume is less than the first bag volume; and   joining the valve to the container to seal the valve to the container, wherein the propellant is sealed within the container.   
     
     
         2 . The method of  claim 1 , wherein the valve is welded to the container. 
     
     
         3 . The method of  claim 1 , wherein joining the valve to the container comprises spinning the valve relative to at least one of the bag and the container to weld the valve to the bag. 
     
     
         4 . The method of  claim 1 , wherein the bag and the valve are separate. 
     
     
         5 . The method of  claim 1 , comprising concentrically blow molding the container and the bag. 
     
     
         6 . The method of  claim 1 , wherein a portion of the bag contacts a portion of the valve to form the temporary seal. 
     
     
         7 . The method of  claim 1 , wherein the propellant flows between a portion of the neck and the bag. 
     
     
         8 . The method of  claim 1 , wherein the propellant flows between a portion of the neck and the valve. 
     
     
         9 . The method of  claim 1 , wherein joining comprises spinning at least one of the valve and the container to spin weld the valve to the container. 
     
     
         10 . The method of  claim 1 , wherein the bag has a first bag pressure prior to introducing propellant into the container and a second bag pressure after propellant has been introduced into the container, and wherein the first bag pressure is less than the second bag pressure. 
     
     
         11 . The method of  claim 1 , wherein the propellant is a multi-phase propellant. 
     
     
         12 . The method of  claim 1 , wherein the second bag volume is from about 0.1% to about 5% of the internal container volume. 
     
     
         13 . The method of  claim 1 , wherein the second bag volume is from about 5% to about 50% of the internal container volume. 
     
     
         14 . The method of  claim 1 , wherein the first bag volume is greater than about 20% of the internal container volume and the second bag volume is less than about 15% of the internal container volume. 
     
     
         15 . The method of  claim 1 , wherein the bag is joined to a portion of the valve prior to the bag and the valve being disposed in the container. 
     
     
         16 . A method of making an aerosol container comprising:
 providing a polymeric container having a closed end bottom and a neck longitudinally opposed to the closed end bottom, wherein the neck defines an opening;   providing a valve and a bag, wherein at least a portion of the valve and the bag are disposed in the opening of the neck;   contacting a portion of at least one of the neck and the bag to a portion of the valve to form a temporary seal;   introducing a propellant into the container;   positioning the valve in an open configuration;   collapsing the bag, wherein at least a portion of a fluid contained within the bag is released through the valve; and   joining a portion of the valve to a portion of the container to seal the propellant within the container.   
     
     
         17 . The method of  claim 16 , wherein the propellant is introduced between the bag and the neck or the valve and the neck. 
     
     
         18 . The method of  claim 16 , wherein the valve is positioned in the open configuration while the propellant is introduced into the container. 
     
     
         19 . The method of  claim 16 , wherein the valve is positioned in the open configuration prior to introducing the propellant into the container. 
     
     
         20 . The method of  claim 16 , comprising positioning the valve in a closed configuration. 
     
     
         21 . The method of  claim 20 , wherein the valve is positioned in an open configuration and a closed configuration while the propellant is being introduced into the container. 
     
     
         22 . The method of  claim 16 , wherein joining comprises spinning at least one of the valve and the container to seal the valve to the container. 
     
     
         23 . A method of making an aerosol container comprising:
 providing a polymeric container having a closed end bottom and a neck longitudinally opposed to the closed end bottom, wherein the neck defines an opening, wherein the container has an internal container volume;   providing a valve and a bag, wherein at least a portion of the valve and the bag are disposed in the opening of the neck;   contacting a portion of at least one of the neck and the bag to a portion of the valve to form a temporary seal;   providing a fluid chamber having a fluid chamber volume;   engaging at least a portion of at least one of the valve and the container with the fluid chamber;   positioning the valve in an open configuration;   introducing a propellant into the container;   releasing a fluid from the bag through the valve and into the fluid chamber; and   joining the valve to the container to seal the valve to the container, wherein the propellant is sealed within the container.   
     
     
         24 . The method of  claim 23 , wherein the valve is positioned in the open configuration prior to introducing propellant into the container. 
     
     
         25 . The method of  claim 23 , wherein the fluid chamber volume is variable. 
     
     
         26 . The method of  claim 23 , wherein the fluid chamber comprises a piston. 
     
     
         27 . The method of  claim 26 , comprising moving the piston from a first position to a second position. 
     
     
         28 . The method of  claim 23 , wherein the fluid chamber volume is less than the internal container volume. 
     
     
         29 . The method of  claim 23 , wherein the fluid chamber volume is from about 10% to about 60% of the internal container volume. 
     
     
         30 . A method of making an aerosol container comprising:
 providing a polymeric container having a closed end bottom and a neck longitudinally opposed to the closed end bottom, wherein the neck defines an opening;   providing a valve and a bag, wherein at least a portion of the valve and the bag are disposed in the opening of the neck;   contacting a portion of at least one of the neck and the bag to a portion of the valve to form a temporary seal;   positioning the valve in an open configuration;   decreasing the pressure within the bag;   introducing a propellant into the container; and   joining the valve to the container to seal the valve to the container, wherein the propellant is sealed within the container.   
     
     
         31 . The method of  claim 30 , wherein the bag has a first bag volume prior to decreasing the pressure within the bag and a second bag volume after decreasing the pressure within the bag. 
     
     
         32 . The method of  claim 31 , wherein the second bag volume is greater than about 95% of the first bag volume. 
     
     
         33 . The method of  claim 31 , wherein the bag has a third bag volume after introducing the propellant into the container, wherein the third bag volume is less than the first bag volume. 
     
     
         34 . The method of  claim 30 , wherein the pressure of the container is decreased prior to introducing the propellant into the container. 
     
     
         35 . The method of  claim 30 , comprising positioning the valve in a closed configuration. 
     
     
         36 . The method of  claim 35 , wherein the valve is positioned in the closed configuration prior to introducing the propellant into the container.