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.