U.S. patent application number 10/264305 was filed with the patent office on 2003-07-03 for stackable, thin-walled containers.
This patent application is currently assigned to CREATIVE EDGE DESIGN GROUP, LTD.. Invention is credited to Becks, Lawrence A., Panasewicz, Dale, Soehnlen, Gregory M..
Application Number | 20030121926 10/264305 |
Document ID | / |
Family ID | 26731060 |
Filed Date | 2003-07-03 |
United States Patent
Application |
20030121926 |
Kind Code |
A1 |
Soehnlen, Gregory M. ; et
al. |
July 3, 2003 |
Stackable, thin-walled containers
Abstract
A liquid container for a comestible product such as milk or
juice includes a base having a substantially planar region, a top
surface having a substantially planar region parallel to the
substantially planar region of the base and having a pour spout. A
sidewall is integrally formed with and extends between the base and
top surface, and includes a structural load distributing feature
that transfers loads from the top surface to the base. A handle is
interposed between the base and top surface and integrally formed
with the base, top surface, and sidewall. The containers can be
arrayed into units and stacked on top of one another. A first
flexible material such as a shrink wrap holds the individual
containers together and a second flexible material maintains the
stacked array of containers together so that cases that typically
hold the containers can be eliminated.
Inventors: |
Soehnlen, Gregory M.; (N.
Canton, OH) ; Panasewicz, Dale; (Strongsville,
OH) ; Becks, Lawrence A.; (N. Canton, OH) |
Correspondence
Address: |
Timothy E. Nauman
FAY, SHARPE, FAGAN, MINNICH & McKEE, LLP
7th Floor
1100 Superior Avenue
Cleveland
OH
44114-2518
US
|
Assignee: |
CREATIVE EDGE DESIGN GROUP,
LTD.
|
Family ID: |
26731060 |
Appl. No.: |
10/264305 |
Filed: |
October 3, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10264305 |
Oct 3, 2002 |
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09472138 |
Dec 23, 1999 |
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09472138 |
Dec 23, 1999 |
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09114244 |
Jun 29, 1998 |
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6068161 |
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60052775 |
Jul 1, 1997 |
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Current U.S.
Class: |
220/771 ;
206/503 |
Current CPC
Class: |
B65D 21/0209 20130101;
B65D 25/2885 20130101; B65D 25/42 20130101; B65D 2571/00567
20130101; B65D 1/20 20130101; B65D 21/02 20130101; B65D 71/06
20130101; B65D 2571/00895 20130101 |
Class at
Publication: |
220/771 ;
206/503 |
International
Class: |
B65D 021/00; B65D
085/62; B65D 025/10; B65D 053/00; B65D 081/24 |
Claims
Having thus described the invention, it is now claimed:
1. A container used in caseless shipping of a product, such as milk
or juice, the container comprising: a base having a substantially
planar region; a top surface having a substantially planar region
parallel to the substantially planar region of the base and having
a pour spout formed therein; a sidewall integrally formed with and
extending between the base and top surface, the sidewall enclosing
an internal cavity in communication with the pour spout; and a
handle extending from the sidewall and defining a finger receiving
region, the handle interposed between the base and top surface and
integrally formed with the base, top surface, and sidewall.
2. The container of claim 1 further comprising a structural load
distributing feature formed therein for conveying bearing loads
from the top surface to the base.
3. The container of claim 2 wherein the structural load
distributing feature includes at least one rib formed in the
sidewall and extending between the top surface and the base.
4. The container of claim 3 wherein the structural load
distributing feature extends in a continuous fashion along the
planar region of the top surface and the sidewall.
5. The container of claim 4 wherein the structural load
distributing feature is disposed between the pour spout and the
handle.
6. The container of claim 1 wherein the sidewall includes a series
of sidewalls and selected ones of the sidewalls include
substantially planar regions for abutting against substantially
planar regions of sidewalls of like containers.
7. The container of claim 1 further comprising a rounded region
along an edge portion of the base beneath the pour spout to
facilitate pouring.
8. The container of claim 1 further comprising a structural load
distributing feature formed therein for conveying bearing loads
from the top surface to the base, the handle extending downwardly
from the top surface toward the base and the structural load
distributing feature substantially aligned with the handle for
transferring loads from the handle to the base.
9. The container of claim 1 further comprising a resealable lid
operatively associated with the pour spout.
10. The container of claim 1 wherein the container is a thin-walled
plastic material.
11. The container of claim 10 wherein the container has a weight to
volume ratio of approximately 55 to 70 grams per gallon
(approximately 18 to 24 grams per liter).
12. The container of claim 1 wherein the pour spout includes an air
opening disposed in spaced relation to a pour opening.
13. The container of claim 1 wherein the center of gravity of the
container is disposed closer to the pour spout than to the handle
to facilitate pouring of liquid from the container.
14. The container of claim 1 wherein the pour spout is disposed
opposite the handle adjacent an edge of the container.
15. The container of claim 1 wherein the container is formed at
least in part of plastic.
16. A handling system comprising: plural similarly configured
containers, each including a substantially planar top surface, a
substantially planar base and a sidewall interconnecting the top
surface and the base; a preselected number of containers being
disposed in contiguous relationship and held together as a unit
with a first flexible wrapping material; and container units being
grouped together and stacked on top of one another for transport,
the container units being held in grouped and stacked array by a
second flexible wrapping material.
17. The handling system of claim 16 wherein the containers each
include a handle defining a finger receiving region.
18. The handling system of claim 17 wherein at least two handles of
contiguous containers are disposed adjacent one another to
facilitate handling of the unit of containers.
19. The handling system of claim 17 wherein the handles are
disposed at outer corner regions of the unit to facilitate handling
thereof.
20. The handling system of claim 16 wherein the containers hold a
liquid.
21. The handling system of claim 16 wherein each container is
formed at least in part of a thin walled plastic material.
22. The handling system of claim 16 wherein the sidewall includes
plural sidewalls.
23. The system of claim 16 wherein at least one of the sidewalls of
each container includes a structural load distributing feature
formed therein and extending between the top surface and base for
adding strength thereto for stacking purposes.
24. The system of claim 16 further comprising a tear strip
associated with the second wrapping material for selectively
separating the container units from the grouped and stacked
array.
25. The container system of claim 16 wherein each container
includes a pour spout disposed opposite the handle and adjacent the
juncture of contiguous sidewalls, the containers that form a unit
arranged so that the pour spouts are disposed inwardly of the group
of containers and the handles of each container are disposed along
a periphery of the unit.
26. The container system of claim 16 wherein the units of
containers are stacked at least five levels high.
27. The container of claim 16 further comprising wherein the units
of containers are oriented in different arrays along each level.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional
application Serial No. 60/052,775, filed Jul. 1, 1997.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to receptacles and
container structures. Specifically, the invention relates to
molded, thin-walled containers that are capable of being stacked
upon one another for storage and shipping purposes. For the purpose
of clarification, caseless shipping is the ability to deliver
products in a shipping container which requires no returnable,
disposable, or replaceable cases.
[0003] To develop the concept of thin-walled containers an
exemplary container will be used to reference thin-walled
containers and establish a working definition that can be
described, for example, as a ratio of the amount of plastic resin
required to make a container relative to the amount of product
capable of being transported in the container. To illustrate the
concept, an industry standard gallon milk container should be used
as the reference container for the development of the concept.
Typical bottle weights for this container range from 90 grams (at
the time the bottle was first introduced back in 1952) to 56 to 60
grams (as manufacturing technology progressed to today's
standards).
[0004] In the field of art relating to the shipping and storage of
bulk food products including milk and beverages, plastic molded
containers are used to contain the products for transport,
distribution, and ultimately for dispensing by consumers. Known
containers usually take the form of blow-molded, one-piece plastic
containers. The pour opening defines the uppermost wall or surface
of the container and is generally located at the center of the
container. A tapering region extends downwardly from the pour spout
merging with four sidewalls that are disposed in substantially
perpendicular relation relative to one another. A handle is
integrally molded in the container and has a generally inverted
L-shape. A first leg of the handle extends generally horizontally
from the tapering region and a second leg of the handle extends
generally vertically, merging with a sidewall junction of the
container just above a base.
[0005] These containers are typically stored and shipped in some
form of shipping case; consequently, these containers have been
designed with little regard to the structural loading,
stackability, and efficient packaging during transport. Unitized
cases contain between four to six containers and take several
different forms such as wire or plastic cases, corrugated boxes, or
corrugated materials which provide structural support to the
individual containers during shipping. These unitized cases are
shown in FIGS. 1A (corrugated boxes) and 1B (plastic cases).
[0006] FIGS. 2A-2C illustrate several delivery mechanisms which are
capable of shipping a large number of full containers which may or
may not be unitized in cases. A brief description of the above
shipping mechanisms will assist in further defining the principle
of thin-walled, caseless shipping. Pallets (FIG. 2A) that support
stackable cases are the most widespread form of shipping product
for the retail or food service industry and the cases are the only
returnable, reusable shipping mechanism considered by the industry.
Bossies (FIG. 2B) and dollies (FIG. 2C) are primarily utilized by
the dairy industry and are considered large, mechanical cases.
There is a large cost associated with bossies and dollies since
they have to be returned, cleaned, and reused in a similar fashion
as the pallet cases.
[0007] For further discussion, the caseless concept will be defined
on the pallet shipping mechanism as described below.
[0008] Cases can be stacked on pallets in several different
configurations based on the pallet footprint. Typical pallets will
have approximately two-hundred to two-hundred-fifty containers
shipped on them and will be stacked from four to six cases high
depending on the pallet size. The forces associated with these
cases is evident from a consideration of the weight of a three
liter milk container that is approximately six to seven pounds (or
approximately eight and one-half pounds per gallon). The structure
and strength of these cases make them ideal for stacking
thin-walled containers that carry a dense product, however, their
use has been problematic. The actual case costs are relatively
inexpensive and are intended to be reused with a typical life of
two years; however, the cases are often misappropriated by vandals
or thieves for use in other applications, i.e., as storage
containers for different articles. The cost associated with cases
really occurs at the manufacturing facility and during
distribution.
[0009] To understand the impact of caseless shipping in
manufacturing facilities using cases, it is important that an
appreciation of the current method for casing product be attained.
The majority of the dairy industry uses plastic cases to some
significant measure if they do not use them exclusively. The basic
cycle of a case is as follows:
[0010] Cases are purchased for a price of approximately $2.00
(sixteen quart case) and are entered into the already large
inventory of cases on an as needed basis. Even in the best
operations, this replenishment process is driven by damage, new
business, theft, customer accumulation, etc. In some instances,
this replacement initiative is quite extensive and demands a
significant portion of management time in order to maintain control
of the case supply.
[0011] During a typical production day, cases must be continually
fed to the facility as product is produced. This requires several
people dedicated to move and unload trailers of empty cases as they
return from the routes and one person dedicated to ensure that a
continual supply of cases are maintained during production hours.
In addition, large, covered areas are needed to house empty cases
which requires maintenance and upkeep. Inventory costs associated
with these cases need to be considered and can be rather extensive
based on the size of the dairy. FIGS. 3 and 4 illustrate some of
the space requirements associated with cases.
[0012] After the cases are unloaded and start through the
production process, the cases must be destacked in the proper
orientation to be prepped for container filling. FIGS. 5A and 5B
illustrate a typical destacker system. The maintenance fees for
this system have a percentage impact on the cost of goods.
Continual supervision is required to ensure the destacker does not
jam or prevent cases from flowing to the next pre-production
stage.
[0013] Cases are then moved to the case cleaning system in which
extremely caustic cleansers wash and clean the cases prior to
container filling. The cleansers affect cost to the system by
increasing sewer bills, replacement and maintenance of the
equipment and expensive cleansers. FIG. 6 illustrates typical case
washing equipment.
[0014] The cases are then conveyed to the filling process. The
cases are loaded through automatic casing equipment and combined
into stacks of five or six case heights. These stacks are conveyed
into refrigerated areas where they are placed into storage
positions for later retrieval as illustrated in FIGS. 7A-7C.
[0015] Distribution costs also impact on the costs associated with
shipping these containers. Hooking, track shipping, or automated
material handling systems are several methods for storing and
retrieving filled cases. These methods are illustrated in FIGS.
8A-8D such as using hooks to pull cases (FIG. 8A), track shipping
(FIG. 8B), using a pallet jack (FIG. 8C), and it should be noted
that the automated material handling systems (FIG. 9) require large
superstructures to house the cased product and are very capital
intensive.
[0016] The containers are then shipped by various means in these
cases. Depending on the system, the customer, and the demand, the
containers will be pulled from various storage systems by the
techniques illustrated above and loaded onto a distribution vehicle
for delivery to a customer.
[0017] Depending on the type of distribution business considered,
distribution expense may range from being very important to the
most important issue in succeeding in a business. For a
distributor, food service, or wholesaler who manufactures no
products, the warehousing and distribution costs are likely the
most crucial to the success of the business. Operational
efficiencies depend on excelling in these areas. As a result,
warehouses and distribution methods have been designed to return
only the industry standard pallets. Reluctantly, and with
substantial costs, many distributors handle product in cases with
hopes that a corrugated alternative may become cost effective in
the future. Smaller, more service-oriented distributors clearly
recognize the value of eliminating returnable cases as the delivery
person becomes much more efficient resulting from the elimination
of non-value adding activities.
[0018] As stated above, the primary method for many customers to
receive product is primarily on pallets or cases stacked on the
floor. Though other variations exist, the fundamental economics are
associated with these two methods.
[0019] Depending on the size of the customer, a typical trailer may
have one to twelve customer orders to be delivered. The orders are
loaded on the trailer in by stop sequence. A driver's typical
delivery day is described below. The first customer will be
delivered and the product will be taken to the cooler. Empty cases
will be loaded onto pallets and wrapped with tape or shrink wrap to
maintain a stable load. These pallets are then loaded into the back
of the truck to be returned to the production facility at the end
of the route as illustrated in FIG. 10.
[0020] The driver then departs to deliver to the next customer. One
of two solutions occur. First, if the trailer was completely loaded
such that there was very little room, the driver will have to
unload the empty cases he just loaded at the previous stop before
he can begin to deliver the next customer. Alternatively, if the
trailer is partially full, the driver may have sufficient room to
work and may not have to rotate empty cases until later stops. It
should be noted that the practice of maximizing trailer loads to
the back door is the norm to minimize distribution costs. The above
empty case rotation is continued until all product is delivered and
all of the empty cases are collected.
[0021] The critical steps for case delivery are summarized
below:
[0022] 1. Drive to the stop
[0023] 2. Unload product for delivery
[0024] 3. Load empty cases
[0025] 4. Drive to stop
[0026] 5. Unload empty cases
[0027] 6. Unload product for delivery
[0028] 7. Load new and old empty cases and/or rotate load
[0029] 8. Drive to stop
[0030] 9. Repeat until load is complete
[0031] It is envisioned that caseless shipping would have enormous
benefits and labor savings associated with, for example, the
distribution, the critical steps for delivery are summarized
below:
[0032] 1. Drive to stop
[0033] 2. Deliver purchases material
[0034] 3. Pick up pallet(s)
[0035] 4. Drive to next stop
[0036] 5. Deliver purchased material
[0037] 6. Pick up pallet(s)
[0038] 7. Repeat until load is complete
[0039] The difference is the lack of non-value services required.
As is realized, there is no wasted time collecting empty cases or
rotating product and empty cases on the trucks. Other obvious
savings are better utilization of trailer loads because no space
needs to be allocated for cases and route efficiencies can be
enjoyed and potential for back hauls can be achieved. Also, if the
trailer is not full because of time constraints, more time on the
route will be enjoyed and more stops placed on the route because
time will not be lost collecting empty cases.
[0040] The current mode of handling cases have a per unit
distribution expense which can be drastically reduced. Based on
simple arithmetic, it has been estimated that the improvement might
be as much as 30%.
[0041] In addition to the problems associated with transporting and
shipping with cases as described above, the production of the
individual plastic containers widely used in the dairy industry is
another area requiring improvement, e.g. reduced production cost. A
typical milk production facility will manufacture or purchase
millions of these containers per year. A cost savings of one-cent
in material resin cost is significant when applied to the number of
containers involved. As a result, there has been much effort in the
past to minimize the material costs without compromising container
integrity. It should be noted that the processing and distribution
costs are much larger than the cost associated with the resin for a
production facility. Thus, a need exists to produce a container
with similar amounts of resin as used today (i.e., thin-walled)
while eliminating cases and all of the associated costs described
above.
[0042] Design efforts relating to containers for food have also
focused on aesthetic appeal and consumer benefits. For example, a
pitcher-like construction which is easy to grasp and tilt and which
provides for easy pourability of the contained product may be
desirable from a marketing perspective. Similarly, the container
should incorporate non-drip characteristics and eliminate or reduce
the potential for "glugging" caused by a lack of venting air into
the container during pouring.
[0043] It would, therefore, be desirable to provide a container
structure which provides for stackability and which eliminates the
need for cases or shippers during bulk transport. It would be
further desirable to provide a container structure which provides
enhanced strength, as well as the above-mentioned consumer
benefits, without adding to the material costs involved in its
manufacture.
SUMMARY OF THE INVENTION
[0044] The present invention contemplates new and improved
containers which eliminate the need for cases or shippers and which
provide increased strength for supporting static or dynamic
vertical loads, thereby facilitating stacking on pallets without
the use of cases while maintaining costs for manufacture.
[0045] In accordance with the present invention, there is provided
a container for a comestible product such as milk or juice that has
a base with a substantially planar region, a top surface with a
substantially planar surface and a pour spout, a sidewall
interposed between the top surface and the base, and a structural
load distributing feature for conveying bearing loads from the
substantially planar surface of the top surface to the base.
[0046] According to another aspect of the invention, the structural
load distributing feature is integrally molded into the sidewall of
the container.
[0047] According to another aspect of the invention, the structural
load distributing feature is provided in part by a sectional
wraparound label.
[0048] According to another aspect of the invention, the container
is manufactured of a plastic material having a weight to volume
ratio of approximately fifty-five to seventy grams per gallon
(approximately eighteen to twenty-four grams per liter).
[0049] According to yet another aspect of the invention, the pour
spout is disposed adjacent an edge of the container and the center
of gravity is disposed closer to the pour spout than the
handle.
[0050] According to another aspect of the invention, a caseless,
liquid handling system includes plural similarly configured
containers, a preselected number of containers held together as a
unit with a first flexible wrapping material, and multiple
container units held in grouped and stacked array by a second
flexible wrapping material.
[0051] A primary advantage of the invention resides in the cost
savings associated with eliminating the use of cases to handle,
store and transport the containers.
[0052] Another advantage of the invention is found in the various
consumer benefits such as a pitcher-like shape with improved
pourability characteristics.
[0053] Still other advantages and benefits of the invention will
become apparent to those skilled in the art upon a reading and
understanding of the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] The invention may take physical form in certain parts and
arrangements of parts, preferred embodiments of which will be
described in detail in the specification illustrated in the
accompanying drawings which form a part hereof, wherein:
[0055] FIGS. 1A and 1B show industry standard cases for handling
milk;
[0056] FIGS. 2A-2C illustrate delivery mechanisms for shipping
large numbers of cases;
[0057] FIGS. 3 and 4 illustrate the space requirements associated
with shipping via cases;
[0058] FIGS. 5A and 5B shows conventional destacking equipment for
handling the cases;
[0059] FIG. 6 represents typical case washing equipment associated
with today's system;
[0060] FIGS. 7A-7C illustrate the filling and storage process
encountered in a dairy;
[0061] FIGS. 8A-8C show three versions of handling filled
cases;
[0062] FIG. 9 is a representation of an automated material handling
system;
[0063] FIG. 10 illustrates a trailer loaded with empty cases;
[0064] FIG. 11A is a perspective view of the first preferred
embodiment and FIGS. 11B-11D are views of alternative sidewall
configurations;
[0065] FIG. 12 is another perspective view of the first preferred
embodiment of a container according to the present invention;
[0066] FIG. 13 is a sectional view of the container illustrated in
FIGS. 11 and 12;
[0067] FIG. 14 is an enlarged sectional view of the upper and lower
spout of the embodiment illustrated in FIGS. 11-13;
[0068] FIG. 15 is a perspective of a grouping of four of the
containers according to a preferred embodiment of the present
invention;
[0069] FIGS. 16-18 are perspective views of a second preferred
embodiment;
[0070] FIG. 19 is a rear elevational view of the second preferred
embodiment;
[0071] FIG. 20 is a top plan view of the second embodiment;
[0072] FIG. 21 is a side elevational view taken generally from the
right-hand side of FIG. 19;
[0073] FIG. 22 is a front view of the second embodiment;
[0074] FIG. 23 is a bottom plan view of the second embodiment;
[0075] FIG. 24 is a perspective of a third preferred embodiment of
the present invention;
[0076] FIGS. 25 and 26 are perspective views of a fourth preferred
embodiment of the present invention;
[0077] FIG. 27 is a top plan view of the fourth embodiment;
[0078] FIGS. 28 and 29 are side elevational views of the fourth
embodiment;
[0079] FIG. 30 is a rear elevational view of the fourth
embodiment;
[0080] FIG. 31 is a front elevational view of the fourth
embodiment;
[0081] FIG. 32 is a bottom plan view of the fourth embodiment;
[0082] FIG. 33 is a perspective view taken generally from the top
and front of a fifth preferred embodiment;
[0083] FIG. 34 is a perspective view of the fifth embodiment taken
generally from the bottom and rear;
[0084] FIGS. 35A and 35B are a perspective view of a sixth
embodiment similar to the fifth embodiment;
[0085] FIG. 36 is an elevational view of a stack of containers
according to either the fourth or fifth embodiments;
[0086] FIGS. 37A-F are elevational and plan views of a sixth
preferred embodiment;
[0087] FIG. 38 is a top plan view of four containers disposed in
abutting relation to form a first unit;
[0088] FIG. 39 is a perspective of a pouring spout according to a
preferred embodiment of the invention;
[0089] FIGS. 40A-F are perspective and plan views of various
insertable spouts configurations; and
[0090] FIGS. 41A and 41B are perspective views from the top, rear
and the bottom, front regions of the container, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0091] Referring now to the drawings wherein the showings are for
the purpose of illustrating the preferred embodiments of the
invention only and not for purposes of limiting the same, the
Figures show the present manner of shipping, storage, and handling
individual milk containers in cases (FIGS. 1-10 described above in
the Background section), and a number of embodiments of new
containers according to the present invention that advantageously
provide a caseless shipping system (FIGS. 11-40).
[0092] Referring to FIGS. 11-13, a container according to the
present invention is designated generally by the number 50 and may
be a standard (3-liter or 1 gallon) size container or any other
size. Those of ordinary skill will recognize that the container
structures described herein are scalable to achieve virtually any
size comprising a blow-molded plastic, although different
manufacturing techniques may be used. Container 50 comprises a top
surface 52, bottom 54 and a wall 56 molded integrally therewith.
The top surface 52 and bottom 54 are of a generally diamond shape
with an apex thereof coinciding with integrally molded handle 58.
The handle proceeds from the top surface along the apex and
terminates before reaching the bottom.
[0093] The top surface 52 includes a stepped conformation having an
upper surface 60 and lower level deck portion 62 which is slightly
vertically recessed from upper surface 60. An orifice 64 is formed
in deck portion 62 for egress of the liquid or other material
contained in container 50. A pouring lip 66 extends upwardly from
the deck portion 62 to form a pouring spout 68 which is of
generally diamond shape. A foil seal 70 is provided for tamper
resistance and detection as well as enhanced sealing capabilities.
A snap-on cap 72 cooperates with foil seal 70 and pouring spout 68.
Seal 70 and cap 72 are of a diamond shape to simplify automation of
the capping process during container filling. Orifice 64 is
generally sized to permit simultaneous egress of fluid and ingress
of air to prevent "glugging." A secondary function of the large
orifice 64 is that it provides for easy ingress of fluid and/or
powder mixture to the container during reuse or initial filling of
the container. The orifice also permits the easy deployment of
stirring utensils within the container. It will be appreciated that
when fluid is poured from container, fluid flows over one apex of
the diamond shape of the spout. Cap upper surface 74 is aligned
with container upper surface 60 when cap 72 is snapped into place.
This provides a large upper stacking surface that is substantially
planar for increased stability and vertical load support. A finger
grip ledge 76 is provided on cap 72 to permit removal thereof
Pouring spout 68 extends outward in a direction opposite handle 58
beyond wall 56 to form a cup guide 78, which functions to permit a
cup (not shown) to be correctly oriented to permit spill-free
pouring.
[0094] According to one aspect of the invention, wall 56 is formed
with a number of structural load distributing or load transferring
features such as vertical ribs 80 which increase the sectional
modulus of wall 56 and prevent bending and/or buckling. Ribs 80 are
preferably of a "V" shape in cross-section, with the apex of the
"V" extending inward of the container and are substantially
continuous along the longitudinal height of the container (see
FIGS. 11-13). This structure permits the construction of
manufacturing molds without the presence of undercuts, which are
inefficient from a manufacturing standpoint. Preferably, vertical
ribs 80 are incorporated into vertical surfaces of wall 56 in an
effort to reduce the unbraced length of the wall and limit
deflections. For example, walls may otherwise be subject to
buckling or crimping as a result of vertical loads or forces while
bulging may be associated with hydrostatic forces. Thus, those wall
regions which are taller than four inches in a three liter
container, for example, would benefit from a change in the section
modulus to limit deflections. This structure will provide the
container with the rigidity required for supporting and
transferring the load from one container to another in a stacked
relation--which the prior milk containers described in the
Background were unable to achieve.
[0095] A sectional wraparound label (not shown) may be incorporated
to add further strength and structural integrity. For example, the
wraparound label can be used to purposely add a preload to the
container and limit the deflections. Alternatively, the structural
load distributing feature may be a series of diagonal
reinforcements (FIG. 11B), offset ribs (FIG. 11C), dimples (FIG.
11D), or combination of these features that are effective in
transferring forces from the top surface to the bottom of the
container. These are preferred alternative ways to change the
section modulus and transfer vertical forces through the container.
The handle, since it extends from the substantially planar top
surface of the container, is also an important element in the load
bearing arrangement.
[0096] Handle 58 is formed integrally with the container 50. One
end of handle 58 extends from upper surface 60 of the container to
provide additional support thereto. An opposite or lower end of
handle 58 extends or merges into wall 56. A finger clearance hole
82 (FIG. 13) provides comfort for a large range of hand sizes of
consumers. The finger receiving region is thus disposed adjacent
the handle and preferably terminates before reaching the base of
the container. Handle 58 extends in a direction that is directly
opposite the apex of pouring spout 68 to provide self-centering of
the spout. The construction of the handle also functions in the
handling of contained arrayed into groups or container units as
will be further explained below.
[0097] Container bottom 54 is provided with a pouring radius 84
which extends into wall 56. Pouring radius 84 is constructed to
permit pivoting of the container on a support surface when pouring
without lifting is desired. This aspect of the invention is
especially beneficial to users, i.e., children or senior citizens,
who have relatively little strength or are physically challenged.
Container bottom 54 is formed with a lower surface 86 which is
slightly concave (FIG. 12) when the container is empty, but which
flattens out when the container is filled with liquid such as milk
or fruit juice to form a generally horizontal surface. As will be
appreciated, lower surface 86, together with the upper surface 60
of an adjacent container (not shown), cooperate such that vertical
loads are evenly distributed among and across the container
surfaces. As shown in FIGS. 12 and 13, wall 56 extends to a slight
recess 87 at container bottom 54.
[0098] FIG. 14 is a sectional view of the pouring spout 68
according to the present invention. Pouring lip 66 includes a
pouring edge 90 that curves sharply downward at its extremity to
create an anti-drip spout. Edge 90 is displaced outward slightly
from the outermost surface of lower pour spout 92. This
configuration prevents liquid from running down the front of
container 50. Cup guide 78 extends downward and inward from lower
pour spout 92 to facilitate proper orientation of the pour spout
relative to a cup.
[0099] FIG. 15 illustrates a grouping of four containers 50
according to a preferred embodiment of the invention. It will be
recognized that two adjacent containers are disposed with their
respective handles 58 adjacent one another to form a combined
carrying handle 96. On an opposite side of the container grouping,
two more handles 58 are similarly situated to from a second
combined handle when arrayed in this fashion. Two carrying handles
96, each comprising a pair of adjacent container handles 58 are
provided on opposite sides of the grouping to permit easy handling
thereof. Of course, other numbers of containers (e.g., six
containers which may be preferred for brick-like stacking on a
pallet) can be grouped together to form a unit and the handles
oriented in a different manner such as at the corners of the group
unit.
[0100] The four to six containers comprising the grouping unit are
held together with a first flexible material, preferably a shrink
wrap thermoplastic 98. As can be seen in FIG. 15, a large combined
upper support surface 100 is provided by the respective upper
surfaces 60 of the containers 50. The first flexible material holds
the individual containers in a desired orientation that is stable
and capable of being positioned into a layer of units that define a
first level of a stacked array.
[0101] Each of the containers in the grouping shown in FIG. 15 are
provided with a flip top 110 which may be hinged to the container
50 using suitable means. Flip top 110 may be equipped with a recess
or projection for engaging the pouring spout (not shown in FIG.
15). It will be recognized that the flip top 110 provides an
extension of the top surface 60 such that a load imposes on the top
surface of the container grouping is more evenly distributed and
supported by a substantially planar surface.
[0102] FIGS. 16-23 show a second preferred embodiment of the
invention that has many similarities to the embodiment described
above in conjunction with FIGS. 11-15. Accordingly, the differences
will be emphasized here and identified by new numerals. For
example, at least one of the structural load distributing ribs or
flutes is a continuous flute 112 that proceeds through the
substantially planar surface of the top surface and down opposite
sides of the container toward the base. Preferably this flute is
situated between the pour spout and the handle. In addition, the
top surface is modified to have a slight arch 114 thereto which is
effective in transferring the forces from the top surface to the
base. Additional flutes or ribs 116 are also provided in the top
surface in the arch region and terminate in the upper portion of
the container. The pour spout area is also modified, eliminating
the flip top (FIG. 15) and the diamond-shaped cap (FIG. 11A), with
a more conventional replaceable push on, screw-off type cap 118,
also known as a snap cap. As is evident, however, the screw-on cap
is located so that it can serve as a part of the top surface (FIG.
22), particularly the substantially planar surface, for
transferring loads from containers stacked on top thereof FIG. 18
illustrates that the bottom or base of the container is also
modified relative to that shown in FIG. 12. It still serves,
however, to define a substantially planar surface 120 that
transfers loads to a next adjacent layer of containers, a pallet,
or the like.
[0103] FIG. 24 illustrates a container 130 according to another
preferred embodiment of the invention. Container 130 is shown in a
vertical orientation with a spout 132 and cap 134 its top 136.
Container 130 includes a stacking wall 138 which permits the
container to be stacked in a horizontal orientation. That is,
container 130 will be laid on its side in during shipping and
warehouse storage. Stacking wall 138 is provided with protrusions
140 and depressions 142 which permit stacking of the containers in
a brick-like fashion. It will be appreciated that a similar
stacking wall is provided on the container opposite the illustrated
one but is hidden from view in FIG. 24. The protrusions are
received in the depressions and provide a horizontal stability to
the stacked assembly. This embodiment incorporates a large recessed
handle 144 which may or may not include a finger hole (not shown).
In this embodiment, ribs are not provided owing to the shallow
construction of the container when it is laid on its stacking wall
138 since only short side walls 146 are present, ribs or flutes are
not needed to provide the required structural rigidity and
stability. A pouring radius 148 is also provided near the bottom
150 of container. This construction is advantageous for containing
and dispensing food products that are not liquid in form.
[0104] FIGS. 25-32 illustrate yet another preferred embodiment that
is substantially identical to that described with reference to FIG.
24. Accordingly like numerals will refer to like elements and new
numerals will identify new elements. The most noticeable addition
are the structural load distributing features comprising a series
of vertically spaced horizontal ribs or flutes 160 that transfer
loads when the containers are stacked one on top of another. In
this particular embodiment, the ribs are circumferentially
continuous and generally equi-spaced along the container, although
it will be appreciated that other arrangements may be used without
departing from the scope and intent of the subject invention.
Moreover, the curved wall 162 just beneath the spout is more
apparent in this embodiment to facilitate receipt over the lip of a
cup (not shown). The handle is again integrally formed with the
remainder of the container and forms a finger receiving opening 164
in the container. Features such as the radius 148, the curved wall
162, and an enlarged spout that provides an anti-glug function as
well as a no-drip function are desirable consumer oriented
attributes.
[0105] A fifth preferred embodiment is shown in FIGS. 33 and 34.
Like the sixth embodiment of FIGS. 35A and 35B, and a related
embodiment of FIGS. 37A-F, this container is intended to transport
larger amounts of milk or fruit juice while taking advantages of
the caseless container concept described above and hereafter. These
embodiments utilize a container structure that is in the form of a
rectangular prism, generally referenced by the numeral 200. The
container is formed of two side portions 202, which are formed
integrally with a center section 204. The side sections 202 and
center section 204 comprise a fluid containing volume for
containing liquid therein. Handle 218 is formed integrally
connecting side sections 202. Center section 204 is formed with a
recess 208 for housing a pivotable spigot or tube 206. The spigot
is pivotably connected to the container in a known manner. Side
walls 212 of the container are formed with a number of rib elements
210 for structural reinforcement thereof. The ribs 210 also improve
the stacking characteristics of the container as will be explained
below. In the embodiment of FIGS. 33 and 34, additional ribs 216
are provided along the center section and are oriented in the
opposite direction from the ribs 210, i.e. in the vertical
direction along the sidewalls and in a horizontal direction along
the upper and lower walls. Moreover, FIGS. 35A and 35B demonstrates
how the protrusion and depression feature may also be incorporated
into the larger containers to aid in stacking in a brick-like
fashion (FIG. 36). It will also be understood that a shrink wrap
may be used with this embodiment for holding the spigot in place
and for purposes of cleanliness.
[0106] FIG. 36 shows a stacking arrangement for these types of
containers. The dimensions of the rectangular prism 200 are
selected such that the height of the container is preferably twice
the width and depth of the container. This construction lends
itself to the stacking arrangement illustrated in FIG. 36.
Containers A, B, and C in FIG. 36 are laid along their sides 210.
Not shown in FIG. 36 are three (3) other containers which are
beneath containers A, B, and C and also laid along their sides 210.
Containers D and E are oriented such that they stand upright with
handles 218 oriented on top of a container. The stacking concept
illustrated in FIG. 36 thus permits a compact grouping unit of
eight containers which may be held together using a flexible
wrapping material such as a shrink wrap thermoplastic as was
explained above. It will be recognized that handles 218 are
oriented to permit easy carrying of the grouping unit illustrated
in FIG. 36. It will also be recognized that those containers B and
C, and the containers disposed beneath them (not shown), will be
oriented such that their respective handles are displayed or
oriented outward of the unit grouping and, thus, will provide
additional handles for carrying or lifting the unit
illustrated.
[0107] FIG. 38 is a plan view similar to FIG. 15 that illustrates
how a group of containers can be grouped together in a unit and the
handles advantageously situated to aid in lifting or transporting
the containers as a unit. For example, as disclosed in FIG. 15 the
first flexible wrapping material only extends about the lower
portion of the abutting containers. This leaves access to the
handles so that the containers can be easily manipulated as a unit.
In FIG. 38, the handles will be located at each corner of the
arrayed containers and the pouring spouts are grouped at the center
of the unit. Of course, different numbers of containers and
different orientations can be used for different purposes and
without departing from the scope and intent of the invention.
[0108] FIG. 39 illustrates a pouring spout according to another
preferred embodiment of the present invention. Like the embodiment
shown in FIG. 1, this embodiment incorporates a deck portion 222 on
which is located a pouring lip 226 extending upward therefrom. Lip
226 forms a pouring spout 228. In this embodiment, a pouring guard
260 is provided on the pouring spout. Guard 226 is provided with a
narrow diamond-shaped aperture 262 which permits egress of the
liquid or other material contained in the container. Guard 260
provides for a more narrow stream of liquid than would be provided
by pouring spout 228 alone.
[0109] FIGS. 40A-F illustrate a variety of removable pouring
inserts that may be incorporated into the pour spout. FIGS. 40A and
40B show a key-shaped opening 270 and a vent or anti-glug opening
272 diametrically opposite therefrom. A droplet-shaped opening 274
is embodied in FIGS. 40C and 40D while a generally U-shaped opening
276 is incorporated into the embodiment of FIGS. 40E and 40F. In
each, the generally planar surface 278 has a taper that allows any
liquid that is spilled over the edge of the pour opening to drain
into the vent opening when the container is oriented in its
upright, vertical position. The removable nature of the pouring
inserts allows the consumer to remove the insert and refill the
container, if desired.
[0110] FIGS. 41A and 41B illustrate yet a further embodiment which
finds application in larger containers such as two and one-half,
three, and five gallon sizes. It includes a vent cap 280 located
adjacent the top surface and ribs 282 in the sidewall for load
transfer to the bottom surface. As best illustrated in FIG. 41B, a
dispensing nozzle 284 receives one end of a dispensing tube 286 and
the other end of the tube is frictionally engaged by a tube
holddown 288 defined by offset flanges 290 that extend from the
front wall of the container. The bottom surface also preferably
includes a slight taper from the domed feet 292 toward the
dispensing nozzle to aid in dispensing product from the
container.
[0111] A differently configured container having a large, wide top
and bottom surface to distribute the stacking load along the
structurally desirable locations such as the cap and handle may be
developed using the features and attributes of the invention.
Structural ribs that run perpendicular to the parting line can be
placed at critical locations along the horizontal, top surface to
resist vertical, plastic deformation and bending. The vent tube,
cap and large, structural handle were designed to handle the load
in parallel to the parting line. The top and bottom surfaces have
been designed to nest in a manner to allow stress from static and
dynamic loads to be distributed to the sidewalls.
[0112] Vertical surfaces are provided with molded, structural ribs
to provide an increased section modulus along the member and
provide improved resistance to bending moments, deflections and
buckling than is available in the presently used milk container.
The ribs also act as columns to distribute loads from the top of
the container to the bottom of the container. The ribs may be
molded to have a "V" or fluted shaped cross-section to permit the
use of molds without undercuts therein. Structural tests conclude
that the stress is transmitted through the footprint of the above
case through the desired crown and down the sides of the
container.
[0113] A structural label may also be used to add strength to the
container. The structure may operate as a pressure vessel and/or a
static structure to support loads typically experienced during
shipping and distribution. Cap and foil seals may be in
incorporated to resist leakage and maintain internal pressures. The
containers will be shrink-wrapped in cases of four, six, or other
appropriate number, for example, which provides structural support
and a unitized method for handling groups of containers through a
distribution network. Thereafter, the units are arrayed and stacked
into larger handling groups such as on a pallet and wrapped by a
second flexible member, e.g. another plastic wrapping material, to
form a larger shipping or transport group that can be handled in
the same general manner as stacks of cases. The containers can be
stacked five or six high--just as the cases are presently
stacked--because of the ability to transfer loads effectively
thorough the container without cases. The overall cost of
manufacturing, cleaning, handling, storage, etc. of cases as
described above is eliminated.
[0114] Structural tests indicate that the shrink-wrapped cases have
a decrease in the column deflections by a factor of three. The
containers were dynamically tested on a vibratory table to
stimulate the dynamic situation which occurs during handling and
truck transport. Pallets are usually handled with motorized fork
trucks which load the trucks. Vibration testing was conducted on
fork truck and trucks in transport. These results were utilized in
the dynamic laboratory testing. It was observed that the columnar
effect that is developed in the pallet configuration allow the
degrees of freedom similar to a building during an earthquake.
These degrees of freedom allow the pallet to act as a unit; yet
flex and move under loading to prevent detrimental stress
concentrations which can negatively impact the structural integrity
of the cases and containers.
[0115] A diamond shaped pouring spout may be included and is of a
large enough dimension to permit venting back into the container to
prevent "glugging" and to prevent dripping. A front surface of the
container may be formed to include a large radius aligned with the
spout to permit a rocking action which allows the container to be
tilted easily without lifting from the support surface. The spout
may be formed with a recess thereunder for placing a glass or cup
and to minimize spills.
[0116] The group of stacked containers is then broken down into the
individual units by removing the second wrapping material. To aid
in its removal, the second flexible material may incorporate a tear
strip or the like into the material to allow easy removal of the
plastic wrapping.
[0117] The invention has been described with reference to the
preferred embodiments. Obviously, modifications and alterations
will be apparent to those of ordinary skill upon a reading and
understanding of the specification. For example, the preferred
material of construction is a food grade plastic such as a high
density polyethylene (HDPE) although alternative materials that
comprise a plastic, at least in part, could be used. The invention
is intended to include all such modifications and alterations.
* * * * *