U.S. patent application number 11/069794 was filed with the patent office on 2006-04-13 for container having textured grip and enhanced wall integrity.
Invention is credited to Thomas J. Hayes, Michael J. Maczuzak, David K. Orr, Ashwin N. Shah.
Application Number | 20060076395 11/069794 |
Document ID | / |
Family ID | 34966019 |
Filed Date | 2006-04-13 |
United States Patent
Application |
20060076395 |
Kind Code |
A1 |
Hayes; Thomas J. ; et
al. |
April 13, 2006 |
Container having textured grip and enhanced wall integrity
Abstract
A nestable or stackable container having at least one recess
formed in the sidewall of the container to improve wall strength
integrity. The surface of the recess further including texturing to
improve grippability such that the container can be grasped in any
direction while providing improved tactile engagement. Engaging
portions include an annular shoulder to maintain spacing between
adjacent stacked containers, and depressions to define
antirotational interlock between adjacent stacked containers.
Inventors: |
Hayes; Thomas J.; (McHenry,
IL) ; Shah; Ashwin N.; (Fairport, NY) ; Orr;
David K.; (Lakewood, IL) ; Maczuzak; Michael J.;
(Bratenahl, OH) |
Correspondence
Address: |
WINSTON & STRAWN LLP
1700 K STREET, N.W.
WASHINGTON
DC
20006
US
|
Family ID: |
34966019 |
Appl. No.: |
11/069794 |
Filed: |
March 1, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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29215059 |
Oct 12, 2004 |
D515358 |
|
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11069794 |
Mar 1, 2005 |
|
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Current U.S.
Class: |
229/400 |
Current CPC
Class: |
B65D 1/265 20130101;
B65D 1/40 20130101; B65D 25/2897 20130101 |
Class at
Publication: |
229/400 |
International
Class: |
B65D 3/00 20060101
B65D003/00 |
Claims
1. A container comprising: a base defining a closed bottom; and a
side wall extending upwardly from the base, the side wall having an
outer surface and at least one recess formed therein, the at least
one recess including a recessed surface defined by a boundary edge,
the recessed surface having a surface texture different than a
surface texture of the outer surface.
2. The container of claim 1, wherein the at least one recess has a
height of between about 50% to about 80% of a height of the side
wall.
3. The container of claim 1, wherein the boundary edge includes a
curvilinear shape.
4. The container of claim 3, wherein the curvilinear shape is a
parabola.
5. The container of claim 1, wherein the at least one recess
includes at least three recesses formed in the side wall; the at
least three recesses being spaced about a periphery of the
sidewall.
6. The container of claim 1, wherein the surface texture of the
recessed surface includes a multidirectional pattern of peaks and
valleys.
7. The container of claim 6, wherein the multidirectional pattern
includes an irregular pattern of protrusions.
8. The container of claim 7, wherein the pattern is substantially
coextensive over an entire recessed surface.
9. The container of claim 1, wherein a first portion of the side
wall has a frustroconical shape.
10. The container of claim 9, wherein the first portion of the side
wall is disposed proximate the base, the side wall further
including a second portion defining an open mouth opposite the
base.
11. The container of claim 10, wherein the second portion has a
substantially bowl-like shape.
12. The container of claim 10, wherein the at least one recess
extends at least partially into the second portion of the side
wall.
13. The container of claim 1, wherein the side wall defines an open
mouth opposite the closed bottom, the container further comprising
an engaging portion to engage a second container of similar shape
received within the mouth of the container.
14. The container of claim 13, wherein the engaging portion
includes at least one depression formed in the side wall proximate
the base.
15. The container of claim 14, wherein the at least one depression
includes a plurality of depressions formed in the side wall
proximate the base, the plurality of depressions being spaced about
a periphery of the side wall.
16. The container of claim 15, wherein the at least one recess
includes a plurality recesses formed in the side wall; each
depression being disposed between two adjacent recesses.
17. The container of claim 13, wherein the base includes an
upstanding base wall extending from the closed bottom, the engaging
portion including a shoulder defined between the upstanding base
wall and the side wall.
18. The container of claim 17 wherein the base includes at least
one indentation formed within the upstanding base wall along a
periphery of the closed bottom.
19. The container of claim 18, wherein the engaging portion further
includes at least one depression formed in the side wall, each
indentation being aligned axially with a corresponding
depression.
20. The container of claim 1, wherein the side wall defines an open
mouth opposite the closed bottom, the container further comprising
a rim disposed along the open mouth, the rim including a radially
extending lip with a flat upper surface.
21. A stack of nestable containers, the stack comprising a first
container; and a second container received within the first
container; each of the first container and the second container
being substantially similar in shape and including a base defining
a closed bottom; and a side wall extending upwardly from the base,
the side wall having an outer surface and at least one recess
formed therein, the at least one recess including a recessed
surface defined by a boundary edge, the recessed surface having a
surface texture different than a surface texture of the outer
surface.
22. The stack of claim 21, wherein the boundary edge of each
container includes a curvilinear shape.
23. The stack of claim 21, wherein the at least one recess of each
container includes at least three recesses formed in the side wall;
the at least three recesses being spaced about a periphery of the
sidewall.
24. The stack of claim 21, wherein the surface texture of the
recessed surface includes a multidirectional pattern of peaks and
valleys.
25. The stack of claim 24, wherein the multidirectional pattern
includes an irregular pattern of protrusions.
26. The stack of claim 25, wherein the pattern is substantially
coextensive over an entire recessed surface.
27. The stack of claim 21, wherein a first portion of the side wall
is disposed proximate the base, and the side wall further includes
a second portion defining an open mouth opposite the base, the
first portion having a shape different than the second portion.
28. The stack of claim 21, wherein the side wall of each container
defines an open mouth opposite the closed bottom, the first
container further including an engaging portion to engage an
engaging portion of the second container when the second container
is received within the mouth of the first container.
29. The stack of claim 28, wherein the engaging portion of the
first container includes at least one depression formed in the side
wall proximate the base.
30. The stack of claim 29, wherein the at least one depression is
configured to interlock the first container and the second
container to inhibit relative rotation therebetween.
31. The stack of claim 29, wherein the side wall of the second
container includes at least one depression formed therein proximate
the base, the at least one depression of the first container
configured to engage the at least one depression of the second
container to inhibit rotational movement therebetween.
32. The stack of claim 21, wherein the base of each container
includes an upstanding base wall extending from the closed bottom,
the engaging portion including a shoulder defined between the
upstanding base wall and the side wall.
33. A container comprising: a base defining a closed bottom, the
base including an upstanding base wall extending from the closed
bottom; a side wall extending upwardly from the base, the side wall
having an outer surface and at least one recess formed therein, the
at least one recess including a recessed surface defined by a
boundary edge, the recessed surface having a surface texture
different than a surface texture of the outer surface; and an
engaging portion to engage a second container of similar shape
received within the mouth of container, the engaging portion
including at least one depression formed in the side wall proximate
the base, and a shoulder defined between the upstanding base wall
and the side wall, the base further including at least one
indentation formed within the upstanding base wall and the side
wall.
Description
CROSS REFERENCE
[0001] The present application is a continuation-in-part of U.S.
Design patent application Ser. No. 29/215,059, filed Oct. 12, 2004,
the contents of which is incorporated in its entirety by reference
herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates to an improved nestable
container, such as for food or beverages. More particularly, the
present invention is directed to a nestable container having
enhanced wall integrity, increased rim strength, and improved
tactile engagement.
[0004] 2. Description of Related Art
[0005] A variety of thermoplastic containers, such as containers
for food and beverages, are well known in the art. Such
thermoplastic containers are relatively inexpensive and disposable;
and therefore are extremely popular. Such containers are often used
at parties, picnics, gatherings, and other occasions where little
or no clean-up is desired.
[0006] Although thermoplastic containers offer consumers many
benefits, there are certain drawbacks affiliated with manufacture
and use of thermoplastic containers. For instance, such a container
can have a weak or flimsy side wall, as well as a weak rim. For
instance, many consumers using thermoplastic drinking cups have
experienced collapsing or crushing of the side wall when the
container is grasped by the consumer. Similarly, the rim of such
container can flex inward when a cup is gripped around the
periphery of the rim. Conventional containers, which have side
walls and rims that exhibit little crush resistance, therefore can
cause messy spills and unwanted waste.
[0007] Another problem associated with thermoplastic containers is
the lack of grippability due to condensation forming on the
sidewall of the container, as well as the insufficient coefficient
of friction of the material of the container. Conventional
containers typically have a sidewall made of a smooth outer
surface. Such a smooth outer surface can be very slippery when wet,
for example, by condensation. Thus, it is difficult for a consumer
to obtain a comfortable and sufficient grip on a container having a
smooth outer surface, unless extra force is used to grip the
container. However, as mentioned above, the typical container can
have a sidewall that lacks sufficient crush resistance to withstand
the extra gripping force required.
[0008] Numerous attempts have been made to develop and improved
container having suitable crush resistance and improved tactile
engagement without increased manufacturing costs. For example, U.S.
Pat. No. 6,554,154, the contents of which is incorporated herein by
reference, discloses a container having a double set of annular
ribs to provide a side wall container. Although suitable for its
intended purpose, there remains a need for a container having the
desired characteristics without the limitation of required
ribs.
SUMMARY OF THE INVENTION
[0009] The purpose and advantages of the present invention will be
set forth in and apparent from the description that follows, as
well as will be learned by practice of the invention. Additional
advantages of the invention will be realized and attained by the
methods and systems particularly pointed out in the written
description and claims hereof.
[0010] Containers having enhanced wall integrity and improved
gripping features are disclosed herein. Generally, each of the
disclosed containers of the present invention has a base defining a
closed bottom and a side wall extending upwardly from the base. The
side wall has an outer surface and at least one recess formed in
the outer surface. The recessed surface has a texture that is
different than the surface texture of the outer surface of the side
wall.
[0011] In accordance with one aspect of the invention, the at least
one recess is defined by a boundary edge. In one preferred
embodiment, the boundary edge has a curvilinear shape. In a further
preferred embodiment, the boundary edge has a parabolic shape.
However, the boundary edge can be configured to have alternative
shapes, if desired.
[0012] In one aspect of the invention, the container includes at
least three recesses formed in the side wall. For example and not
limitation, a preferred container has recesses formed in the side
wall. The at least three recesses can be disposed equally about the
periphery of the side wall of the container. Each of the at least
three recesses can be defined by a boundary edge having a similar
curvilinear shape and size. However, it is to be understood that at
least some of the recesses can have a shape or size that is
different than another recess of the same container.
[0013] In one embodiment, the at least one recess forms a recessed
surface having a texture that increases tactile engagement.
Although a variety of textures can be used, a preferred texture has
a multidirectional surface pattern capable of increasing tactile
engagement generally in any direction. In a preferred aspect of the
invention, the multidirectional surface pattern includes an
irregular surface pattern of protrusions and/or indentations, such
as bumps, peaks and valleys. For example and not limitation, the
texture can extend circumferentially, axially, or diagonally across
the recessed surface. In accordance with a further preferred aspect
of the invention, the texture extends entirely across the recessed
surface.
[0014] In accordance with another aspect of the invention, the
container is stackable with a second container of similar shape. In
this aspect of the invention, each container includes an engaging
portion to engage an adjacent container of similar shape, which is
received in the mouth of the first container. The engaging portion
includes at least one depression formed substantially proximate the
base of the container. The at least one depression is configured to
interlock with the adjacent container and thus inhibit the
independent rotation of each container, with respect to the
adjacent container, if necessary or desired. In one embodiment, the
engaging portion includes a plurality of depressions spaced from
the base and disposed about the periphery of the side wall of the
container. Alternatively, the engaging portion can include a
plurality of depressions disposed about the base of the container.
The plurality of depressions can be aligned with or disposed
between adjacent recesses. At least one depression can have a
height less than the height of the at least one recess. In this
regard, and in a preferred embodiment, the container includes
alternating recesses and depressions along the periphery of the
side wall, the height of each depression being less than the height
of each adjacent recess.
[0015] In another aspect of the invention, the base of the
container includes an upstanding base wall extending from the
closed bottom, and the engaging portion includes a shoulder defined
between the upstanding base wall and the side wall of the
container. The shoulder defines a ledge along an inner surface of
the container, such that either the bottom wall or the shoulder of
an adjacent container, as desired, engages the ledge of the first
container to maintain a defined spacing therebetween. In one
embodiment, the base further includes at least one indentation
formed in the upstanding base wall along a periphery of the closed
bottom. In one aspect, the indentation is axially aligned with a
depression, if provided.
[0016] In another aspect of the invention, a stack of nestable
containers is provided. The stack comprises a first container and a
second container received within the first container. Each of the
containers is substantially similar in shape and includes the one
or more of the same features described above.
[0017] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and are intended to provide further explanation of the invention
claimed.
BRIEF DESCRIPTION OF THE FIGURES
[0018] FIG. 1 is a schematic perspective view of a first
representative embodiment of a container in accordance with the
present invention.
[0019] FIG. 2 is a schematic side view of the container of FIG. 1
in accordance with the present invention.
[0020] FIG. 3 is a schematic top view of the container of FIG. 1 in
accordance with the present invention.
[0021] FIG. 4 is a schematic bottom view of the container of FIG. 1
in accordance with the present invention.
[0022] FIG. 5 is schematic view of another embodiment of a
container in accordance with the present invention.
[0023] FIG. 6 is a side view of the container of FIG. 5 in
accordance with the present invention.
[0024] FIG. 7 is a top view of the container of FIG. 5 in
accordance with the present invention.
[0025] FIG. 8 is a bottom view of the container of FIG. 5 in
accordance with the present invention.
[0026] FIG. 9 is a cross section of the container in accordance of
FIG. 1 in accordance with the present invention.
[0027] FIG. 10 is schematic view of a first representative
embodiment of a stack of nested containers in accordance with the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0028] Reference will now be made in detail to the present
preferred embodiments of the invention, an example of which is
illustrated in the accompanying drawings.
[0029] The present invention provides for a container having
enhanced wall strength and improved tactile engagement such that
the container is configured to be capable of being gripped from
substantially any direction. Such containers generally include but
are not limited to beverage cups and food containers.
[0030] In accordance with the invention, a container is provided
having a base defining a closed bottom, and a side wall extending
upwardly from the base. The sidewall includes an outer surface and
an inner surface. The closed bottom and the sidewall extending from
the base define a receptacle space. The sidewall defines a mouth
formed opposite the closed bottom. In accordance with the
invention, the container further includes at least one recess
having a recessed surface formed in the sidewall of the container.
The recessed surface has a texture to increase tactile engagement
therewith. In accordance with a particular aspect of the invention,
the textured surface is configured to increase tactile engagement
when grasped from substantially any direction.
[0031] For purpose of explanation and illustration, and not
limitation, an exemplary embodiment of the container in accordance
with the invention is shown in FIG. 1 and is designated by
reference character 100. Additional features, aspects and
embodiments of a container in accordance with the invention are
provided in FIGS. 2-10, as will be described.
[0032] For purposes of illustration and not limitation, as embodied
herein and as depicted in FIG. 1, the container 100 has a base 112
defining a closed bottom 103, and a base wall 112a extending
upwardly from the base. In one preferred embodiment, the base wall
112a has a reverse taper. That is, the basewall 112a has an
upwardly and inwardly taper. A mouth 105 is formed opposite the
closed bottom 103. The base 112 and side wall 114 define a
receptacle space capable of holding contents in the container
100.
[0033] The sidewall, embodied herein, is substantially cylindrical,
and more preferably frustoconical, in shape, as shown generally in
FIGS. 1 to 4. However, the sidewall can be configured to have a
variety of other shapes, including but not limited to rectangular,
hexagonal, or octagonal polyhedronal shapes. In one preferred
embodiment, as depicted in FIGS. 2 and 4, the sidewall 114 has an
upwardly and outwardly taper. Accordingly, the diameter of the
mouth 105 is greater than the diameter of the closed bottom 103.
Alternatively, however, the sidewall 114 can be configured such
that the diameter of the mouth 105 can be substantially the same as
closed bottom 103, if desired.
[0034] The dimensions of sidewall 114 depend on the particular
application. For example and not limitation, if the container is an
18 ounce beverage cup, sidewall 114 can have a height approximately
4.5 inches, and a radius at the base of approximately 1 inch and a
radius at the mouth of approximately 2 inches.
[0035] In accordance with a further aspect of the invention,
container 100 further includes a first portion 130 and a second
portion 132, as depicted in FIG. 2. First portion 130 includes at
least a first section of sidewall 114a disposed proximate base 112
and extending upwardly to second portion 132 of container 100. The
second portion 132 includes at least a second section of sidewall
114b disposed proximate mouth 105. In one preferred embodiment,
sidewall 114a of first portion 130 has a shape different than
sidewall 114b of second portion 132 of container 100.
[0036] For the purpose of illustration and not limitation, and as
depicted in FIG. 2, sidewall 114a can have a substantially
frustoconical shape, and sidewall 114b can have a substantially
bowl-like shape. In this manner, sidewall 114a is proximate base
112 and extends upwardly at a constant taper or angle to a location
162 proximate second portion 132 of container 100. The portion of
sidewall 114b has a radius that extends outwardly greater than the
radius achieved by sidewall 114a. The greater radius of sidewall
114a thus can define in part a wider mouth 105 as well as a
contoured surface ergonomically shaped for a user's hand.
Preferably, the first portion extends between about 50% to about
75% the height of the sidewall. Although the shape of sidewall 114a
and sidewall 114b are at least in part dictated by the radii of
base 112 and mouth 105, respectively, sidewall 114a and sidewall
114b can have a variety of alternative shapes. Further, the shape
of sidewall 114a and sidewall 114b can have substantially the same
shape and radius to provide a continuous tapered or non-tapered
container, if desired.
[0037] In accordance with a further aspect of the invention, the
side wall 114 has at least one recess 120 formed in the side wall.
The at least one recess is configured to increase crush resistance
of the side wall 114. The term "crush resistance" as used herein
refers to the resistance to inward deflection of the sidewall of
the container. In particular, the wall integrity of the container
100 is increased by the recess, thereby reducing the occurrences of
sidewall collapse when container 100 is grasped. In a preferred
embodiment, container 100 can have a plurality of recesses. For
example and not limitation, in one preferred embodiment, container
100 has four recesses.
[0038] The at least one recess includes a recessed surface 121
defined by a boundary edge 122, as depicted in FIG. 1. In one
preferred embodiment, the boundary edge 122 has a curvilinear
shape, and more preferably a continuously curved shape.
Particularly, and in accordance with a preferred aspect of the
invention, the boundary edge defines a parabola with an apex
located opposite the base. Hence, the at least one recess has a
bottom portion and a top portion. The width of the bottom portion
of the at least one recess is greater than the width at the top
portion of the at least one recess, such that the width decreases
with increasing height along the container 100, and the top portion
of the at least one recess forms an apex. In this manner, recess
120 also has a curvilinear shape. However, boundary edge 122 can be
configured to have alternative shapes, for example and not
limitation, polygonal shapes, as deemed suitable or desirable for
the intended purpose.
[0039] In further accordance with an additional aspect of the
invention, the boundary edge 122 defines an edge surface 123
extending between the recessed surface 121 and the sidewall 114. As
depicted herein, the edge surface is parabolic in shape and angled
relative to the recessed surface and the sidewall,
respectively.
[0040] For the purpose of illustration and not limitation, as
embodied herein and depicted in FIG. 2, the at least one recess 120
has a height generally perpendicular to closed bottom 103 that is
between about 50% to about 80% of a height of sidewall 114. In one
preferred embodiment, the at least one recess extends upwardly from
base 112 and is formed in the first portion 130 of sidewall 114.
Further preferred, at least a portion of boundary edge 122 such as
the edge surface can extend to at least the second portion 132 of
sidewall 114 of container 100, as depicted in FIG. 2.
[0041] As described further below, and in accordance with another
aspect of the invention, the base 112 can include a base wall 112a
extending upwardly from the closed bottom. The base wall 112a and
the sidewall 114 define an annular shoulder 146 therebetween. As
embodied herein, and as depicted in FIG. 2, the at least one recess
can extend from the annular shoulder 146 upwardly of sidewall 114.
Alternatively, the at least one recess 120 can extend from closed
bottom 103 of container 100 upwardly along a height of sidewall
114, if desired or if no annular shoulder is provided.
[0042] In accordance with yet another aspect of the invention, the
recessed surface can define a generally partial cylindrical,
frustoconical, or even-bowl shaped surface configuration, as
desired. For example, and as depicted in FIG. 2, the sidewall can
extend upwardly at a first angle to define a frustoconical surface
configuration, and the recessed surface of the at least one recess
can extend upwardly at a second different angle to define a portion
of a second frustoconical surface configuration. By providing
different angles or configurations therebetween the at least one
recess can be further defined from the sidewall and the strength of
the sidewall can be further enhanced. In yet another alternative,
the sidewall and the at least one recess can extend upwardly at
substantially the same angle in a spaced relationship. In this
manner, the at least one recess can be further defined from the
sidewall by providing a step in the sidewall.
[0043] In accordance with a further aspect of the invention, the
recessed surface of the at least one recess is configured for
increased tactile engagement by a user. Particularly, and as
embodied herein, the recessed surface 121 is provided with a
texture 124 to increase tactile engagement. A variety of textures
can be incorporated, either individually or in combination. Such
textures include ribs, protrusions and indentations. In accordance
with a preferred aspect of the invention, the textured surface is
configured to increase tactile engagement when gripped from
virtually any direction. The textured surface therefore is
preferably defined or formed by a multidirectional surface pattern
of protrusions and/or indentations, such as but not limited to a
regular or irregular pattern of protrusions defining peaks and
valleys. In accordance with the invention, the multidirectional
surface patterns can extend circumferentially, axially, or
diagonally across the recessed surface 121. In accordance with yet
another aspect of the invention, the recessed surface can include a
combination of ribs and a multidirectional surface pattern texture.
For example and not limitation, the recessed surface can include
ribs or ridges having a textured surface thereon or therebetween.
The ribs or ridges can be arranged in any suitable pattern, for
example and not limitation, the ribs can form a linear array or
alternatively form a circular pattern, with the multidirectional
surface pattern extending circumferentially axially or
diagonally.
[0044] The multidirectional surface pattern enhances tactile
engagement and improves grippability of the container. For the
purpose of illustration and not limitation, the protrusions provide
greater surface area for tactile engagement by a user, and the
indentations can provide a plurality of troughs to house and wick
away condensation. In this manner, the multidirectional surface
pattern increases tactile engagement by reducing slippage when a
container in accordance with the present invention has condensation
formation on its outer surface. Further, the greater surface area
and/or coefficient of friction provided by the multidirectional
surface pattern enhances tactile engagement and improves
grippability of a container having a dry surface. Additionally,
because the texture is a multidirectional pattern of, for example,
bumps, protrusions, dimples, and indentations, or grid-like cross
hatching, the container is configured for increased tactile
engagement regardless of the direction in which it is grasped. That
is, a discrete pattern of ribs or ridges generally provides tactile
engagement in a single direction. In this regard, the particular
direction or orientation of the ribs or ridges on the surface of
the container dictate the direction in which the container should
be grasped if improved grippability is to be attained. By contrast,
the use of a multidirectional pattern in accordance with the
present invention provides a surface on the container for increased
tactile engagement despite the orientation of the container when
grasped. Further, the texture in accordance with the present
invention can be provided with an increased coefficient of friction
when measured in a variety of directions, unlike a discrete pattern
that may only provide an increased coefficient of friction in a
limited number of directions. The greater coefficient of friction
of the multidirectional pattern of protrusions and/or indentations
enhances tactile engagement and grippability when container 100 is
grasped by a consumer.
[0045] A variety of multidirectional patterns are suitable for the
present invention. For example, the multidirectional pattern can be
provided in the form of a regular pattern of offset bumps or
intersecting raised cross hatching. Alternatively, an irregular
pattern of bumps or protrusions can be used, as preferred and
embodied herein.
[0046] Additionally, the texture in accordance with this aspect of
present invention can provide the advantage of eliminating at least
one step in the manufacturing process, so as to provide a more
efficient and less costly procedure. By providing the texture with
an irregular pattern, for example, imperfections otherwise visible
with a regular or symmetrical pattern are not relevant. That is,
each irregular pattern is unique, and not limited by symmetry. In
this regard, the manufacturing process to form a container 100 in
accordance with the present invention does not require an
additional quality control inspection to ensure that each container
produced on the assembly line includes a texture having an
identical pattern. In contrast, the manufacturing process to form
containers having a regular pattern, such as a pattern including
ribs or ridges, generally requires a step in the process for visual
inspection of each container to ensure that the regular pattern is
maintained for each container. Other advantages of providing a
container having a texture in accordance with the present invention
is that the texturing eliminates blemishes from the moldings, so as
to conceal heat-check marks, sink marks, and flow marks.
[0047] In accordance with another aspect of the invention, the
texture is coextensive with the entire recessed surface. In this
manner, and unlike a discrete or isolated raised rib, an increased
tactile engagement can be accomplished anywhere within the boundary
of the recessed surface. Such an arrangement increases the
predictability in grasping the container with the recesses
provided. The container can further include additional suitable
surface treatments as known in the art.
[0048] A variety of techniques can be used for forming the texture
on the recessed surface in accordance with the invention. For the
purpose of illustration and not limitation, container 100 can be
provided having texture 124 on a surface of recess 120 by a
textured mold. In this manner, a metal mold, for example but not
limitation, an aluminum mold body can be configured with a
multidirectional, and preferably, an irregular pattern in
accordance with the present invention. For example, but not
limitation, the metal mold can be acid etched to define a texture
pattern. In this regard, an acid can be applied to a portion of the
metal mold to degrade the metal material in a particular or desired
pattern. Alternatively, a hobbing process can be used, in which a
master having a particular texture is applied with force to a metal
mold, such as for example an aluminum mold. The particular pattern
on the master displaces portions of the metal mold to create the
desired texture. The textured mold is then used to fabricate the
container in accordance with the present invention. In a preferred
embodiment, the mold is configured to provide an irregular pattern
of protrusions, similar to that depicted in FIGS. 1 and 5, to
define a depth of approximately 0.008'' and a draft angle of
approximately 12.degree. minimum. Such textured molds can be formed
and provided by, for example, a variety of texturing suppliers
known in the art.
[0049] In accordance with a further aspect of the invention, the
container includes an engaging portion configured to engage a
second container of similar shape received in a nested relationship
within the mouth of the container. The engaging portion is
generally disposed proximate base. In accordance with one aspect of
the invention, and as previously described, base 112 can include an
upstanding base wall 112a extending from the closed bottom 103. As
shown in FIG. 2, engaging portion 140 includes shoulder 146 defined
between upstanding base wall 112a and the sidewall 114. The
shoulder defines a ledge on the inner surface of the container, as
depicted in FIG. 3 and in the cross section in FIG. 9. The ledge
can be configured to engage the bottom 103 of an adjacent container
received within the first container so as to maintain a spaced
relationship between the two containers as depicted in FIG. 10.
Alternatively, the ledge can be configured to engage the shoulder
of an adjacent container as described with regard to the
embodiments of FIG. 5 below.
[0050] Additionally, or alternatively, the engaging portion of the
invention can include an anti-rotational interlock element to
prevent relative rotation between adjacent containers received in a
nested relationship. Particularly, and as embodied herein, an
anti-rotational interlock element includes at least one depression
142 formed proximate the base 112. The at least one depression 142
is configured to inhibit rotational movement of a container when
engaged with a second container of similar shape.
[0051] In a preferred embodiment, the at least one depression has a
sufficient depth to define or form a protruding shelf 144 extending
from an inner surface of sidewall 114 into the receptacle of
container 100, as best can be viewed from FIG. 3 and a cross
section in FIG. 9. The depth of the at least one depression can be
constant across a height of the at least one depression.
Alternatively, the depth of the at least one depression can vary
across a height of the at least one depression. For example and not
limitation, the at least one depression can have a depth that
increases with an increase in height. The protruding shelf 144
defined by the depth of the at least one depression is capable of
engaging a corresponding depression of a second container of
similar shape. The engagement between the depressions of adjacent
containers thereby maintains proper alignment for stacking and
prevents rotation therebetween. Further, the at least one
depression can be configured to maintain an axial spaced
relationship between the sidewall 114 of one container and a
sidewall of a second container when in a stacked or nested
orientation, if desired.
[0052] For example, and as embodied herein as depicted in FIG. 3,
the at least one depression 142 includes a plurality of depressions
formed in the side wall proximate the base 112. Particularly, and
as embodied herein, the at least one depression is disposed in the
sidewall above the annular shoulder. As shown in FIG. 4, the
plurality of depressions are disposed about the periphery of the
side wall 114. In one preferred embodiment, the at least one
depression 142 is disposed between two adjacent recesses 120.
Alternatively, however, the at least one depression can be
configured to be in axial alignment with at least one recess
120.
[0053] As schematically shown in FIG. 4, the at least one
depression has a height less than the height of the at least one
recess. Although the dimensions of the at least one depression can
depend on the particular application. For example and not
limitation, for a beverage cup, the at least one depression can
have a height of approximately 0.4 inch and a depth of
approximately 0.045 inch to about 0.082 inch. In one aspect of the
invention, the at least one depression can be configured to have a
depth that increases with increasing height. In this manner, the at
least one depression can have a depth of approximately 0.045 inch
proximate the base and a depth of approximately 0.082 inch at the
height of 0.4 inch upwardly from the base. In this manner, the at
least one depression can have a continuously increasing depth
across the height of the depression. Alternatively, the at least
one depression can be configured to include a step to define an
increased depth.
[0054] Further, the base 112 can include indentation 116, which can
best be seen in FIG. 4, formed within the base wall 112a along a
periphery of the closed bottom 103. In one embodiment, indentation
116 is axially aligned with a corresponding depression 142,
although alternative arrangements can be provided.
[0055] In another preferred embodiment, the at least one depression
is formed in the base wall 112a of base 112 below the annular
shoulder 146, as depicted in FIG. 5. As depicted in FIG. 6, and can
be best viewed in FIG. 7, the at least one depression extends
radially inward beyond the ledge formed by the annular shoulder. In
this embodiment, the base 112 of the container is configured to
have a smaller diameter than the internal diameter provided by the
ledge formed by the annular shoulder. In this regard, the shoulder
of an adjacent container that is inserted into the mouth of a first
container will engage the ledge formed by the shoulder of the first
container. The depression 142 therefore defines a shelf for
engagement by a corresponding depression in an adjacent container
that is inserted into the mouth of the first container to establish
the desired anti-rotational interlock and /or spacing features of
the engagement portion. The ledge formed by the annular shoulder
also can be configured to maintain a spaced relationship between
the sidewall of the container and a sidewall of a second container
when in a stacked orientation. Alternatively, and in lieu of an
annular shoulder, the depression can be formed proximate the base
in the sidewall, either between or aligned with the recesses. For
the purpose of illustration and not limitation, the at least one
depression can have a curvilinear shape, as depicted in FIG. 2.
Alternatively, however, the at least one depression can be
configured to have any of a variety of suitable shapes, such as for
example, a square, rectangular, triangular or other polygonal
shape, as depicted in FIG. 5.
[0056] Further in accordance with the invention, the mouth 105 of
container 100 includes an annular lip 150. In a preferred
embodiment, the lip has a substantially planar top surface 152, and
a flange 154 angle laterally from the substantially planar top
surface 152, as depicted in FIG. 1. The flange 154 is folded at
least partially under the substantially planar top surface 152 such
that the flange is configured at an angle of approximately
25.degree. and greater, for example and not limitation 45.degree.,
relative to the substantially planar top surface 152. The
configuration of the annular lip therefore can have a substantially
triangular configuration. In one preferred embodiment, the unique
annular lip configuration can be formed by known lip forming
techniques. In this manner, a lip forming machine is used to form a
lip on the rim of the thermoformed containers, such as disposable
cups, food packages, and the like. A stack of nested containers is
fed into a conveyor, which directs the containers into a space
between a set of rotating feed rollers. The feed rollers engage the
rim of the containers and rotate the stack of nested containers.
The containers are thereby advanced into the interior of a heating
oven having a heating source, such as for example a calrod. The
stack of nested containers are heated in the oven, and then are
directed to a set of rotating forming screws. The forming screws
engage the heated rims of the containers and progressively fold a
portion of the rim downward to create the triangular lip
configuration on the rim of each container. However, the annular
lip can also have other configurations, such as but not limited to
a rounded, rectangular, or square configuration, or can otherwise
be folded or rolled in a conventional manner.
[0057] The dimensions of the annular lip, including the
substantially planar top surface 152, and flange 154, as well as
the particular angle at which the flange is rolled will depend upon
the intended application of the container. For example and not
limitation, for a beverage container, such as a cup, the planar top
surface has a length of approximately 0.15 inch, the flange 152 has
a length of approximately 0.10 inch, and the flange is preferably
at an angle of approximately 28.degree. in relation to the planar
top surface 152.
[0058] As shown in FIG. 2, sidewall 114 can be configured to
include at least one ridge 160 disposed circumferentially about a
surface of the sidewall, if desired. For example and not
limitation, ridge 160 is disposed proximate to annular lip 150.
Alternatively, however, ridge 160 can be disposed at other
locations, if desired. Additionally, a plurality of ridges can be
disposed circumferentially about the sidewall 114 of container
100.
[0059] Particularly, an 18 oz. disposable beverage container in
accordance with the present invention, and having a configuration
similar to that of FIGS. 1 to 4, was formed with the following
relevant dimensions: height 4.75 in.; base diameter 2.33 in.; mouth
diameter 4.00 in.; number of recesses 4; recess height including
boundary edge 3.10 in.; and a formed lip including a top planar
surface having a length of 0.15 in., a flange having a length of
0.15 in., the flange forming an angle of 28.degree. relative to the
top planar surface.
[0060] As mentioned above, the container in accordance with the
present invention has improved sidewall crush resistance or
improved wall strength integrity, as well as improved lip strength.
To demonstrate the improvement in strength of a container in
accordance with the present invention a standard comparison
deflection test was performed on the sidewall and the lip of a
container in accordance with the present invention and of a
commercially available container of generally similar size. Each
container sample tested was an 18 oz. beverage cup. The results of
the comparative deflection test illustrated that the container in
accordance with the present invention has about an 8% increase in
sidewall strength as compared to the standard commercially
available container. The results also illustrated that the
container in accordance with the present invention has about a 31%
increase in lip strength as compared to the standard commercially
available container. Thus, the results of the comparative
deflection analysis illustrated the improvement in structural
integrity of both the sidewall and the lip achieved by the
container in accordance with the present invention.
[0061] In accordance with another aspect of the invention, a stack
of nestable containers 110 is provided. The stack of nestable
containers includes a first container 100 and an adjacent container
101 received within the first container. Each stackable container
has a substantially similar shape as described above.
[0062] For the purpose of illustration and not limitation, and as
depicted in FIG. 10, in a preferred embodiment, a second container
100' is received within the mouth 105 of the first container 100
such that the body of the second container extends downwardly
through the mouth and into the receptacle of the first container.
As discussed above, and as depicted in FIG. 10, the annular
shoulder 146 of the first container 100 provides a ledge along an
inner surface of the first container, such that when the second
container 100' is disposed within the mouth 105 of the first
container and extends downwardly through its receptacle, the bottom
of the second container 100' engages the ledge on the inner surface
of the first container 100 to maintain a defined spacing
therebetween. Alternatively, and as previously noted with regard to
the embodiment of FIG. 5, the bottom can be dimensioned so as to be
smaller than the cross dimension of the ledge. In this manner, the
bottom of the second container will be disposed within the volume
defined by the upstanding base wall of the first container, and the
shoulder of the second container will engage the ledge of the first
container.
[0063] In accordance with one preferred embodiment, as depicted in
FIG. 10, the ridge 160 disposed circumferentially about the surface
of the sidewall 114 of the first container 100 engages at least a
portion of the annular lip 150 of the adjacent container 101 when
in a stacked orientation.
[0064] In accordance with a further aspect of the invention, the
engaging portion 140 of the first container includes at least one
depression to engage a corresponding engaging portion of the second
container. In one embodiment, the at least one depression 142 has a
substantially constant depth and provides a protruding shelf 144
that extends along an inner surface of the first container 100. In
this manner, the protruding shelf 144 provided by the at least one
depression 142 engages an outer surface of the at least one
depression 142 of the second container 100'. The at least one
depression 142 in conjunction with the protruding shelf 144 assist
in providing proper alignment of the nested first and second
containers. Further, the at least one depression and protruding
shelf also inhibit independent rotational movement of each
container, if needed. The anti-rotational feature provides benefits
during manufacturing, for example, during lip forming, such that
the stack of nested container maintain proper alignment. Further,
the at least one depression is configured to maintain a spaced
relationship between the sidewall of the first container and the
sidewall of the second container. The spacing and lack of
rotational movement prevents extensive wear on the containers.
[0065] Any of a variety of suitable polymers can be used for
container of the present invention, including but not limited to
polystyrenes and copolymers thereof, propylene polymers, such as,
for example polypropylene homopolymers, polypropylene random
copolymers, or polypropylene impact copolymers, ethylene polymers,
such as, for example, high density polyethylene, medium density
polyethylene, or low density polyethylene, polybutenes and
copolymers thereof, polyesters, and mixtures or copolymers
thereof.
[0066] In accordance with a preferred embodiment, the container
material can include at least one colorant. The colorant can be any
suitable material capable of providing a vivid color, including,
but not limited to any color of the spectrum, as well as white and
black, to the material of the container. The colorants that can be
used in the present invention include, but are not limited to,
pigments or dyes. The colorants may be used in a variety of modes,
including but not limited to, dry color, conventional color
concentrates, liquid color and precolored resin. The colorant is
provided in a sufficient concentration to provide the desired
color.
[0067] It will be apparent to those skilled in the art that various
modifications and variations can be made in the method and system
of the present invention without departing from the spirit or scope
of the invention. Thus, it is intended that the present invention
includes modifications and variations that are within the scope of
the appended claims and their equivalents.
* * * * *