U.S. patent application number 13/021907 was filed with the patent office on 2011-05-26 for collapsible container handle configuration.
Invention is credited to Jeff Kalman, John Nottingham, John Spirk, Nick E. Stanca.
Application Number | 20110121026 13/021907 |
Document ID | / |
Family ID | 36000716 |
Filed Date | 2011-05-26 |
United States Patent
Application |
20110121026 |
Kind Code |
A1 |
Nottingham; John ; et
al. |
May 26, 2011 |
COLLAPSIBLE CONTAINER HANDLE CONFIGURATION
Abstract
A semi-collapsible container has a hollow body with support and
collapsible portions, and can be maintained in a collapsed or an
expanded condition. The container is useful for storing liquid, and
is especially adapted in its collapsed condition for storing
relatively small volumes of concentrated liquid, powders or the
like, and in its expanded condition for containing larger volumes
of liquid. Via a dispenser in the container, a closure assembly is
coupled to the container for securing the contents thereof from
leakage.
Inventors: |
Nottingham; John;
(Bratenahl, OH) ; Spirk; John; (Gates Mills,
OH) ; Stanca; Nick E.; (Westlake, OH) ;
Kalman; Jeff; (Cleveland Heights, OH) |
Family ID: |
36000716 |
Appl. No.: |
13/021907 |
Filed: |
February 7, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11217088 |
Aug 31, 2005 |
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13021907 |
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60606085 |
Aug 31, 2004 |
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Current U.S.
Class: |
222/92 ;
220/666 |
Current CPC
Class: |
B65D 23/10 20130101;
B65D 1/0292 20130101 |
Class at
Publication: |
222/92 ;
220/666 |
International
Class: |
B65D 37/00 20060101
B65D037/00 |
Claims
1. A contained product comprising: a collapsible container
comprising: a support portion; a handle portion connected to said
support portion on top of said support portion; a collapsible
portion connected to the support portion such that an internal
volume is defined between the support portion and the collapsible
portion; wherein the collapsible portion is moveable between an
expanded condition and a collapsed condition; wherein when said
collapsible portion is in said collapsed condition the collapsible
portion is inverted into the internal cavity to form an outwardly
facing concavity; a concentrated product disposed in an internal
volume of the collapsible container when the collapsible portion is
in said collapsed condition.
2. The contained product of claim 1 wherein said handle is offset
from a central axis of the container.
3. The contained product of claim 1 wherein the support portion
includes a dispenser and the handle is positioned adjacent to the
dispenser.
4. The contained product of claim 1 wherein the handle is
hollow.
5. The contained product of claim 1 wherein the support portion,
the collapsible portion, and the handle are all made from one
material having uniform properties.
6. The contained product of claim 5 wherein said one material is a
blend of Low Density Polyethylene and High Density
Polyethylene.
7. The contained product of claim 1 wherein the collapsible portion
is configured such that adding water to the collapsible container
when the collapsible portion is in the collapsed condition causes
the collapsible portion to move to the expanded position.
8. The contained product of claim 1 further comprising a seal that
is applied to the collapsible container immediately upon addition
of said concentrated product to said internal volume of the
collapsible container such that a vacuum forms in said collapsible
container due to an increase in internal volume caused by the force
of adding said concentrated product.
9. A contained product comprising: a collapsible container
comprising: a support portion; a dispenser disposed on top of said
support portion; a hollow handle portion connected to said support
portion on top of said support portion, wherein in a first end of
said hollow handle is in fluid communication with said support
portion adjacent to said dispenser and a second end of said hollow
handle is in fluid communication with said support portion at a
second location spaced apart from said dispenser; a collapsible
portion connected to the support portion such that an internal
volume is defined between the support portion and the collapsible
portion; wherein the collapsible portion is moveable between an
expanded condition and a collapsed condition; wherein when said
collapsible portion is in said collapsed condition the collapsible
portion is inverted into the internal cavity of the support portion
to reduce said internal volume of the collapsible container and to
faun an outwardly facing concavity; a concentrated product disposed
in an internal volume of the collapsible container when the
collapsible portion is in said collapsed condition.
10. The contained product of claim 9 wherein said handle is offset
from a central axis of the container.
11. The contained product of claim 9 wherein the support portion,
the dispenser, the collapsible portion, and the handle are made
from one material having uniform properties.
12. The contained product of claim 11 wherein said one material is
a blend of Low Density Polyethylene and High Density
Polyethylene.
13. The contained product of claim 9 wherein the collapsible
portion is configured such that adding water to the collapsible
container when the collapsible portion is in the collapsed
condition causes the collapsible portion to move to the expanded
position.
14. The contained product of claim 9 further comprising a seal that
is applied to the collapsible container immediately upon addition
of said concentrated product to said internal volume of the
collapsible container such that a vacuum forms in said collapsible
container due to an increase in internal volume caused by the force
of adding said concentrated product.
15. A collapsible container comprising: a support portion; a
dispenser disposed on top of said support portion; a hollow handle
portion connected to said support portion on top of said support
portion, wherein in a first end of said hollow handle is in fluid
communication with said support portion adjacent to said dispenser
and a second end of said hollow handle is in fluid communication
with said support portion at a second location spaced apart from
said dispenser; a collapsible portion connected to the support
portion such that an internal volume is defined between the support
portion and the collapsible portion; wherein the collapsible
portion is moveable between a expanded condition and a collapsed
condition; wherein when said collapsible portion is in said
collapsed condition the collapsible portion is inverted into the
internal cavity of the support portion to reduce said internal
volume of the collapsible container and to form an outwardly facing
concavity.
16. The collapsible container of claim 15 wherein said handle is
offset from a central axis of the container.
17. The collapsible container of claim 15 wherein the support
portion, the dispenser, the collapsible portion, and the handle are
made from one material having uniform properties.
18. The collapsible container of claim 17 wherein said one material
is a blend of Low Density Polyethylene and High Density
Polyethylene.
19. The collapsible container of claim 15 wherein the collapsible
portion is configured such that adding water to the collapsible
container when the collapsible portion is in the collapsed
condition causes the collapsible portion to move to the expanded
position.
20. The contained product of claim 15 further comprising a seal
that is applied to the collapsible container immediately upon
addition of a concentrated product to said internal volume of the
collapsible container such that a vacuum forms in said collapsible
container due to an increase in internal volume caused by the force
of adding said concentrated product.
Description
PRIORITY CLAIM
[0001] This application is a divisional application of U.S. patent
application Ser. No. 11/217,088, filed Aug. 31, 2005, titled
"Semi-Collapsible Container", which claims priority to U.S.
Provisional Patent Application 60/606,085, filed Aug. 31, 2004,
both of which are incorporated herein by reference in their
entirety.
TECHNICAL FIELD
[0002] The invention is generally applicable to semi-collapsible
containers. More specifically, the invention is applicable to
semi-collapsible containers that expand from a relatively minimum
internal volume to a larger internal volume to accommodate the
addition of liquid or liquid-based solutions. The containers are
particularly useful for storage of liquid concentrates, powders and
the like in the collapsed condition, and upon addition of a
diluting liquid, for the containment of the diluted contents in the
expanded condition.
BACKGROUND OF INVENTION
[0003] Many consumer and industrial products are composed of active
ingredients dissolved in solvents, such as water. These type of
products have traditionally been sold preformulated and packaged by
the manufacturer. This is to say that the manufacturer dissolves
the active ingredients in a solvent, packages the resulting
solution in a container, and markets the product to its consumer or
industrial clients. This method provides for a fully constituted
end product; however, the method also maximizes the volume and
weight of the product, which is often undesirable. There is a
general need to provide apparatus and methods of providing
liquid-based solutions to the market while decreasing the weight of
the product and space needed to store the product.
[0004] The minimization of weight and volume of products is
advantageous to manufactures, retailers and consumers. The
manufacturer can reduce the costs of shipping products by reducing
the overall weight and cargo volume of shipments. The manufacturer
can also improve the shelf life of certain products by eliminating
diluting liquids such as water. Retailers can display goods using
less shelf space and reduce the physical workload on employers who
stock the shelves. Consumers can more easily handle the lighter
products and store them more conveniently in their homes or
businesses prior to using the product.
[0005] One method of achieving these goals is to sell only the
active ingredients. A consumer can purchase the active ingredients
and wait until the product is needed to add the solvent and
constitute the final product. This method achieves the goal of
reducing weight of the product and storage space of the product.
However, this method inconveniences the consumer if an adequate
package for accommodating the additional liquid is not provided
with the concentrated ingredient. Not only does an adequate
container need to accommodate the proper volume, it must also be
made of material that is safe when brought into contact with the
active ingredients, and it must be designed for appropriate and
safe dispensing of the diluted contents. The design of a container
can minimize splashing during pouring or make dispensing small
amounts easier. In the absence of an appropriate container, the
consumer may have difficulty in utilizing the concentrated product
correctly, efficiently, and in some instances, safely. Accordingly,
a need exists for consumer product packaging that allows
manufactures to provide products in a concentrated form that
minimizes weight and volume, potentially improves product shelf
life, and insures the contained product is used conveniently,
safely and efficiently by the consumer.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention provides in various
embodiments a container for storing and dispensing products in
their concentrated and diluted fauns. The invention also provides
methods for manufacture of the container. The container is
semi-collapsible, has a hollow body with support and collapsible
portions, and can be maintained in a substantially collapsed or a
substantially expanded condition. The container is particularly
useful for storing liquid. In its collapsed condition, the
container is especially adapted for storing relatively small
volumes of concentrated liquid, powders or the like, occupying
minimal space and having a minimal weight. In its expanded
condition, the container is especially adapted for receiving and
containing larger volumes of liquid which may be added by the
consumer of the contained product to dilute the concentrated
contents. Addition of diluting liquids and dispensing of the
contained product from the container is achieved via a dispenser in
the container, and the container is secured from leakage via a
closure assembly that is coupled to the dispenser.
[0007] In various embodiments, the invention provides a
semi-collapsible container capable of moving between a collapsed
condition and an expanded condition. The container includes hollow
interior that is defined at least in part by a side wall and is
capable of storing liquid when the container is in both its
collapsed and expanded conditions, and a dispenser communicating
with the hollow interior. The container also includes a base
forming a portion of the hollow interior of the container, the base
being capable of non-movably supporting the container when the
container is filled with liquid in both its collapsed and expanded
conditions, a frame forming a portion of the side wall of the
container, the frame maintaining the dispenser in a fixed position
with respect to the base regardless if the container is in its
collapsed or expanded condition, and at leas one collapsible
portion cooperating with the base and frame to define the hollow
interior of the container. In some embodiments, the container is
collapsible in a fashion such that its front profile is essentially
the same regardless of whether the container is in its collapsed or
expanded condition.
[0008] In accordance with some embodiments, the frame of the
container is provided in the form of an upper end with a dispenser
therein, and a lower support base. The support portion of the
container has an interior cavity that defines a portion of the
volume of the container, and a collapsible portion with a shape
that defines a volume that influences the total internal volume of
the container. The collapsible portion is adapted to be physically
movable relative to the support portion between an expanded
position and a collapsed position. When the collapsible portion is
in the expanded position, the internal volume defined by the cavity
of the collapsible portion is available to accommodate liquid or
other contents within the interior of the container. According to
some embodiments, when the collapsible portion is in the collapsed
position, the collapsible portion is inverted into the interior
cavity of the support portion, and the cavities of the collapsible
and support portions are at least partially nested, thereby
reducing the internal volume of the container available to
accommodate liquid or other contents. In other embodiments, the
support portion is not nested with the collapsible portion when in
the collapsed condition. According to such embodiments, the
collapsible portion is in a non expanded condition.
[0009] In various embodiments, the invention also provides a
process for making a semi-collapsible blow molded article. The
process includes the steps of forming a parison from at least one
polymeric resinous material; positioning the parison in a blow mold
having an inner shape that defines the shape of the article to
include at least one support portion and at least one collapsible
portion, and introducing air into the parison to force the parison
to conform to the inner shape of the mold; and processing the blown
article, including the steps, in any order, of removing the article
from the mold and inverting a collapsible portion of the article
into an interior space within a support portion of the article. In
some embodiments, the process provides a semi-collapsible blow
molded article that is made of at least two different materials,
wherein a parison is formed from at least two different polymeric
resinous materials, at least one of which materials is positioned
in the parison in a location that corresponds with the inner shape
of the mold that defines the at least one support portion, and
another of which materials is positioned in the parison in a
location that corresponds with the inner shape of the mold that
defines the at least one collapsible portion.
[0010] Additional features and advantages of the invention will be
set forth in part in the description which follows, and in part
will be obvious from the description, or may be learned by practice
of the invention. The features and advantages of the invention will
be realized and attained by means of the elements and combinations
particularly pointed out in the appended claims. It is to be
understood that both the foregoing general description and the
following detailed description are exemplary and explanatory only
and are not restrictive of the invention, as claimed.
[0011] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate several
embodiments of the invention, and together with the description,
serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows a perspective view of one embodiment of a
semi-collapsible container;
[0013] FIG. 2 shows another perspective view of the embodiment of
the semi-collapsible container in FIG. 1;
[0014] FIG. 3 panel A shows a top view of the semi-collapsible
container shown in FIG. 1 in a expanded condition; panel B shows
the corresponding bottom view; panel C show the corresponding side
view;
[0015] FIG. 4 panel A shows a perspective view of the
semi-collapsible container shown in FIG. 1 in a collapsed
condition; panel B shows an alternate perspective view; panel C
show the corresponding side view; and
[0016] FIG. 5 panel A shows a cut away side view of the
semi-collapsible container shown in FIG. 1 in an expanded
condition; panel B shows an exploded cutaway side view of the
detail of an actuation means; panel C shows a cut away side view of
the semi-collapsible container in a collapsed condition alternate;
panel D shows a cut away top view of the semi-collapsible container
in an expanded condition; panel E shows a cut away top view of the
semi-collapsible container in a collapsed condition.
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention will now be described with occasional
reference to specific embodiments of the invention. This invention
may, however, be embodied in different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided so that this disclosure will fully
convey the scope of the invention to those skilled in the art.
[0018] Except as otherwise specifically defined herein, all terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only, and is not intended to be
limiting of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise.
[0019] Unless otherwise indicated, all numbers expressing
quantities, properties, and so forth as used in the specification
and claims are to be understood as being modified in all instances
by the term "about." Accordingly, unless otherwise indicated, the
numerical properties set forth in the following specification and
claims are approximations that may vary depending on the desired
properties sought to be obtained in embodiments of the present
invention. Notwithstanding that the numerical ranges and parameters
setting forth the broad scope of the invention are approximations,
the numerical values to the extent that such are set forth in the
specific examples are reported as precisely as possible. Any
numerical values, however, inherently contain certain errors
necessarily resulting from error found in their respective
measurements.
[0020] Except as otherwise indicated, the disclosure of all
patents, patent applications (and any patents which issue thereon,
as well as any corresponding published foreign patent
applications), and publications mentioned throughout this
description are hereby incorporated by reference herein. It is
expressly not admitted, however, that any of the documents
incorporated by reference herein teach or disclose the present
invention.
[0021] The invention is directed, in various embodiments, to a
semi-collapsible container for storing and dispensing products in
their concentrated and diluted forms. The terms "collapsible" and
"semi-collapsible" are used to refer to any space within a
container that is effectively reducible in its size or internal
volume by the application of mechanical force to distort its shape,
such as by inverting a portion of the container to fold over
another portion. The container is capable of expanding from a
substantially collapsed condition to a substantially expanded
condition to accommodate the addition of liquid or other material,
and has a hollow body made substantially of an appropriate
material, such as a thermoplastic material.
[0022] According to various embodiments, the semi-collapsible
container of the instant invention includes a hollow interior that
is defined at least in part by a side wall and is capable of
storing liquid when the container is in both its collapsed and
expanded conditions, a dispenser communicating with the hollow
interior, a base forming a portion of the hollow interior of the
container, the base being capable of non-movably supporting the
container when the container is filled with liquid in both its
collapsed and expanded conditions, a frame forming a portion of the
side wall of the container, the frame maintaining the dispenser in
a fixed position with respect to the base regardless if the
container is in its collapsed or expanded condition, and a
collapsible portion cooperating with the base and frame to define
the hollow interior of the container. In some embodiments, the
container is collapsible so that its front profile is essentially
the same regardless of whether the container is in its collapsed or
expanded condition. In some particular embodiments, the frame and
the base are essentially rigid as compared to the collapsible
portion. As used herein, the terms rigid and essentially rigid
refer to material properties that influence the stiffness of
portions of the container. For certain embodiments in which the
size and volumes of containers are large, rigidity of portions of
the container will influence the ability of the container when
filled with to resist deformation caused by the weight of the
fluid.
[0023] The collapsible portion is adapted to be physically movable
relative to the support portion between an expanded position and a
collapsed position. When the collapsible portion is in the expanded
position, the internal volume defined by the cavity of the
collapsible portion is available to accommodate liquid or other
contents within the interior of the container. When the collapsible
portion is in the collapsed position, the collapsible portion is
not expanded, and is in some embodiments inverted into the interior
cavity of the support portion such that the cavities of the
collapsible and support portions are at least partially nested. In
other embodiments, the collapsible portion is in a relaxed,
flattened, folded or partially inverted state. In the various
embodiments, the collapsible portion in its collapsed state
effectively reduces the internal volume of the container available
to accommodate liquid or other contents.
[0024] FIG. 1 shows a perspective view of one embodiment of a
semi-collapsible container. Referring to FIG. 1, the container 100
has an upper end 105 with a dispenser 110 therein, and a lower
support base 115 for supporting the container in both its collapsed
and expanded conditions when resting in a generally upright
position on a surface. The container has a support portion 120
having an interior cavity (125, see FIG. 2) that defines a portion
of the total volume of the container. The container 100 also has at
least one collapsible portion 130 with a shape that defines a
cavity (135, see FIG. 2) that influences the total internal volume
of the container. The collapsible portion 130 is adapted to move
between a substantially expanded position and a substantially
collapsed position. In the expanded condition, the cavity 135 of
the collapsible portion 130 contributes positively to the total
volume of the container 100. In the collapsed condition, the cavity
135 of the collapsible portion 130 contributes negatively to the
total volume of the container 100. As can be seen in FIG. 3, the
collapsible portion 130 in this embodiment appears to protrude form
the side of the support portion 120 when in an expanded
position.
[0025] A container 100 according to the instant invention is formed
of one or more materials that are suited to use in the expanded and
collapsed conditions. The particular material is generally selected
to be compatible with the intended contents of a container 100. As
discussed more fully below, a container 100 may be manufactured by
one of a variety of methods of making containers that are well
known in the art. Good results are obtained producing hollow
containers using extrusion blow molding techniques with a variety
of thermoplastic and elastomeric materials. Accordingly, in various
embodiments according to the instant invention, a container 100 may
be made from one or a combination of thermoplastic or elastomeric
materials, such as: polyesters, Polycarbonate (PC), polypropylene
(PP), polyethylene (PE), High Density Polyethylene (HDPE), Low
Density Polyethylene (LDPE), Polyvinyl Chloride (PVC), polyester
terphthalate, butadiene-styrene co-polymers, polyamides,
ethylene-vinyl-alcohol copolymer, polyethylene napthaphthalate,
thermoplastic and thermosetting resins, polybutylene terephthalate,
polyoxymethylenes, polyphenylene, polyphenylene sulfides,
polyphenylene oxides, polymethylmethacrylate,
polyethylene-terephthalate (PET), polyvinylidenechloride,
polymethylpentene-1, nylon 6, nylon 66, Polyethylene Terephthalate
Modified with CHDM (PETG), and mixtures thereof.
[0026] Use of thermoplastic or elastomeric materials in making the
container 100 penults the selection of a broad range of possible
material properties, including the properties of rigidity,
flexibility, elasticity, thermal and chemical resistance,
electrical resistance/conductance, mechanical abrasion resistance,
catalytic surface activity, color, transparency/opacity,
reflectivity, and texture. According to some embodiments of the
invention, the container 100 is made entirely from one material
that has uniform properties. According to other embodiments of the
invention, the container 100 is made entirely from one material
that has varying properties in various parts of the container 100.
For example, the same thermoplastic or elastomeric material may be
selected for the entire container 100 but the percentages of
functional components in each may be varied to provide varied
properties at discrete portions of the container 100. Similarly, in
yet other embodiments, two or more different thermoplastic or
elastomeric materials may be selected for the container 100, each
forming a discrete portions of the container 100. According to such
embodiments, portions such as the collapsible portion 130 and the
support portion 120 of the container 100 may vary in
properties.
[0027] In a particular embodiment, 24. the material of the support
portion 120 has the property of being more rigid than the material
of the collapsible portion 130, either by varying the functional
components of the same material or by varying the materials. One
such embodiment of the invention is a container made up of two
portions with each portion manufactured from a different material.
The support portion 120 is made of a semi-rigid material, of the
type that is commonly used for containers that are known in the art
for containing products such as juices, or automotive fluids.
Typically, such material is a clear or opaque thermoplastic. The
semi-rigid material is rigid enough to maintain a given shape
whether there is contents in the container or the container is
empty. However, the material is not so rigid that a force applied
to the material would not cause some deformation. The collapsible
portion 130 of the container 100 is made of a pliant material. The
pliant material generally, adjusts to take the shape of the
substance inside the container 100. An example of such an
embodiment is a container 100 in which the material of the support
portion comprises a blend of LDPE and HDPE, and wherein the
material of the collapsible portion comprises one of LDPE and a
blend of LDPE and HDPE. Of course a very large number of
combinations of materials can be combined in making a container
according to the instant invention, and methods for making them are
well know in the art. In additional embodiments of the invention,
the collapsible portion 130 can be made of an elastic material that
stretches as liquid is added to the container 100. The elastic
nature of the material could more accurately adjust to the shape of
the contents of the container and potentially further minimize the
exterior dimensions of the container. In addition, these
embodiments could make it easier for an end user to dispense the
product from the container 100.
[0028] Referring now to FIG. 2, the container 100 is shown in
cutaway perspective view in an expanded condition. In the expanded
condition, the container 100 has an internal volume that includes
the volumes provided by the interior cavity 125 of the support
portion 120 and the cavity 135 of the collapsible portion 130. The
container 100 is particularly useful for storing liquid, and other
flowable materials, and in its collapsed condition, the container
100 is especially adapted for storing relatively small volumes of
products such as concentrated liquids, powders or the like, the
products occupying minimal space and having a minimal weight
relative to their diluted forms. In its expanded condition, the
container 100 is especially adapted for receiving and containing
larger volumes of liquid or other flowable materials which may be
added by the consumer of the contained product to dilute the
concentrated product contents. Addition of diluting liquids and
dispensing of the contained product from the container is achieved
via the dispenser 110 in the container 100, and the container 100
is secured from leakage via a closure assembly (not shown) that is
coupled to the dispenser 110.
[0029] Referring now to FIG. 3, various perspectives of the
container 100 in an expanded condition are shown. Panel A provides
a top view of the container 100 as illustrated in FIG. 1, in an
expanded condition, and shows the top segment 131 of the
collapsible portion 130 and the upper end 105 of the container 100.
Panel B provides a corresponding bottom view of the container 100,
and shows the bottom segment 132 of the collapsible portion 130 and
the lower support base 115. And panel C provides a side view of the
container 100 in an expanded condition, and shows the relative
shapes, sizes and configurations of the support portion 120 and the
collapsible portion 130 according to one possible embodiment of the
container 100. Referring to FIG. 3 C, the support portion 120 is
formed of a substantially vertical wall, which in some embodiments
includes a vertical front wall 121, and in some embodiments, as
depicted in FIG. 3, the support portion 120 also includes two
substantially vertical sidewalls 122 and 122' (122' not shown), and
a back wall 123. In alternate embodiments of the container 100, the
support portion 120 may comprise a different configuration of
substantially vertical wall or walls around its periphery, as
dictated by the overall shape of the container, as discussed more
fully below.
[0030] Still referring to FIG. 3 C, the collapsible portion 130
also includes a substantially vertical sidewall 133 which is
bounded on the top by the top segment 131 and on the bottom by the
bottom segment 132. In alternate embodiments of the container 100,
the collapsible portion 130 may comprise a different configuration
of substantially vertical wall or walls, as dictated by the overall
shape of the container, as discussed more fully below. As can be
seen in the various views of FIG. 3, the total volume of the
container 100 includes the volumes contributed by the interior
cavity 125 of the support portion 120 and the cavity 135 of the
collapsible portion 130; thus, the cavity 135 of the collapsible
portion 130 makes a positive contribution to the volume of the
container 100 in the expanded condition.
[0031] According to some embodiments, when in the collapsed
condition, the collapsible portion 130 is inverted into the
interior cavity 125 of the support portion 120, as depicted in the
various views provided in FIG. 4. Referring now to FIG. 4, panel A
provides a front perspective view of the container 100, panel B
provides a corresponding rear perspective view, and panel C
provides a side view. As can be seen, the cavity 135 of the
collapsible portion 130 is nested within the interior cavity 125 of
the support portion 120. According to the depicted embodiment of
the container 100, when the cavities of the support 120 and
collapsible 130 portions are nested, the substantially vertical
walls 121, 122, and 122' of the support portion 120 and the
substantially vertical wall 133 of the collapsible portion 130 are
moved adjacent to one another, and are in some embodiments at least
partially in contact. Likewise, in the collapsed condition, the
bottom segment 132 of the collapsible portion 130 and the lower
support base 115 are moved adjacent to one another, and are in some
embodiments at least partially in contact. Of course it will be
appreciated that in other embodiments, the position of the
collapsible portion 130 relative to that of the support portion 120
may vary; for instance, the collapsible portion 130 may be in a
flattened or relaxed state, it may be folded, creased or otherwise
positioned without being inverted or nested with the support
portion 120.
[0032] Of course it will be understood, as more fully discussed
below, that the overall shape of each of the nested cavities 125
and 135 of the support 120 and collapsible 130 portions will
influence the extent to which the segments of the container 100 are
adjacent to or in contact when the container 100 is in the
collapsed condition. And it will be appreciated by one of ordinary
skill that when the cavities 125 and 135 of the support 120 and
collapsible 130 portions are nested, the cavity 135 of the
collapsible portion 130 contributes negatively to the total volume
of the container 100 by effectively reducing the total volume of
the container by the volume of the cavity 135 of the collapsible
portion 130 and by at least a portion of the volume of the internal
cavity 125 of the support portion 120. The extent of the volume
reduction of the internal cavity 125 of the support portion 120 is
influenced by the overall dimensions and shape of the collapsible
portion 120.
[0033] In various embodiments, the container 100 according to the
invention is capable of being manipulated between a collapsed and
an expanded condition. The collapsible portion 130 is moved between
an expanded position and a collapsed position by actuation of a
means located at the interface 200 between the collapsible portion
130 and the support portion 120. As noted above in relation to FIG.
4, when in the collapsed condition, the collapsible portion 130 is
inverted into the interior cavity 125 of the support portion 120.
Referring again to FIG. 4, panel B provides a rear perspective view
of the container 100 illustrated in FIG. 1, in a collapsed
condition, and shows the interface 200 between the support portion
120 and the collapsible portion 130 (which is inverted, and nested
within the cavity 125 of the support portion 120). The actuation
means 250 is positioned substantially at the interface 200, and is
adapted to permit the movement of the collapsible portion 130
between the expanded and the collapsed positions.
[0034] Referring still to FIG. 4 B, as shown in the depicted
embodiment, the actuation means 250 is integral with the container
100 and is adapted to maintain a watertight seal at the interface
200 between the support portion 120 and the collapsible portion
130. Generally, the actuation means 250 is made of a material that
is the same as or similar to the material(s) used to make one or
both of the support portion 120 and the collapsible portion 130. As
shown in the various figures provided herein, the actuation means
250 is formed from the same material(s) used to make one or both of
the support portion 120 and the collapsible portion 130. In other
embodiments not illustrated herein, the actuation means 250 may be
formed from material that is different from the material(s) used to
make one or both of the support portion 120 and the collapsible
portion 130. In yet other embodiments not illustrated herein, the
actuation means 250 may be formed separately from and not
integrated with the either or both the support portion 120 and the
collapsible portion 130. According to such embodiments, the
actuation means 250 may be in the form of a gasket, grommet, or
other band or seal that is inserted at the interface 200 after
manufacture of the support and collapsible portions 120 and 130.
And in yet other embodiments, the material forming the actuation
means 250 is different from those of the support and collapsible
portions 120 and 130 and is inserted or attached to the container
100 as a final assembly step.
[0035] In some embodiments, the actuation means 250 is a hinge or
hinge like structure. Examples of hinge shapes and configurations
suitable for the actuation means 250 according to the instant
invention include shapes that have one, two, three, four or more
bends. Examples of single bend hinges include hinges that are
generally "C," "U," or "V" shaped. Examples of double bend hinges
include hinges that are generally "S," or "Z" shaped. Yet other
hinges with additional bends may be used according to the
invention. According to embodiments wherein the actuation means 250
is a hinge, a variety of hinge shapes and types are known in the
art.
[0036] According to embodiments of the invention in which the
actuation means 250 is a hinge, a variety of hinge shapes and types
are known in the art and may be selected therefrom. An example of a
type of hinge type that is useful according to the instant
invention is a living hinge. As used herein, the term "living
hinge" means a hinge with no moving parts that is characterized by
its excellent fatigue resistance. Living hinges are typically
formed of thin segments of plastic that connect two parts of an
article to keep them together and allow the article to be opened
and closed. Living hinges are desirable because they are generally
able to flex up to a million or more cycles without failure. The
materials used to make a living hinge include very flexible
plastics, such as polypropylene and polyethylene, and other
thermoplastic materials as described herein.
[0037] The actuation means 250 shown in FIG. 5 (and the other
figures shown herein) is a Z shaped living hinge. Panel A provides
a cutaway side view of a container 100 in the expanded condition.
The figure features a dotted circle in the lower left hand portion
corner highlighting the detail of the actuation means 250. Panel B
provides an exploded cut away perspective view of the detailed area
from Panel A, showing the Z-shaped living hinge actuation means 250
of the illustrated embodiment. As can be seen in FIG. 5 B, the
illustrated portion of the actuation means 250 is shown adjacent to
the lower support base 115 of the container (bottom right of the
figure) and the collapsible portion 130 (upper left of the figure).
Still referring to FIG. 5 B, the depicted hinge has three legs 251,
252, and 253, arranged in series, with leg 251 adjacent and
attached to the support portion 120. Leg 252 is positioned between
leg 251 and 253, and leg 253 is in turn adjacent to the collapsible
portion 130 of the container 100. The illustrated actuation means
250 allows for the collapsible portion 130 to be inverted from the
expanded position by folding along the hinge. FIG. 5 C provides a
cutaway side view of a container 100 in the collapsed condition,
and FIGS. 5 D and 5E each show a cutaway plan view of the container
100 in the expanded and collapsed conditions, respectively. As can
be seen from each of these views, the legs 251 and 252 of the
actuation means 250 intersect to form a hinge edge 255 that extends
from the surface of the container 100 around the interface 200
between the support and collapsible portions. In alternate
embodiments in which a hinge having fewer than three legs is used,
the hinge edge may not be present. In yet other embodiments in
which additional hinge legs are used or different hinge
configurations are used, a more pronounced or differently shaped
hinge edge may be present. The choice of hinge, or of living hinge
design, is influenced by the properties of material used, including
pliability, rigidity, elasticity and the like. Hinge selection is
within the skill of those of ordinary skill in the art.
[0038] According to the invention, the container 100 has a shape
that is suited to containing liquid and other flowable materials.
As such, the overall size, shape and configuration of the container
100 may vary as suited to the intended contents and uses by the
consumer of the contained goods. Likewise, the relative proportions
of the upper end 105, lower support base 115, support portion 120
and collapsible portion 130 may vary as needed to accommodate
contents of varying density, viscosity, etc. For particularly small
containers, certain shapes may be favored, such as more streamlined
cylindrical shapes. For particularly large containers that will
hold larger volumes, and hence be heavier upon addition of diluent,
less streamlined and more hefty and ergonomically designed shapes
may be favored. One of ordinary skill will appreciate that the
overall shape and arrangement of features such as dispending
openings, handles, and other features may be selected as
appropriate to the use of the container.
[0039] In some embodiments, the container 100 according to the
invention has an overall substantially cylindrical shape. In other
embodiments, the container 100 has an overall substantially
polyhedral shape. In yet other embodiments, portions of the
container 100 has a shape that is a combination of cylindrical and
polyhedral shapes. For example, in some embodiments, both the
support portion 120 and the collapsible portion 130 have a
substantially cylindrical shape, wherein the support portion 120
has a substantially arcuate vertical wall, and wherein the
collapsible portion 130 has a substantially cylindrical vertical
face. In other embodiments, both the support portion 120 and the
collapsible portion 130 have a substantially polyhedral shape,
wherein the support portion 120 has a substantially flat vertical
wall bounded by sides that are either substantially flat or
rounded, and wherein the collapsible portion 130 has a
substantially cylindrical vertical face a substantially flat
vertical wall likewise bounded by sides that are either
substantially flat or rounded. And in yet other embodiments, one of
the support and collapsible portions 120 and 130, respectively, has
a substantially polyhedral shape while the other has a
substantially cylindrical shape.
[0040] In various embodiments, the collapsible portion 130
according to the invention has top and bottom segments 131 and 132
of varying shapes. In some embodiments, the top segment 131 has a
domed shape, and the bottom segment 132 is flattened, as shown in
the embodiment of the container 100 depicted in the figures, for
example, FIG. 2. In yet other embodiments that are not shown, the
top segment 131 has a squared or peaked shape, and the bottom
segment 132 is rounded. In still other embodiments, the segments of
the collapsible portion 130 may be baffled or folded, and may be
ribbed, rippled or pleated. One of ordinary skill will appreciate
that a variety of combinations of shapes and folds may be used for
the top and bottom segments 131 and 132 of the collapsible portion
130 of the container 100 according to the instant invention.
[0041] Likewise, the vertical wall 121 of the support portion 120
may be formed in the shape of a cylinder, as mentioned above,
wherein the vertical wall 121 is substantially continuous and
arcuate in shape. In other embodiments, the vertical wall 121 of
the support portion 120 may be generally polyhedral in shape, and
formed of a substantially flat front wall 121 bounded by
substantially flat or curved side walls 122 and 122' and have a
back wall 123 opposing the flat front wall 121, the back wall 123
being substantially flat or curved.
[0042] The interface 200 between the support portion 120 and the
collapsible portion 130 may have a variety of shapes and
configurations. According to the illustrated embodiment, as shown
in representative FIG. 4B, the interface 200 is generally arch
shaped on the top and squared on the bottom, the shape being formed
by the generally domed shape of the top segment 131 and the
generally flatted shape of the bottom segment 133 of the
collapsible portion 130. Of course it will be appreciated that
variations in the shape of the segments of the collapsible portion
130 will influence the shape of the interface 200, and that
generally any shape will be suitable to accommodate the function of
actuating movement of the collapsible portion 130 between the
expanded and collapsed positions. More generally, containers, such
as bottles, having a variety of shapes are well known in the art,
and the design of shaped features are known to those of ordinary
skill.
[0043] Referring again to FIG. 1, the container 100 in accordance
with the instant invention has an internal volume that includes the
combined volumes of the cavities of the support and collapsible
portions. According to the embodiment depicted in the figures, the
support portion 120 forms at least one half of the surface area of
the container 100 and about one half or more of the volume of the
container 100; the collapsible portion 130 forms not more than one
half of the surface area of the container 100, and about one half
or less of its volume. In alternate embodiments that are not shown,
the relative contributions to the container 100 size and volume by
each of the collapsible and support portions 130 and 120,
respectively, may vary. For example, in some embodiments, the
support portion 130 may contribute as little as 10, 15, 20, 25, 30,
35, 40 or 45 percent of the container or its volume. And in other
embodiments, the support portion 130 may contribute as much as 55,
60, 65, 70, 75, 80, 85, 90 or 95 percent of the container or its
volume. By varying the sizes, shapes, and relative thickness and
rigidity of the collapsible and support portions 130 and 120 of the
container 100, a wide variety of container configurations are
possible in accordance with the invention.
[0044] Referring still to FIG. 1, in its various embodiments, the
lower support base 115 and the upper end 105 are on the support
portion 120 of the container 100. In various embodiments, the lower
support base 115 is either substantially rectangular, square,
circular, crescent, or disc-like in shape. The illustrated
embodiment has a lower support base 115 that is substantially
rectangular, as shown in representative FIG. 3B. The support base
115 is in contact with the support portion 120 at least at the
front of its vertical wall 121. In the depicted embodiment shown in
FIG. 1, the support base 115 is in contact around its perimeter
with the support portion 120 at the front wall 121, side walls 122
and 122' and back wall 123. Other configurations are possible. In
some embodiments, the support base 115 is in contact with the
support portion 120 via an edge 140, which is identified in FIG.
3C. The edge 140 may be beveled as shown in the illustrated
embodiment, it may be rounded, or it may have another shape,
curvature or texture, including one or more levels formed, for
example, by one or more beads or crowns. In other embodiments, the
support base is in contact with the support portion at
substantially a 90 degree angle, in the absence of an edge or
bevel.
[0045] Referring again to FIG. 1, the upper end 105 of the
container 100 includes a dispenser 110. And in the depicted
embodiment, the container 100 also includes a handle 112, although
it will be appreciated that in other embodiments, the feature of a
handle is not included. In various embodiments, the upper end 105
has a shape that is conducive to efficient dispensing of the
contents of the container 100. In some embodiments that are not
shown, the upper end 105 has a substantially domed shape, with the
dispenser positioned at the top of the dome. In other embodiments
(not shown), the upper end 105 has a substantially inverted
truncated conical shape, with the dispenser positioned at the apex
of the cone. And in still other un-shown embodiments, the upper end
105 has a substantially cylindrically shaped neck that is tapered
relative to the body of the container, with the dispenser
positioned at the top of the neck. It will be appreciate that a
wide range of shapes and configurations of bottle tops and
dispensers are known in the art and can be adapted for use with the
containers of the instant invention.
[0046] As mentioned previously, in some embodiments the container
100 has a handle. A handle provides a variety of functions that
influence efficient use of the container 100. For particularly
large-volume containers, a handle is useful for providing
structural support to aid in stacking and weight distribution when
the container is filled. A handle is also useful for ergonomic
purposes, particularly when the contents are heavy and difficult to
dispense merely by grasping the body or neck of the container.
Likewise, a handle reduces the need for structural rigidity in the
body of the container, which is more important if the container is
to be grasped by the body for dispensing. Finally, a handle, when
hollow and positioned at or near the top of the container, can aid
in venting during dispensing, and thereby improve flow when the
contents are dispensed. In embodiments of the container 100 that
comprise a handle, the handle 112 may be offset from a central axis
of the container, being positioned on the upper end 105 and
adjacent to the dispenser 110. In other embodiments, the handle 112
may be positioned on the upper end 105 and inline with the
dispenser 110. And in yet other embodiments, the handle 112 may be
positioned at some distant location relative to the upper end 105,
such as along the vertical wall of the support section 120. And in
still other embodiments, the container 100 may have more than one
handle 112, each handle being positioned at one or more of the
various locations on the container 100, arranged in either a
symmetrical or nonsymmetrical relative orientation.
[0047] In various embodiments, the container may comprise a closure
means 150, as identified in FIG. 2. A variety of closure means for
sealing containers and other bottles are well known in the art, and
include, but are not limited to openings that have ridges, threads
and other structural features for receiving and retaining a closure
device, such as a cap or lid. The container 100 may likewise
comprise a closure assembly, such as a cap or lid. The closure
assembly (not shown) may be in one or more pieces, and may have
features that indicate rupture of a seal, protect against opening
by children, or protect against leakage or passage of liquid or
vapor into or out of the container 100. According to such various
embodiments, the closure assembly may be removably coupled to the
container 100, or it may be a single use closure. In some
embodiments of the invention, a device, such as a pull ring, may be
attached to the outside of the collapsible portion 130 to enable
the user to manually pull the collapsible portion 130 away from the
body of the container 100 when the container is in a collapsed
condition.
[0048] In all embodiments described above it is understood that the
container may come in a variety of sizes and shapes. The figures
presented show traditional one gallon and half-gallon bottle
container; however, this does not preclude the container from
taking on other sizes and shapes, such as all sizes of drums,
barrels, boxes, cans, and the like.
Methods of Making Containers
[0049] The invention also provides methods for making
semi-collapsible containers. Generally, there are many methods for
making containers. An exemplary method is extrusion blow molding.
The extrusion blow molding process involves multiple steps,
including conventional extrusion of a parison or tube, using a die.
The parison is commonly extruded downward between one or more
sections (usually two halves) of an open blow mold that has an
internal shape that forms the shape of the article to be molded.
The parison is quite hot, while the internal surface of the mold is
relatively cold. When the parison reaches the proper length, the
mold is closed, and the parison is caught and held in place at
either end. A rod-like blow pin is inserted into the one end of the
hot parison to inflate the parison inside the mold cavity, and in
some cases, to form a thread or other structure at what will be the
dispenser of the container. After the blown article cools, the mold
is opened and the article is removed or ejected. The article is
then processed to trim any excess plastic from the areas that were
pinched at the neck and bottom and along the seams of the mold. The
procedures for forming bottles and other containers are well known.
For example, see Modern Plastics Encyclopedia, Vol. 54, No. 10A,
1977-1978, McGraw-Hill Publishing Co. (e.g., section on "Blow
Molding" at page 230, et seq.; also see section on "Injection Blow
Molding" at page 232 et seq.).
[0050] According to the invention, modifications to the blow
molding process provide for making a semi-collapsible blow molded
article. The process includes the steps of forming a parison from
at least one polymeric resinous material; positioning the parison
in a blow mold having an inner shape that defines the shape of the
article to include at least one support portion and at least one
collapsible portion, and introducing air into the parison to force
the parison to conform to the inner shape of the mold; and finally
processing the blown article, including the steps, in any order, of
removing the article from the mold and inverting a collapsible
portion of the article into an interior space within a support
portion of the article.
[0051] The step of collapsing the container may be achieved by
introducing an additional mandrel bearing a punch or other tool
that conforms to the shape of the support portion and is adapted
for removable insertion to effectively collapse the container
without causing damage to its structure. Alternatively, the
collapsing step may be performed manually, such as with a hand, or
a specially adapted tool. In some embodiments, the parison is
formed from at least two different polymeric resinous materials, at
least one of which materials is positioned in the parison in a
location that corresponds with the inner shape of the mold that
defines the at least one support portion, and another of which
materials is positioned in the parison in a location that
corresponds with the inner shape of the mold that defines the at
least one collapsible portion. According to such embodiments,
containers having portions made of different materials can be made,
such as containers in which the collapsible portion and the support
portions vary in their flexibility, rigidity, elasticity, or
opacity or color.
Use of Containers
[0052] Containers of the instant invention are intended for use by
consumers of a variety of products of an industrial, household, or
other nature, that can be provided in a concentrated form (either
powder, liquid, or other form) for later suspension, reconstitution
or dilution. The cavity of the support portion that is available in
the collapsed condition of the containers provides sufficient space
to contain active ingredients or a concentrated liquid solution.
Accordingly, after manufacture of a container, it is ready for
placement of an appropriate amount of active ingredient or
concentrated solution into the container. Thereafter, the container
is sealed. An advantage of the container design according to the
invention is that the addition of product to the collapsed
container results in some degree of distortion of the container and
an attendant increase in the internal volume. Thus, if a seal is
applied to the container immediately upon addition of the product,
a vacuum will form due to the increase in internal volume caused by
the force of the added product. In some instances, manufactures and
packagers may be spared the requirement of evacuation if the
product contents are otherwise stable.
[0053] After the product in the container is purchased, the user
adds water or another appropriate solvent to the container to
arrive at the correct concentration of product. As the liquid is
added, the collapsible portion expands and moves out of the
interior of the support portion and assumes its shape as it is
filled with the added solvent. In general, in some embodiments of
the invention, the collapsible material does not necessarily rely
on significant elasticity to accommodate increases in container
volume. The material itself does not substantially stretch or
shrink when liquid is added or removed, only the shape of the
collapsible material changes to increase or decrease the volume
capacity of the container. When the container is in either the
expanded or the collapsed condition, the bottom of the support
portion supports and maintains the container in an upright position
when set onto an level surface.
[0054] The flexibility of the internal volume and outside
dimensions of the container allow for efficiency gains in the
packing and shipping of containers by conserving overall space and
volume when containers are situated next to one another. Containers
can be designed in a manner where the shape of the support portion
fits into the shape of the non-expanded pliable portion. Generally,
the shape of the support portion is compatible with the shape of
the collapsible portion. This allows the support portion of a
container to be seated adjacent to the collapsible portion of a
container situated next to it, however, the shelf space needed to
accommodate the containers is smaller. When viewed from the front
by a shopper, the containers on a shelf appear very similar to
traditional containers, and include labels, markings and other
product-related indicia typically associated with more
traditionally packaged products.
[0055] Manufactures, retailers and customers alike further benefit
from the space saving design of the container, since the void
provided in the outwardly facing concavities of the body of the
container provide a space that can be used for enclosing tools for
use with the container, such as pumps, measuring cups or spoons,
dispensing containers, additional caps and the like. The space can
also be used for enclosing instructions. And the space can be used
for enclosing promotional items, such as coupons, juice glasses,
children's toys, and other items that appeal to consumers.
[0056] The embodiments described above are examples only, and are
not intended to limit the scope of the claims set forth below.
Variations to the inventions described herein, including alternate
embodiments not specifically described, are quiet possible and are
encompassed by the claims as understood by one of ordinary skill in
the art. Indeed, the claimed inventions have their broad and
ordinary meaning as set forth below in the claims.
* * * * *