U.S. patent application number 15/958677 was filed with the patent office on 2019-10-24 for container base constructions and methods of making the same.
The applicant listed for this patent is Inline Plastics Corp.. Invention is credited to Roman D'Alessandro, Sameh Guirguis, Victor Ivenitsky, Daniel A. Landan, Irene Makarchuk.
Application Number | 20190322406 15/958677 |
Document ID | / |
Family ID | 68237393 |
Filed Date | 2019-10-24 |
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United States Patent
Application |
20190322406 |
Kind Code |
A1 |
Makarchuk; Irene ; et
al. |
October 24, 2019 |
CONTAINER BASE CONSTRUCTIONS AND METHODS OF MAKING THE SAME
Abstract
Disclosed are container base constructions and methods of making
the same. Such container are adapted and configured to reduce or
eliminate deformation of the base and/or sidewall when the
container is filled and/or stacked. The containers have a sidewall
that has a top end and a bottom end; and a base attached to the
bottom end of the sidewall. The base of the container includes a
center panel which is positioned above the bottom end of the
sidewall and an outer convex section. In certain constructions, the
center panel is flat. Alternatively, the center panel can be curved
(e.g., convex).
Inventors: |
Makarchuk; Irene;
(Fairfield, CT) ; Landan; Daniel A.; (Milford,
CT) ; D'Alessandro; Roman; (Brookfield, CT) ;
Ivenitsky; Victor; (South Salem, NY) ; Guirguis;
Sameh; (Monroe, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Inline Plastics Corp. |
Shelton |
CT |
US |
|
|
Family ID: |
68237393 |
Appl. No.: |
15/958677 |
Filed: |
April 20, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 1/26 20130101; B65D
21/0209 20130101; B65D 2543/00296 20130101; B65D 1/265 20130101;
B65D 2543/00092 20130101; B65D 43/162 20130101 |
International
Class: |
B65D 1/26 20060101
B65D001/26; B65D 43/16 20060101 B65D043/16; B65D 21/02 20060101
B65D021/02 |
Claims
1. A container comprising: a frustoconical sidewall having a top
end and a bottom end; and a base attached to the bottom end of the
sidewall defining a cavity bounded by the sidewall and the base,
the base including a center panel and an outer convex section, the
center panel being positioned above the bottom end of the sidewall,
wherein the outer convex section arcuately projects from the bottom
end of the sidewall inwardly and upwardly, wherein the bottom end
of the sidewall defines a bottom plane of the container and the
sidewall extends radially outward at an angle greater than 90
degrees with respect to the bottom plane.
2. The container as recited in claim 1, wherein the center panel is
flat.
3. The container as recited in claim 1, wherein the center panel is
convex.
4. The container as recited in claim 1, wherein an inner panel
connects the center panel to the outer convex section of the
base.
5. The container as recited in claim 4, wherein the inner panel is
ring-shaped.
6. The container as recited in claim 1, wherein the sidewall is
cylindrical and defines a longitudinal axis for the container and
the base has a cross section that is axially symmetrical.
7. The container as recited in claim 1, further comprising a lid
which engages with the sidewall to form a leak resistant seal.
8. The container as recited in claim 7, further comprising a hinge
joining the lid to the sidewall of the container.
9. The container as recited in claim 1, wherein a material
thickness is different for the lid, sidewall and base.
10. The container as recited in claim 1, wherein the sidewall is
formed at an angle greater than 90 degrees with respect to a
surface upon which the container will rest.
11. The container as recited in claim 1, wherein the base,
sidewall, lid and hinge are formed from a single sheet of
material.
12. The container as recited in claim 1, wherein a deflection of
the center panel of the base does not exceed 0.029 inches when the
container is fully loaded.
13. The container as recited in claim 1, wherein the container is
made from a thermoformed polymer.
14. A container comprising: a frustoconical sidewall having a top
end and a bottom end; and a base attached to the bottom end of the
sidewall defining a cavity bounded by the sidewall and the base,
the base including a flat center panel and an outer convex section,
the center panel being positioned above the bottom end of the
sidewall, wherein the outer convex section arcuately projects from
the bottom end of the sidewall inwardly and upwardly, wherein the
bottom end of the sidewall defines a bottom plane of the container
and the sidewall extends at an angle greater than 90 degrees with
respect to the bottom plane.
15. A container comprising: a frustoconical sidewall having a top
end and a bottom end; and a base attached to the bottom end of the
sidewall defining a cavity bounded by the sidewall and the base,
the base including a convex center panel and an outer convex
section, the convex center panel being positioned above the bottom
end of the sidewall, wherein the outer convex section arcuately
projects from the bottom end of the sidewall inwardly and upwardly,
wherein the bottom end of the sidewall defines a bottom plane of
the container and the sidewall extends at an angle greater than 90
degrees with respect to the bottom plane.
16. A container comprising: a frustoconical sidewall having a top
end and a bottom end; and a base attached to the bottom end of the
sidewall defining a cavity bounded by the sidewall and the base,
the base including a flat center panel and an outer convex section,
the center panel being positioned above the bottom end of the
sidewall and joined to the outer convex section through an inner
ring panel, wherein the outer convex section arcuately projects
from the bottom end of the sidewall inwardly and upwardly, wherein
the bottom end of the sidewall defines a bottom plane of the
container and the sidewall extends at an angle greater than 90
degrees with respect to the bottom plane.
Description
FIELD OF THE INVENTION
[0001] The present disclosure is directed to container base
constructions and methods of making the same, and more particularly
to, containers that have a base which is adapted and configured to
reduce or eliminate deformation of the base and/or sidewall when
the container is filled and/or stacked.
BACKGROUND OF THE INVENTION
[0002] When a thermoplastic container or cup is filled with a
product, typically a liquid, and then sealed, internal pressure can
be created within the container. As a result, the base and/or
sidewall of the container often bulge/deform. This is particularly
a problem when the walls of the cup are thin, or otherwise not
sufficiently rigid to prevent the bulging or deformation. This is
increasingly the case as manufacturing targets require minimal use
of material or where the aim is to reduce the overall weight of the
container. This deformation results in a number of possible
problems, including altering the appearance of the container to the
point that consumers may not purchase or would otherwise return a
product in a container with bulging or deformed walls. Furthermore,
when such containers are to be stacked on store shelves, for
example, bulging may have a negative impact on the stackability of
the containers.
[0003] As is known in the art, it is possible to mitigate some of
the effects of bulging by designing containers with thicker walls,
or incorporating other strengthening or structural elements into
the container walls. However, these solutions are not always
possible or can lead to increased material costs, container weight
and other manufacturing and/or design inefficiencies.
[0004] There is a need therefore, for container base constructions
and methods of making the same, and more particularly to,
containers that have a base which is adapted and configured to
reduce or eliminate deformation of the base and/or sidewall when
the container is filled and/or stacked.
SUMMARY OF THE INVENTION
[0005] The purpose and advantages of the below described
illustrated embodiments will be set forth in and apparent from the
description that follows. Additional advantages of the illustrated
embodiments will be realized and attained by the containers and
methods particularly pointed out in the written description and the
claims herein, as well as from the drawings.
[0006] To achieve these and other advantages and in accordance with
the purpose of the illustrated embodiments, in one embodiment,
described herein is a container that includes a sidewall that has a
top end and a bottom end; and a base attached to the bottom end of
the sidewall. A cavity is bounded by or defined by the sidewall and
the base. The base of the container includes a center panel which
is positioned above the bottom end of the sidewall and an outer
convex section. In certain constructions, the center panel is flat.
Alternatively, the center panel can be convex.
[0007] In embodiments of the present disclosure, an inner panel
connects the center panel to the outer convex section of the base.
It is envisioned that in constructions wherein the container is
round, the inner panel can be ring-shaped. In such constructions, a
cross-section taken through the sidewall is circular and defines a
longitudinal axis for the container. Moreover, in such embodiments
the base has a cross section that is axially symmetrical.
[0008] It is envisioned that the container can further include a
lid which engages with the sidewall to form a leak resistant or
proof seal. Moreover, the container can also include a hinge
joining the lid to the sidewall of the container.
[0009] In certain embodiments, a material thickness is the same for
the lid, sidewall and base. In such constructions, the base,
sidewall, lid and hinge can be formed from a single sheet of
material. However, in certain constructions the thickness of the
lid, sidewall and base can vary. For example, it could be
advantageous to form the lid using a thinner material. It is
envisioned that the material used to form the container can be a
polymer and the container can be thermoformed from a single sheet
of material.
[0010] It is also envisioned that in certain embodiments, the
sidewall is formed at an angle greater than 90 degrees with respect
to the base and/or the surface upon which the container will
rest.
[0011] Preferably, the deflection of the center panel of the base
does not exceed 0.029 inches when the container is fully
loaded.
[0012] The present disclosure is also directed to a further
container embodiment that includes a sidewall having a top end and
a bottom end; and a base attached to the bottom end of the sidewall
and defining a cavity bounded by the sidewall and the base. In such
a construction, the base includes a flat center panel and an outer
convex section. The center panel is positioned above the bottom end
of the sidewall.
[0013] The present disclosure is further directed to a container
embodiment that includes a sidewall that has a top end and a bottom
end; and a base attached to the bottom end of the sidewall. The
base and the sidewall cooperate to define a cavity. In this
embodiment, the base includes a convex center panel and an outer
convex section, wherein the convex center panel is positioned above
the bottom end of the sidewall.
[0014] The present disclosure is further directed to a container
that includes a sidewall having a top end and a bottom end; and a
base attached to the bottom end of the sidewall. A cavity is
defined by the sidewall and the base. In this embodiment, the base
includes a flat center panel and an outer convex section, wherein
the center panel is positioned above the bottom end of the sidewall
and is joined to the outer convex section through an inner ring
panel.
[0015] Still further, the present disclosure is directed to a
method of forming a container that includes the steps of: forming a
lid from a portion of a single sheet of at least partially
transparent plastic material; forming a sidewall from a second
portion of the single sheet of at least partially transparent
plastic material, the sidewall having a top end and a bottom end;
and forming a base from a third portion of the single sheet of at
least partially transparent plastic material, the base being
attached to the bottom end of the sidewall defining a cavity
bounded by the sidewall and the base, the base including a center
panel and an outer convex section, wherein the center panel is
positioned above the bottom end of the sidewall. In certain
embodiments, the single sheet of at least partially transparent
plastic material is entirely transparent.
[0016] It is envisioned that the center panel can be flat, convex
or concave. Moreover, in certain embodiments, an inner panel
connects the center panel to the outer convex section of the base.
Preferably, in round containers, the inner panel is ring-shaped.
Additionally, the sidewall has a circular cross-section and defines
a longitudinal axis for the container and the base has a cross
section that is axially symmetrical.
[0017] Preferably, the lid is formed so as to engage with the top
end of the side wall and form a leak resistant or leak proof seal.
Additionally, the disclosed method can further include the step of
forming a hinge that joins the lid to the sidewall of the container
from the single sheet of plastic material. Preferably, in certain
constructions at least one line of weakness is formed in the hinge.
In is envisioned that the single sheet of plastic material can have
a uniform material thickness such that the lid, sidewall and base
each are formed having the same thickness.
[0018] The disclosed method can further include the step of forming
the sidewall at an angle greater than 90 degrees with respect to
the base. It is envisioned that the step of forming the sidewall
further includes forming an upwardly projecting bead at the top end
of the sidewall which extends substantially about the perimeter of
the container and is configured to substantially surround a
peripheral edge of the lid and hinder access to the container when
the container is closed.
[0019] The disclosed method can further include the step of forming
vents in the container to promote airflow therethrough.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] So that those having ordinary skill in the art, to which the
present embodiments pertain, will more readily understand how to
manufacture the novel containers and employ the novel methods,
certain illustrated embodiments thereof will be described in detail
herein-below with reference to the drawings, wherein:
[0021] FIG. 1A is a perspective view of a container which has been
constructed in accordance with an embodiment of the present
disclosure showing the container in the open position;
[0022] FIG. 1B is a perspective view of the container of FIG. 1A
shown in the closed position;
[0023] FIGS. 2A-B provide a top plan view and elevational view of
the open container of FIG. 1A;
[0024] FIGS. 3A-B provide a top plan view and elevational view of
the closed container of FIG. 1B;
[0025] FIG. 4 provides a cross-section of the base of a prior art
container;
[0026] FIG. 5 provides a cross-section of the base of a container
which has been constructed in accordance with an embodiment of the
present disclosure and includes a flat center panel, an inner ring
panel and an outer convex section;
[0027] FIG. 6 provides a cross-section of the base of a container
which has been constructed in accordance with a further embodiment
of the present disclosure and includes a convex center panel and an
outer convex section;
[0028] FIG. 7 provides a cross-section of the base of a container
which has been constructed in accordance with yet a further
embodiment of the present disclosure and includes a flat center
panel and an outer convex section;
[0029] FIGS. 8A-8B illustrate the test setup for determining the
deflection of the bottom panel of a loaded container;
[0030] FIG. 9 provides a boxplot graphical illustration of the
amount of deflection of the center panel for four container
embodiments.
[0031] FIG. 10 provides a boxplot graphical illustration of the
amount lift deflection occurring around the bottom edge of the
sidewall of four container embodiments; and
[0032] FIG. 11 provides a boxplot graphical illustration of the
amount lift deflection occurring around the bottom edge of the
sidewall of four container embodiments for a double stack of
containers.
[0033] These and other aspects of the subject invention will become
more readily apparent to those having ordinary skill in the art
from the following detailed description of the invention taken in
conjunction with the drawings.
DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS
[0034] The below illustrated embodiments are directed to container
base constructions and methods of making the same, and more
particularly to, containers that have a base which is constructed
to reduce or eliminate deformation of the base and/or sidewall when
the container is filled and/or stacked during shipment and retail.
It is to be appreciated the below illustrated embodiments are not
limited in any way to what is shown, as the illustrated embodiments
described below are merely exemplary of the invention, which can be
embodied in various forms, as appreciated by one skilled in the
art. Therefore, it is to be understood that any structural and
functional details disclosed herein are not to be interpreted as
limiting, but merely as a basis for the claims and as a
representative for teaching one skilled in the art to variously
employ the certain illustrated embodiments.
[0035] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art relating to the below illustrated
embodiments. Although any methods and materials similar or
equivalent to those described herein can also be used in the
practice or testing of the below illustrated embodiments, exemplary
methods and materials are now described.
[0036] Referring now to FIGS. 1A-1B, 2A-2B and 3A-3B, there is
illustrated a container which has been constructed in accordance
with an embodiment of the present invention that has been
designated as reference numeral 100. Container 100 is a round cup
but those skilled in the art will readily appreciated that other
size and shape containers, vessels, etc. can be used without
departing from the scope of the present disclosure.
[0037] Container 100 includes a sidewall 20 that has a top end 24
and a bottom end 22. A base 40 is attached to the bottom end 22 of
the sidewall 20. A cavity 50 is bounded by or defined by the
sidewall 20 and the base 40. As shown in FIGS. 2B and 3B, the
sidewall 20 of container 100 is formed at an angle .alpha. that is
greater than 90 degrees with respect to the base 40 or surface upon
which the container will rest.
[0038] The container 100 further includes a lid 60. Lid 60 includes
a flat center panel 62 which is surrounded by a peripheral sealing
surface 64. The top end 24 of the sidewall includes an upper
peripheral rim 26 and a sealing surface 28 (see FIG. 2B) which
engages with a sealing surface 64 associated with the lid 60 to
form a leak resistant seal.
[0039] In the embodiment shown in FIGS. 1A-3B, container 100 also
includes a hinge 70 joining the lid 60 to the sidewall 20 of the
container 100. As a result, container 100 is a single piece
construction. However, those skilled in the art will appreciate
that container 100 could be a two-piece construction without
departing from the scope of the present invention. Moreover,
containers constructed in accordance with the teachings of this
disclosure do not need a lid and may simply include a foil cover or
some other type of closure mechanism.
[0040] Referring now to FIGS. 4-7 which illustrate various base
constructions which can be used with container 100. FIG. 4
illustrates a prior art base construction which is referred to as
base 140. As shown in this figure, base 140 includes a raised, flat
center panel 142, an angled inner panel 144 and a flat outer panel
146 which would sit flat upon the supporting surface. The inventors
of the present invention have learned through experience that
containers which have been constructed to have a base as shown in
FIG. 4 tend to deform or bulge when fully loaded. It was determined
that the flat outer panel 146 acted as a lever which facilitated
deformation of the base and sidewall when the container was loaded.
More specifically, as will be described in detail below, when the
container is loaded the weight of the product will cause the center
panel 142 to deflect downward which in turn causes the outer edge
148 of the base 140 to lift off the supporting surface. This makes
the container particularly unsuitable for stacking.
[0041] Referring now to FIGS. 5-7 which illustrates three base
embodiments which have been constructed in accordance with the
present invention and have been identified using reference numerals
240, 340 and 440, respectively.
[0042] As shown in FIG. 5, base 240 includes a flat center panel
242, an inner ring panel 244 and an outer convex panel 246. As can
be readily seen, a smooth, radiused transition is made between the
center panel 242 and inner ring panel 244 and the outer convex
panel 246. In each of the disclosed embodiments, the base
240/340/440 of the container 100 includes a center panel
242/342/442 which is positioned above the bottom end 22 of the
sidewall 20 and an outer convex section 246/346/446.
[0043] As shown in FIG. 6, base 340 includes a convex center panel
342 and an outer convex panel 346. As can be readily seen, a
smooth, radiused transition is made between the center panel 342
and the outer convex panel 346.
[0044] As shown in FIG. 7, base 440 includes a flat center panel
442 and an outer convex panel 446. As can be readily seen, a
smooth, radiused transition is made between the center panel 442
and the outer convex panel 446.
[0045] The above described constructions illustrate round
containers or cups and in such embodiments, the inner panel and out
convex panel are ring-shaped. However, as noted about the container
does not need to be round and could be other shapes, such as square
or oval.
[0046] Referring now to FIGS. 8A and 8B which illustrate a bench
test set-up for determining the deflection of the base center panel
when the container is loaded. An exemplary testing procedure can be
summarized as follows:
[0047] 1. Place an empty container into the test fixture;
[0048] 2. Zero out the dial indicator;
[0049] 3. Pour 2 lbs of water into the container; and
[0050] 4. Record the measurement on the dial indicator.
[0051] The prior art container of FIG. 4 and each of the containers
shown in FIGS. 5-7 where tested. The results obtained for the three
base embodiments were as follows:
TABLE-US-00001 Deflection Under 2 Lbs of H2O in Inches Sample #
Base 440 Base 240 Base 340 1 0.03 0.028 0.02 2 0.029 0.029 0.021 3
0.029 0.026 0.02 4 0.029 0.028 0.019 5 0.026 0.024 0.018 6 0.0255
0.024 0.0185 7 0.0235 0.025 0.016 8 0.024 0.026 0.018 9 0.023 0.028
0.017 Ave. 0.027 0.026 0.017
[0052] This data was converted into a BOX PLOT which is shown in
FIG. 9. FIG. 9 also includes the data from prior art base 140. The
data readily illustrates that the prior art base 140 exhibited the
largest amount of deflection as compared to the others. Worth
noting is the fact that the prior art container that was tested had
a material thickness of 51.2 mil while the containers having base
constructions 240, 340 and 440 had a material thickness of only
45.3 mil. Of the three base constructions, base 340 performed the
best.
[0053] The deflection occurring at the bottom of the sidewall was
also measured for these same four containers constructions and data
representing the deflection in a single stack of containers and a
double stack of containers is shown in the BOX PLOTS provided in
FIGS. 10 and 11 respectively. As shown therein, the containers
having base constructions 240, 340 and 440 did not exhibit any lift
at the bottom of the sidewall or lift off of the supporting surface
while that prior art base design 140 despite being a thicker gauge
container lifted significantly.
[0054] As shown in the figures, each of the containers described
herein includes tamper resistant and tamper evident features. These
features are similar to those described in U.S. Pat. Nos.
7,073,680; 7,118,003; 8,795,580; 9,132,942 and 9,527,640 which are
herein incorporated by reference to the extend they do not conflict
with the present disclosure.
[0055] Still further, an exemplary method for constructing the
previously described containers of the present disclosure can
include the following steps the order of which can vary:
[0056] 1. Forming a lid from a portion of a single sheet of at
least partially transparent plastic material;
[0057] 2. Forming a sidewall from a second portion of the single
sheet of at least partially transparent plastic material, the
sidewall having a top end and a bottom end; and
[0058] 3. Forming a base from a third portion of the single sheet
of at least partially transparent plastic material, the base being
attached to the bottom end of the sidewall defining a cavity
bounded by the sidewall and the base, the base including a center
panel and an outer convex section, the center panel being
positioned above the bottom end of the sidewall.
[0059] The method can further include the step of forming a hinge
that joins the lid to the sidewall of the container from the single
sheet of plastic material. Preferably, the single sheet of plastic
material has a uniform material thickness such that the lid,
sidewall and base each are formed having the same thickness. The
disclosed method can further include the steps of: forming the
sidewall at an angle greater than 90 degrees with respect to the
base and forming vents in the container to promote airflow
therethrough.
[0060] The techniques described herein are exemplary, and should
not be construed as implying any particular limitation on the
present disclosure. It should be understood that various
alternatives, combinations and modifications could be devised by
those skilled in the art. For example, steps associated with the
processes described herein can be performed in any order, unless
otherwise specified or dictated by the steps themselves. The
present disclosure is intended to embrace all such alternatives,
modifications and variances that fall within the scope of the
appended claims.
[0061] The terms "comprise", "include", and conjugations thereof
are to be interpreted as specifying the presence of the stated
features, integers, steps or components, but not precluding the
presence of one or more other features, integers, steps or
components or groups thereof.
[0062] Although the containers and methods of the subject invention
have been described with respect to the embodiments disclosed
above, those skilled in the art will readily appreciate that
changes and modifications may be made thereto without departing
from the spirit and scope of the subject invention as defined by
the appended claims.
* * * * *