U.S. patent application number 16/449706 was filed with the patent office on 2019-12-05 for blow molded container.
The applicant listed for this patent is TECHTRONIC CORDLESS GP. Invention is credited to Wai Tat CHOI, Zengjun JIANG, Sanming WANG, Huadong ZHANG, Chao ZHONG.
Application Number | 20190367240 16/449706 |
Document ID | / |
Family ID | 54765981 |
Filed Date | 2019-12-05 |
View All Diagrams
United States Patent
Application |
20190367240 |
Kind Code |
A1 |
CHOI; Wai Tat ; et
al. |
December 5, 2019 |
BLOW MOLDED CONTAINER
Abstract
A blow molded container includes a main member comprising a top,
a first side orthogonal to the top, a second side orthogonal to the
top, an external wall, and an internal wall defining a tool cavity.
A corner portion is defined as a portion of the main member and
includes least a first layer and a second layer. The first layer
forming at least a part of the external wall and the second layer
forming at least a part of the internal wall. The first layer and
the second layer are adhered together to along a predetermined
pattern to form at least a first line segment and a second line
segment on one of the internal wall or the external wall of the
corner portion.
Inventors: |
CHOI; Wai Tat; (Houjie Town,
CN) ; JIANG; Zengjun; (Houjie Town, CN) ;
WANG; Sanming; (Houjie Town, CN) ; ZHONG; Chao;
(Houjie Town, CN) ; ZHANG; Huadong; (Houjie Town,
CN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
TECHTRONIC CORDLESS GP |
Anderson |
SC |
US |
|
|
Family ID: |
54765981 |
Appl. No.: |
16/449706 |
Filed: |
June 24, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15316446 |
Dec 5, 2016 |
10377551 |
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PCT/CN2014/083772 |
Aug 6, 2014 |
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16449706 |
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PCT/CN2014/079415 |
Jun 6, 2014 |
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15316446 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B25H 3/003 20130101;
B25H 3/006 20130101; B29L 2031/712 20130101; B65D 81/027 20130101;
B25H 3/02 20130101 |
International
Class: |
B65D 81/02 20060101
B65D081/02; B25H 3/02 20060101 B25H003/02; B25H 3/00 20060101
B25H003/00 |
Claims
1. A blow molded container comprising: a main member comprising a
top, a first side orthogonal to the top, a second side orthogonal
to the top, an external wall, and an internal wall defining a tool
cavity; a corner portion defined as a portion of the main member,
the corner portion comprising at least a first layer and a second
layer, the first layer forming at least a part of the external wall
and the second layer forming at least a part of the internal wall,
wherein the first layer and the second layer are adhered together
to along a predetermined pattern to form at least a first line
segment and a second line segment on one of the internal wall or
the external wall of the corner portion.
2. The blow molded container according to claim 1, wherein the
first layer and the second layer are separate from each other to
form a gap between the first layer and the second layer in
locations other than the predetermined pattern.
3. The blow molded container according to claim 2, wherein the gap
between the first layer and the second layer is constant.
4. The blow molded container according to claim 3, wherein the gap
between the first layer and the second layer includes a triangular
cross section.
5. The blow molded container according to claim 1, wherein the
first line segment and the second line segment intersect at
respective middle portions to form a substantial cross shape.
6. The blow molded container according to claim 5, wherein the
substantial cross shape forms a groove on the internal wall of the
corner portion.
7. The blow molded container according to claim 5, wherein the
substantial cross shape forms a protrusion on the external wall of
the corner portion.
8. The blow molded container according to claim 1, wherein a third
line segment is formed on at least one of the internal wall or the
external wall of the corner portion.
9. The blow molded container according to claim 8, wherein the
first line segment, the second line segment, and the third line
segment connect in series to form a first shape.
10. The blow molded container according to claim 9, wherein the
first shape forms a groove on the internal wall of the corner
portion.
11. The blow molded container according to claim 9, wherein the
predetermined pattern includes a dot region separate from the first
shape.
12. The blow molded container according to claim 9, wherein the
predetermined pattern includes a continuous area connected to an
end of the first line segment, the second line segment, or the
third line segment.
13. The blow molded container according to claim 9, wherein the
first shape forms a protrusion on the external wall of the corner
portion.
14. The blow molded container according to claim 13, wherein the
predetermined pattern includes a dot region separate from the first
shape.
15. The blow molded container according to claim 13 wherein the
predetermined pattern includes a continuous area connected to an
end of the first line segment, the second line segment, or the
third line segment.
16. The blow molded container according to claim 8, wherein the
third line segment is a lateral line segment that connects the
first line segment and the second line segment to each other to
form a substantial cup shape.
17. The blow molded container according to claim 16, wherein the
substantial cup shape forms a groove on the internal wall of the
corner portion.
18. The blow molded container according to claim 12, wherein the
substantial cup shape forms an external protrusion on the external
wall of the corner portion.
19. The blow molded container according to claim 1, wherein the
first layer and the second layer each have a thickness of 2.5
mm.
20. The blow molded container according to claim 1, wherein the
predetermined pattern has a thickness of 5 mm.
21. A blow molded container comprising: a main member comprising a
top, a first side orthogonal to the top, a first angled portion
extending between the first side and the top, an external wall, and
an internal wall defining a tool cavity; a corner portion defined
as a portion of the main member, the corner portion comprising a
bevel wall having a second side adjacent the first side, a second
angled portion adjacent the first angled portion, at least a first
layer forming at least a part of the external wall, and at least a
second layer forming at least a part of the internal wall, wherein
the first layer and the second layer are affixed together at an
intersection of the first side and the second side and the first
angled portion and the second angled portion to form a first line
segment of a predetermined pattern.
22. The blow molded container according to claim 21, wherein the
first layer and the second layer are separate from each other to
form a gap between the first layer and the second layer in
locations other than the predetermined pattern.
23. The blow molded container according to claim 22, wherein the
gap is formed between the first layer and the second layer on the
first side of the corner portion.
24. The blow molded container according to claim 23, wherein the
gap between the first layer and the second layer forms a triangular
cross section.
25. The blow molded container according to claim 21, wherein the
first layer and the second layer are affixed together at an
intersection of the top and each of the first angled portion and
the second angled portion to form a second line segment of the
predetermined pattern.
26. The blow molded container according to claim 25, wherein the
first line segment and the second line segment intersect to form
the predetermined pattern.
27. The blow molded container according to claim 26, wherein the
first line segment and the second line segment intersect at
respective middle portions to form a substantial cross shape.
28. The blow molded container according to claim 27, wherein the
predetermined pattern forms a groove on the internal wall of the
corner portion.
29. The blow molded container according to claim 28, wherein a tip
portion is formed at an end portion of the groove.
30. The blow molded container according to claim 21, wherein the
first layer and the second layer each have a thickness of 2.5
mm.
31. The blow molded container according to claim 21, wherein the
predetermined pattern has a thickness of 5 mm.
32. A blow molded container comprising: a main member comprising a
top, a first side orthogonal to the top, a first angled portion
extending between the first side and the top, an external wall, and
an internal wall defining a tool cavity; a corner portion defined
as a portion of the main member, the corner portion comprising a
bevel wall having a second side adjacent the first side, a second
angled portion adjacent the first angled portion, at least a first
layer forming at least a part of the external wall, and a second
layer forming at least a part of the internal wall, wherein the
first layer and the second layer are affixed together at an
intersection of the top and each of the first angled portion and
the second angled portion to form a first portion of a
predetermined pattern.
33. The blow molded container according to claim 32, wherein the
first layer and the second layer are affixed together at an
intersection of the first side and the second side and the first
angled portion and the second angled portion to form a second
portion of the predetermined pattern.
34. The blow molded container according to claim 33, wherein the
first portion and the second portion of the predetermined pattern
intersect at respective middle portions to form a substantial cross
shape.
35. The blow molded container according to claim 32, wherein the
first layer and the second layer are separate from each other to
form a gap between the first layer and the second layer in
locations other than the predetermined pattern.
36. The blow molded container according to claim 35, wherein the
gap between the first layer and the second layer is constant.
37. The blow molded container according to claim 35, wherein the
gap between the first layer and the second layer includes a
triangular cross section.
38. The blow molded container according to claim 32, wherein the
predetermined pattern forms a groove on the internal wall of the
corner portion.
39. The blow molded container according to claim 38, wherein a tip
portion is formed at an end portion of the groove.
40. The blow molded container according to claim 32, wherein the
predetermined pattern has a thickness of 5 mm.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/316,446 filed on Dec. 5, 2016, which is a
national stage filing under 35 U.S.C. 371 of International
Application No. PCT/CN2014/083772 filed on Aug. 6, 2014, which is a
continuation of International Application No. PCT/CN2014/079415
filed on Jun. 6, 2014, which are all hereby incorporated by
reference herein in their entireties.
FIELD OF THE INVENTION
[0002] This invention relates generally to the field of blow molded
plastic containers, and more specifically to corner design of a
generally rectangular blow molded plastic container that such
corners have improved resistance to deformation.
BACKGROUND OF THE INVENTION
[0003] Many types of articles, such as toolboxes for a portable
power tool, are manufactured by using blow-molding techniques to
produce a double wall body. By producing an article in this manner,
one is able to easily create an article that has two, hard plastic
walls with a buffering space between them, thereby resulting in a
body with a multitude of desirable physical characteristics, such
as strength, rigidity, scuff resistance, and impact absorption, but
that is also relatively inexpensive to manufacture.
[0004] Typically, the blow-molding process involves the use of a
mold consisting of two separate halves or portions having cavities
of particularly desired shapes and sizes. Usually, one extrudes a
large-diameter, sealed tube of molten material (commonly referred
to as a "parison"), places the tube between the mold halves, and
closes the mold around the tube. Fluid pressure is then introduced
into the tube, forcing the molten tube against the walls of the
cavities, conforming the tube to the shape thereof. The pressure is
maintained until the molten material cools and solidifies. The
pressure is then released, the mold halves are pulled apart, and
the hardened article is ejected therefrom.
[0005] However, since fluid pressure is introduced to force the
molten tube against the walls to create predetermined spacing
between the walls, problems will be encountered for corner portions
of the article where its surface geometry experiences sudden
changes in orientation and/or plane of extension. In particular, to
ensure that the thickness of each wall of the article at the corner
portion is uniform and achieving a desired level, spacing of the
two walls at the corner portion where sudden change of surface
direction happens often have to be increased to avoid accidental
adhesion of the two walls or non-uniformity in material strength.
However, with the increased spacing between the walls, the corner
portion is more vulnerable to external impact that easily results
in deformation or dent of the corner portion.
SUMMARY OF THE INVENTION
[0006] In the light of the foregoing background, it is an object of
the present invention to provide an alternate blow molded container
with improved corner portion design.
[0007] The above object is met by the combination of features of
the main claim; the sub-claims disclose further advantageous
embodiments of the invention.
[0008] One skilled in the art will derive from the following
description other objects of the invention. Therefore, the
foregoing statements of object are not exhaustive and serve merely
to illustrate some of the many objects of the present
invention.
[0009] Accordingly, the present invention in one aspect is a blow
molded container including a main member forming a tool cavity. The
main member has an inner surface. The main member further contains
at least one corner portion and at the corner portion, the main
member includes at least a first layer and a second layer. The
first layer forming the inner surface, and the first layer and the
second layer are affixed together along a predetermined pattern
while being separated from each other elsewhere. The first layer is
formed with a first protruding part along the predetermined
pattern, and the second layer is formed with a second protruding
part along the predetermined pattern. The first protruding part and
the second protruding part are affixed together.
[0010] Preferably, a surface of the first protruding part facing
the second layer is closer to the second layer than a portion of
the first layer immediately adjacent to the predetermined
pattern.
[0011] Additionally/alternatively, a surface of the second
protruding part facing the first layer is closer to the first layer
than a portion of the second layer immediately adjacent to the
predetermined pattern.
[0012] In one implementation, the first protruding part and the
second protruding part are of equal height.
[0013] In one variation, the first layer is formed with a third
protruding part which protrudes from the first layer toward a
direction away from the tool cavity.
[0014] Preferably, the third protruding part is in the form of a
rim portion on an external surface of the blow molded
container.
[0015] Preferably, the third protruding part is a portion of the
first layer bent to form the rim portion.
[0016] In one implementation, the third protruding part is in the
form of a bent surface connecting the first layer and second
layer.
[0017] In some variations, the predetermined pattern is a plurality
of dot regions separated from each other.
[0018] In other variations, the predetermined pattern is a
continuous area.
[0019] In some further variations, the continuous area further
includes a plurality of sub-areas, wherein at least two the
sub-areas are positioned in different planes.
[0020] In some further variations, the predetermined pattern
further contains a plurality of line segments connected to each
other.
[0021] Preferably, the main member is in a rectangular shape.
[0022] Preferably, the first layer and the second layer are of
equal thickness. Other features and aspects of the disclosure will
become apparent by consideration of the following detailed
description and accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
[0023] The foregoing and further features of the present invention
will be apparent from the following description of preferred
embodiments which are provided by way of example only in connection
with the accompanying figures, of which:
[0024] FIG. 1 illustrates a blow molded container in its open
status according to one embodiment of the present invention.
[0025] FIG. 2a is a perspective view of a corner portion of a blow
molded container according to one embodiment of the present
invention.
[0026] FIG. 2b shows the corner portion in FIG. 2a from another
viewpoint.
[0027] FIG. 3 shows a front view of the corner portion in FIG. 2a
towards its internal cavity.
[0028] FIG. 4a is the cross-sectional view of the corner portion in
FIG. 3 along line B-B.
[0029] FIG. 4b is the cross-sectional view of the corner portion in
FIG. 3 along line C-C.
[0030] FIG. 5a shows the enlarged view of the tip portion A in FIG.
3.
[0031] FIG. 5b shows the enlarged view of the tip portion B in FIG.
3.
[0032] FIG. 6a is a perspective view of a corner portion of a blow
molded container according to another embodiment of the present
invention.
[0033] FIG. 6b shows the corner portion in FIG. 6a from another
viewpoint.
[0034] FIG. 7a is a perspective view of a corner portion of a blow
molded container according to another embodiment of the present
invention.
[0035] FIG. 7b shows the corner portion in FIG. 7a from another
viewpoint.
[0036] FIG. 7c shows an alternative internal structure of the
corner portion of FIG. 7a.
[0037] FIGS. 8a and 8b illustrate a kissing point design of corner
portions of a blow molded container according to one embodiment of
the present invention.
[0038] FIG. 9 illustrates a kissing area design of corner portions
of a blow molded container according to one embodiment of the
present invention.
[0039] FIG. 10a illustrates an alternative kissing line design of
corner portions of a blow molded container according to one
embodiment of the present invention.
[0040] FIG. 10b shows the corner portion of FIG. 10a viewed from
external surface of the blow molded container, with a perspective
view of the kissing line pattern.
[0041] FIG. 10c illustrates the adhering region in the corner
portion of FIG. 10a.
[0042] FIG. 11a illustrates an alternative kissing line design of
corner portions of a blow molded container according to one
embodiment of the present invention.
[0043] FIG. 11b shows the corner portion of FIG. 11a viewed from
external surface of the blow molded container, with a perspective
view of the kissing line pattern.
[0044] FIG. 11c illustrates the adhering region in the corner
portion of FIG. 11a.
[0045] FIG. 12a illustrates an alternative kissing line design of
corner portions of a blow molded container according to one
embodiment of the present invention.
[0046] FIG. 12b shows the corner portion of FIG. 12a viewed from
external surface of the blow molded container, with a perspective
view of the kissing line pattern.
[0047] FIG. 12c illustrates the adhering region in the corner
portion of FIG. 12a.
[0048] FIG. 13a illustrates an alternative kissing line design of
corner portions of a blow molded container according to one
embodiment of the present invention.
[0049] FIG. 13b shows the corner portion of FIG. 13a viewed from
external surface of the blow molded container, with a perspective
view of the kissing line pattern.
[0050] FIG. 13c illustrates the adhering region in the corner
portion of FIG. 13a.
[0051] FIG. 14a illustrates an alternative kissing line design of
corner portions of a blow molded container according to one
embodiment of the present invention.
[0052] FIG. 14b shows the corner portion of FIG. 14a viewed from
external surface of the blow molded container, with a perspective
view of the kissing line pattern.
[0053] FIG. 15a illustrates an alternative kissing line design of
corner portions of a blow molded container according to one
embodiment of the present invention.
[0054] FIG. 15b shows the corner portion of FIG. 15a viewed from
external surface of the blow molded container, with a perspective
view of the kissing line pattern.
[0055] FIG. 16a is a perspective view of a blow molded container
showing its top side according to another embodiment of the present
invention.
[0056] FIG. 16b is another perspective view of the blow molded
container in FIG. 16a showing its bottom side.
[0057] FIG. 17a is a perspective view of a corner portion of a blow
molded container according to another embodiment of the present
invention.
[0058] FIG. 17b a cross-sectional view of the corner portion in
FIG. 17a.
[0059] FIG. 17c is another perspective view of the corner portion
in FIG. 17a from another angle.
[0060] FIG. 18a is a perspective view of a corner portion of a blow
molded container according to another embodiment of the present
invention.
[0061] FIG. 18b a cross-sectional view of the corner portion in
FIG. 18a.
[0062] FIG. 18c is another perspective view of the corner portion
in FIG. 18a from another angle.
[0063] FIG. 19 is a cross-sectional view of a corner portion of a
blow molded container according to another embodiment of the
present invention.
[0064] FIG. 20 is a cross-sectional view of a corner portion of a
blow molded container according to another embodiment of the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0065] In the claims which follow and in the preceding description
of the invention, except where the context requires otherwise due
to express language or necessary implication, the word "comprise"
or variations such as "comprises" or "comprising" is used in an
inclusive sense, i.e. to specify the presence of the stated
features but not to preclude the presence or addition of further
features in various embodiments of the invention.
[0066] Referring now to FIG. 1, the first embodiment of the present
invention is a blow molded container for storing various tools and
accessories, in particular a portable electrical drill with various
drill bits. The blow molded container includes a main member 20
forming a tool cavity. As illustrated in FIG. 1 the main member 20
is consisted of a base member 22, and a lid member 24 hingedly
connected to the based member 22 by two hinges 28. Preferably, for
each hinge 28 one piece is integrally formed with the base member
22 and the other piece is integrally formed with the lid member 24.
On both the base member 22 and the lid member 24, there are formed
various cavities 26 corresponding to form factors of the electrical
drill and its accessories. The cavities 26 thus make up the tool
cavity of the main member 20 for storing the portable electrical
drill and its accessories. Also illustrated in FIG. 1 are various
corner portions 30 of the main member 20 which will be described in
greater details below.
[0067] Turning now to FIGS. 2a-2b, the corner portion of a blow
molded container according to one embodiment has an irregular
geometrical shape. The corner portion includes a first layer 40 and
a second layer 42 which form the external wall and the internal
wall of the blow molded container respectively. Note that although
in FIGS. 2a-2b only a part of the blow molded container is shown
(i.e. the corner portion), the first layer 40 and the second layer
42 extends to other parts of the blow molded container as well to
form the whole main member. The first layer 40 and a second layer
42 are adhered together along a predetermined pattern, in this
embodiment the kissing lines 44. In FIG. 2b and FIG. 3, the kissing
lines 44 are best shown to have a substantial cross shape, i.e. two
lines intersect at their respective middle portions. The structure
of the kissing lines 44 is shown clearly in FIG. 4a and FIG. 4b,
both showing cross-sectional view of the corner portion and in
particular relevant positioning of the first layer 40 and the
second layer 42. As shown in FIG. 4a, in certain regions of the
corner portion the first layer 40 forming the external surface of
the blow molded container and the second layer 42 forming the
internal surface of the blow molded container are affixed together
along the kissing line 44, but are otherwise separated from each
other elsewhere as shown in FIG. 4a. Preferably, the distance
between the first layer 40 and the second layer 42 is kept constant
when they are separated. Also, preferably the thickness of the
first layer 40 and the second layer 42 are equal, and in one
exemplary embodiment the thickness of both the first layer 40 and
the second layer 42 is 2.5 mm. However, at the kissing line 44
region when the first layer 40 and the second layer 42 are affixed
together, the total thickness of the material equals to the sum of
the thickness of the first layer 40 and the second layer 42. For
example, in case the thickness of both the first layer 40 and the
second layer 42 are both 2.5 mm, the total thickness at the kissing
line 44 will be 5 mm.
[0068] FIG. 4b shows the cross sectional view of the corner portion
in other regions, where the first layer 40 and the second layer 42
are affixed together along the kissing line (indicated by the line
46), but at an upper point the first layer 40 and the second layer
42 starts to separate from each other and a gap 48 is created
between them as a result. FIGS. 5a-5b show other kissing line
designs at some tip portions of the corner portion.
[0069] In alternative embodiments, the kissing line design in
corner portions of the blow molded container has a different
pattern. In FIGS. 6a-6b, it can be seen that the kissing lines 50
is in a folded shape consisted of three line segments connected
head-to-tail. The corner portion design in FIG. 7a could have two
alternative internal designs as illustrated in FIG. 7b and FIG. 7c
respectively. The kissing lines 52 in FIG. 7b are two separated
line segments while in FIG. 7c the kissing lines 54 includes two
line segments connected to each other by another lateral line
segment.
[0070] In FIGS. 8a and 8b, a kissing dot design according to an
embodiment of the present invention is illustrated. Here the
predetermined pattern is not a combination of line segments, but
instead a plurality of dot regions 56 separated from each other
forms the predetermined pattern. As shown in FIG. 8b, the first
layer 58 and the second layer 60 are affixed to each other only at
the dot regions 56 that are spread out in the corner portion.
[0071] In FIG. 9, a kissing area design according to another
embodiment of the present invention is illustrated. Here the
predetermined pattern is not lines or dots, but rather it is a
continuous area. The continuous area further contains a plurality
of sub-areas 66, 68, and as can be seen from FIG. 9 at least the
sub-area 68 and sub-area 66 are positioned in different planes,
i.e. they are not parallel to each other.
[0072] FIGS. 10a-15b show various kissing line designs of the
corner portion according to embodiments of the present invention.
In FIGS. 10a-10c, the kissing lines are consisted of two separated
line segments diverged outwards similar to that in FIG. 7b. In
FIGS. 11a-11c, the kissing lines are consisted of three line
segments connected head-to-tail to form a folded shape, similar to
that in FIG. 6b. In FIGS. 12a-12c, the kissing lines are consisted
of three line segments connected head-to-tail to form a substantial
cup shape, similar to that in FIG. 7c. In FIGS. 13a-13c, the
kissing lines are consisted of two line segments intersecting at
their middle portion to form a cross shape. In FIGS. 14a-14b, the
predetermined pattern of the kissing design is consisted of a dot
region and a line portion separated from the dot region, where the
line portion has a shape similar to that in FIG. 6b. In FIGS.
15a-15b, the predetermined pattern of the kissing design is
consisted of a line portion and a continuous area connected to one
end of the line portion.
[0073] Turning now to FIGS. 16a and 16b, in which the general
appearance of a rectangular blow molded container is illustrated.
Note that corner portions of this blow molded container contain
visible "grooves" or patterns 121 extending from the lid member 124
to the base member 122. Such corner portions are different from
those depicted in FIGS. 2a-7c and will be described in greater
details below.
[0074] In FIGS. 17a-17c, a corner portion similar to that found in
the blow molded container in FIGS. 16a-16b is illustrated, which
has on the external surface of the corner portion grooves 121 along
a predetermined pattern. The shape of the predetermined pattern in
FIG. 17a is similar to that in FIG. 7a, although in the latter
there is no visible groove formed on the external surface of the
corner portion. Since the predetermined pattern shown in FIG. 17a
is a connection of multiple line segments, this is also called a
kissing line design similar to the definition provided in previous
embodiments.
[0075] FIG. 17b best illustrates how the visible grooves 121 are
formed. The corner portion includes a first layer 140 and a second
layer 142 which form the external wall and the internal wall of the
blow molded container respectively. Although in FIGS. 17a-17b only
a part of the blow molded container is shown (i.e. the corner
portion), the first layer 140 and the second layer 142 extends to
other parts of the blow molded container as well in this embodiment
to form the whole main member. The first layer 140 and a second
layer 142 are adhered together along a predetermined pattern, along
which the visible grooves 121 are formed and visible to the user
from outside of the blow molded container.
[0076] As shown in FIG. 17b, in certain regions of the corner
portion the first layer 140 forming the external surface of the
blow molded container and the second layer 142 forming the internal
surface of the blow molded container are affixed together, but are
otherwise separated from each other elsewhere. At the location
where the first layer 140 and the second layer 142 are affixed
together along the predetermined pattern, the first layer 140 is
formed with a first protruding part 143 and the second layer 142 is
formed with a second protruding part 145. The surface of the first
protruding part 143 and the surface of the second protruding part
145 are affixed together so that the first layer 140 and the second
layer 142 are affixed together along the predetermined pattern. As
one can see the first protruding part 143 is formed by a portion of
the first layer 140 bent to form an protruding, yet essentially
cuboid structure and the bent portion of the first layer 140
creates a recess with rectangular cross-section that is walled on
its three sides by the external surface of the first layer 140.
Although not shown, the second protruding part 145 is also formed
in a similar way. The recess is the visible groove 121 that can be
observed by a user from the outside of the blow molded container.
One can readily see from FIG. 17b that the surfaces of the first
protruding part 143 facing the second layer 142 is closer to the
second layer 142 than other portions of the first layer 140
immediately adjacent to the predetermined pattern. Similarly,
surfaces of the second protruding part 145 facing the first layer
140 is closer to the first layer 140 than other portions of the
second layer 142 immediately adjacent to the predetermined pattern.
In other words, the first protruding part 143 and the second
protruding part 145 are formed to protrude toward the other one of
the first layer 140 and second layer 142 respectively. Such a
configuration ensures that the first layer 140 and second layer 142
are only affixed together along the predetermined pattern while
kept away from each other otherwise. In a preferred embodiment, the
first protruding part 143 and the second protruding part 145 are of
equal height, in other words the portions of the first layer 140
and second layer 142 (that are the first protruding part 143 and
the second protruding part 145) touches each other at middle way in
the distance between the first layer 140 and second layer 142.
[0077] In FIG. 17c, it is shown that as a result of the second
protruding part formed on the second layer 142, viewing from
internal space of the corner portion one can also see various
grooves 123 on the inner surface of the second layer 142. Formation
of the grooves 123 is in principle similar to that of grooves 121
described above. In the present embodiment, both on the external
surface and inner surfaces of the casing there will be formed
visible grooves due to bent portions of both the first and second
layers.
[0078] Preferably, the distance between the first layer 140 and the
second layer 142 is kept constant when they are separated. Also,
preferably the thickness of the first layer 140 and the second
layer 142 are equal, and in one exemplary embodiment the thickness
of both the first layer 140 and the second layer 142 is 2.5 mm.
[0079] FIGS. 18a to 18c show a corner portion in general similar to
that in FIGS. 17a to 17c, except that the corner portion in FIGS.
18a to 18c includes a rim portion. The rim portion is formed by
bending a portion of the first layer 140, as best shown in FIG.
18b. While in this embodiment the first layer 140 and second layer
142 are affixed together at certain locations (that is along a
predetermined pattern) while spaced apart otherwise similar to that
in FIGS. 17a-17c, a second portion of the first layer 140, which is
different from the portions of the first layer 140 affixed to the
second layer 142, is also bent to form a third protruding part 170.
The third protruding part 170 protrudes from the first layer 140
toward a direction away from the tool cavity (not shown). As shown
in FIGS. 18b and 18c, the protruding part 170 is a single layer
structure, and has a span 171 between the two side walls so that a
rim portion with a certain width is formed.
[0080] In alternative embodiments shown in FIGS. 19 and 20, other
corner portions with particular rim portion designs in the present
invention are shown. In FIG. 19, a first layer 140 and a second
layer 142 are affixed together along a predetermined pattern
similar to that described above. However, at the edge of the corner
portion there is a rim portion formed by a third protruding portion
170, and the third protruding part 170 is in the form of a bent
surface connecting the first layer 140 and second layer 142.
[0081] It should be noted that although in FIG. 16a-FIG. 20 the
predetermined pattern along which the two layers are affixed
together are connection of line segments, i.e. kissing line
designs, other types of pattern may be equally applied, including a
plurality of dot regions separated from each other (kissing dots),
and a continuous area (kissing area).
[0082] The above exemplary embodiments thus show the use of kissing
design of internal and external layers of the blow molded container
along a predetermined pattern. "Kissing" as described herein means
making outside and inside walls/layers touching together, and a
skilled person should realize that any suitable means or techniques
may be used to affixing outside and inside walls/layers together,
including but not limited to glues or other bonding agents. By
affixing two walls together at the kissing lines the strength of
the corner portion can be greatly improved since any impact on the
external surface at the kissing lines will be transferred mostly to
the inner surface as well, therefore avoid deformation or collapse
of one wall relative to another.
[0083] While the invention has been illustrated and described in
detail in the drawings and foregoing description, the same is to be
considered as illustrative and not restrictive in character, it
being understood that only exemplary embodiments have been shown
and described and do not limit the scope of the invention in any
manner. It can be appreciated that any of the features described
herein may be used with any embodiment. The illustrative
embodiments are not exclusive of each other or of other embodiments
not recited herein. Accordingly, the invention also provides
embodiments that comprise combinations of one or more of the
illustrative embodiments described above. Modifications and
variations of the invention as herein set forth can be made without
departing from the spirit and scope thereof, and, therefore, only
such limitations should be imposed as are indicated by the appended
claims.
[0084] It is to be understood that, if any prior art publication is
referred to herein, such reference does not constitute an admission
that the publication forms a part of the common general knowledge
in the art, in Australia or any other country.
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