U.S. patent application number 17/237170 was filed with the patent office on 2021-08-05 for container with reinforced bottom.
This patent application is currently assigned to Gateway Plastics, Inc.. The applicant listed for this patent is Gateway Plastics, Inc.. Invention is credited to Arthur W. Habitz.
Application Number | 20210237959 17/237170 |
Document ID | / |
Family ID | 1000005535084 |
Filed Date | 2021-08-05 |
United States Patent
Application |
20210237959 |
Kind Code |
A1 |
Habitz; Arthur W. |
August 5, 2021 |
CONTAINER WITH REINFORCED BOTTOM
Abstract
A method of fabricating a container is provided. The container
includes multiple sidewalls extending in a substantially vertical
direction and a bottom wall. The bottom wall includes a central
portion, a first curved portion and a second curved portion. The
first curved portion includes a first radius of curvature with a
first center of curvature located on a first side of the bottom
wall of the container, while the second curved portion terminates
at the sidewalls and include a second radius of curvature with a
second center of curvature located on a second side of the bottom
wall of the container. The container further includes multiple
reinforcing ribs located on the second side, each of the
reinforcing ribs having a minimum height proximate the first curved
portion and a maximum height proximate the second curved
portion.
Inventors: |
Habitz; Arthur W.;
(Milwaukee, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Gateway Plastics, Inc. |
Mequon |
WI |
US |
|
|
Assignee: |
Gateway Plastics, Inc.
Mequon
WI
|
Family ID: |
1000005535084 |
Appl. No.: |
17/237170 |
Filed: |
April 22, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
16384398 |
Apr 15, 2019 |
11014731 |
|
|
17237170 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 1/46 20130101; B65D
85/30 20130101; B65D 81/02 20130101; B65D 88/02 20130101; B29B
2911/14345 20150501 |
International
Class: |
B65D 81/02 20060101
B65D081/02; B65D 1/46 20060101 B65D001/46; B65D 85/30 20060101
B65D085/30; B65D 88/02 20060101 B65D088/02 |
Claims
1. A method of fabricating a container, comprising: providing a
mold for the container, the container comprising: a plurality of
sidewalls extending in a substantially vertical direction, the
plurality of sidewalls terminating at a bottom plane; a bottom wall
comprising: a central region; a first curved portion having a first
radius of curvature with a first center of curvature located on a
first side of the bottom wall; and a second curved portion
terminating at the plurality of sidewalls, the second curved
portion having a second radius of curvature with a second center of
curvature located on a second side of the bottom wall opposite the
first side; and a plurality of reinforcing ribs located on the
second side of the bottom wall, each of the plurality of
reinforcing ribs having a minimum height proximate the first curved
portion and a maximum height proximate the second curved portion,
one of the plurality of reinforcing ribs having a bottom surface
that is substantially coplanar with an outer surrounding portion of
the central region and separated from the bottom plane; injecting
the mold with a molten material; and upon expiration of a cooling
period, removing the container from the mold.
2. The method of claim 1, wherein the molten material is
polypropylene resin.
3. The method of claim 1, further comprising: inserting an in-mold
label into the mold.
4. The method of claim 3, further comprising: retaining the in-mold
label in the mold using a static charge, a vacuum, or compressed
air.
5. The method of claim 3, wherein the in-mold label is fabricated
from polypropylene foil.
6. A method of fabricating a container, comprising: providing a
mold for the container, the container comprising: a plurality of
sidewalls extending in a substantially vertical direction, the
plurality of sidewalls terminating at a bottom plane; a bottom wall
comprising: a substantially flat region; a a sloped region
comprising a first curved portion defining an upward slope and a
second curved portion defining a downward slope, the second curved
portion merging with the plurality of sidewalls such that an
intersection of the second curved portion and the plurality of
sidewalls is substantially perpendicular; and a plurality of
reinforcing ribs disposed beneath the sloped region, one of the
plurality of reinforcing ribs having a bottom surface that is
substantially coplanar with an outer surrounding portion of the
substantially flat region and separated from the bottom plane;
injecting the mold with a molten material; and upon expiration of a
cooling period, removing the container from the mold.
7. The method of claim 6, wherein the molten material is
polypropylene resin.
8. The method of claim 6, further comprising: inserting an in-mold
label into the mold.
9. The method of claim 8, further comprising: retaining the in-mold
label in the mold using a static charge, a vacuum, or compressed
air.
10. The method of claim 8, wherein the in-mold label is fabricated
from polypropylene foil.
11. A method of fabricating a container, comprising: providing a
mold for the container, the container comprising: a sidewall
extending in a substantially vertical direction, the sidewall
terminating at a bottom plane; a bottom wall comprising: a first
curved portion having a first radius of curvature with a first
center of curvature located on a first side of the bottom wall; and
a second curved portion terminating at the sidewall, the second
curved portion having a second radius of curvature with a second
center of curvature located on a second side of the bottom wall
opposite the first side; and a reinforcing rib located on the
second side of the bottom wall, the reinforcing rib having a bottom
surface that is substantially coplanar with an outer surrounding
portion of the bottom wall and separated from the bottom plane,
wherein the first radius of curvature is greater than the second
radius of curvature; injecting the mold with a molten material; and
upon expiration of a cooling period, removing the container from
the mold.
12. The method of claim 11, wherein the molten material is
polypropylene resin.
13. The method of claim 11, further comprising: inserting an
in-mold label into the mold.
14. The method of claim 13, further comprising: retaining the
in-mold label in the mold using a static charge, a vacuum, or
compressed air.
15. The method of claim 13, wherein the in-mold label is fabricated
from polypropylene foil.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application is a division of U.S. patent application
Ser. No. 16/384,398 filed Apr. 15, 2019, the entire disclosure of
which is incorporated by reference herein.
BACKGROUND
[0002] The present disclosure relates generally to injection molded
containers and more particularly to an injection molded container
with a reinforced bottom. Containers for industrial products or
consumer goods often undergo rigorous testing to ensure the safety
of the products enclosed in the containers as well as the users
handling the containers. For example, a common series of drop tests
may require a container to withstand a drop from a height of 18
inches or more at a variety of temperatures (e.g., 35.degree. F.,
room temperature, 145.degree. F.) without damage. At the same time,
product manufacturers desire the use of in-mold labeling techniques
to create attractive and eye-catching containers for their
products. A container optimized for both in-molding labeling and
rough handling conditions would therefore be useful.
SUMMARY
[0003] One implementation of the present disclosure is a container.
The container includes multiple sidewalls extending in a
substantially vertical direction and a bottom wall. The bottom wall
includes a central portion, a first curved portion and a second
curved portion. The first curved portion includes a first radius of
curvature with a first center of curvature located on a first side
of the bottom wall of the container, while the second curved
portion terminates at the sidewalls and include a second radius of
curvature with a second center of curvature located on a second
side of the bottom wall of the container. The container further
includes multiple reinforcing ribs located on the second side, each
of the reinforcing ribs having a minimum height proximate the first
curved portion and a maximum height proximate the second curved
portion.
[0004] Another implementation of the present disclosure is a
container. The container includes multiple sidewalls extending in a
substantially vertical direction and a bottom wall. The bottom wall
includes a substantially flat region and a sloped region. The
sloped region includes a first curved portion defining an upward
slope and a second curved portion defining a downward slope. The
second curved portion merges with the sidewalls such that the
intersection of the second curved portion and the sidewalls is
substantially perpendicular.
[0005] Yet another implementation of the present disclosure is a
method of fabricating a container. The method includes providing a
mold for a container. The container includes multiple sidewalls
extending in a substantially vertical direction and a bottom wall.
The bottom wall includes a substantially flat region and a sloped
region. The sloped region includes a first curved portion defining
an upward slope and a second curved portion defining a downward
slope. The second curved portion merges with the sidewalls such
that the intersection of the second curved portion and the
sidewalls is substantially perpendicular. The method further
includes filling the mold with a molten material, and upon
expiration of a cooling period, removing the container from the
mold.
[0006] Those skilled in the art will appreciate that the summary is
illustrative only and is not intended to be in any way limiting.
Other aspects, inventive features, and advantages of the devices
and/or processes described herein, as defined solely by the claims,
will become apparent in the detailed description set forth herein
and taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a perspective view of a container according to an
exemplary embodiment.
[0008] FIG. 2 is a perspective view of the container of FIG. 1
depicting the bottom wall, according to an exemplary
embodiment.
[0009] FIG. 3 is a cross-sectional view of the bottom wall of FIG.
2, according to an exemplary embodiment.
DETAILED DESCRIPTION
[0010] Before discussing further details of the filter disc and the
beverage pod assembly and the components thereof, it should be
noted that references to "front," "back," "rear," "upper," "lower,"
"inner," "outer," "right," and "left," and other directions in this
description are merely used to identify the various elements as
they are oriented in the FIGURES. These terms are not meant to
limit the element which they describe, as the various elements may
be oriented differently in various applications. Additionally, any
dimensions or sizes specified for the filter disc for the beverage
pod assembly and/or the components thereof should be interpreted as
describing an exemplary embodiment and should not be regarded as
limiting. The filter disc and the beverage pod assembly can have
any of a variety of shapes and/or sizes in various
applications.
[0011] FIGS. 1-3 depict a container 100 according to an exemplary
embodiment. Referring specifically to FIG. 1, a perspective view
depicting the container 100 is shown. Container 100 is configured
to define an interior region 102. For example, container 100 may be
a drum or a pail used for the transport and storage of solid or
liquid industrial products (e.g., paint, cleaning products,
solvents, powders). In other embodiments, container 100 may be a
package for the transport and storage of a variety of consumer
products (e.g., foodstuffs, personal care products, detergents, cat
litter). Container 100 may have any overall dimensions (e.g.,
height, width, diameter, wall thickness) required to suit the
characteristics of the product to be filled within the interior
region 102. For example, if the maximum volume of the container 100
is approximately 5 gallons, the container 100 may have a maximum
height of approximately (i.e., .+-.0.5 inches) 14.5 inches, a
maximum width of approximately 12.0 inches, and a nominal wall
thickness of approximately (i.e., .+-.0.5 inches
[0012] Container 100 may include multiple sidewalls 104, 106
extending in a substantially vertical direction relative to a plane
corresponding with a surface on which the container is located
(e.g., a floor, a table, a shelf). Sidewalls 104, 106 may be
"substantially" vertical in that they may be exactly perpendicular
to the plane, or situated at a draft angle. For example, if the
container 100 is formed using a molding process, sidewalls 104, 106
may extend at an outward draft angle ranging from 0.5.degree. to
3.0.degree. to aid in the removal of the container 100 from the
molding apparatus. Sidewalls 104, 106 may be joined by corner walls
108. As depicted in FIGS. 1-3, the sidewalls 104, 106 and corner
walls 108 may form a container 100 with a substantially rectangular
perimeter. In other words, each container 100 may include two
sidewalls 104 located opposite each other and two sidewalls 106
located opposite each other, with the length of each sidewall 104
exceeding the length of each sidewall 106. In other embodiments,
the lengths of sidewalls 104 and 106 may be equal, such that
container 100 has a substantially square perimeter. In still
further embodiments, the sidewalls 104, 106 and the corner walls
108 may not be distinct surfaces, but instead may form a continuous
surface such that container 100 has a substantially circular or
oval-shaped perimeter.
[0013] The sidewalls 104, 106 and the corner walls 108 may include
various features that aid in the handling of the container 100. As
shown in FIG. 1, both sidewalls 104 and 106 may include grip
surfaces 110 located near the top of the interior region 102. Grip
surfaces 110 may protrude from the sidewalls 104, 106 to permit a
user to locate his or her hands between the sidewalls 104, 106 and
the grip surfaces 110 in order to grasp the grip surfaces 110 and
lift the container 100. In some embodiments, one or more of the
grip surfaces 110 may be configured to act as an attachment point
for a pail handle (not shown). Although FIG. 1 depicts the
container 100 as including grip surfaces 110 on both sidewalls 104
and 106, the container 100 may include any number of grip surfaces
110 having any desired geometry to suit the contents of the
container 100. For example, if the container 100 is only a few
inches tall and is configured to be filled with a foodstuff, the
grip surfaces 110 may be omitted from the container 100. The
sidewalls 104, 106 are further shown to include cover retention
features 112 situated above the grip surfaces 110. Cover retention
features 112 may have any geometry required to permit the coupling
of a lid or cover (not shown) and the container 100. For example,
the cover may include complementary features to the cover retention
features 112 such that the cover may be coupled to the container
100 using a snap fit assembly process.
[0014] Referring now to FIG. 2, a perspective view depicting the
container 100 including the bottom wall 114 is shown, according to
some embodiments. The bottom wall 114 may include a central region
with an inner portion 116, an inner surrounding portion 118, and an
outer surrounding portion 120. The inner portion 116 is shown to
have a substantially circular shape, while the inner surrounding
portion 118 is shown to have a rounded rectangular shape. In other
embodiments, the inner portion 116 and the inner surrounding
portion 118 may have any other desired shape. In some embodiments,
the mold for the container 100 is shaped such that the "gate" or
injection site through which the molding material flows is situated
near the inner portion 116. When the mold includes this geometry, a
"vestige" or small lump of material may remain on the inner portion
116 when the container 100 is removed from the mold. Thus, the
inner surrounding portion 118 and the outer surrounding portion 120
may be stepped or vertically offset relative to the inner portion
116. This geometry may prevent the inner portion 116 from flexing
due to gravity or the weight of the contents of the container 100
and striking a surface on which the container 100 is located (e.g.,
a floor, a lid of another container 100 if the containers 100 are
stacked).
[0015] The bottom wall 114 is further shown to include multiple
reinforcing ribs 124 distributed in a curved region 122 situated at
the outer perimeter of the bottom wall 114. Bottom wall 114 may
include any number of reinforcing ribs 124 required to support the
sidewalls 104, 106 and corner walls 108 proximate the bottom wall
114. For example, as shown in FIG. 2, container 100 may include
eight reinforcing ribs 124 situated below the sidewalls 104 and six
reinforcing ribs 124 situated below the sidewalls 106. In some
embodiments, the reinforcing ribs 124 may be distributed at regular
or semi-regular intervals about the curved region 122. For example,
if the container 100 has the rectangular perimeter as shown in
FIGS. 1-2, the spacing between adjacent reinforcing ribs 124
situated below the sidewalls 104 may be different than the spacing
between adjacent reinforcing ribs 124 situated below the sidewalls
106. In other embodiments, the spacing between adjacent reinforcing
ribs 124 situated below the sidewalls 104 may be the same as the
spacing between adjacent reinforcing ribs 124 situated below the
sidewalls 106. In still further embodiments, the bottom wall 114
may not include any reinforcing ribs 124.
[0016] Turning now to FIG. 3, a cross-sectional view depicting the
bottom wall 114 of the container 100 in greater detail is shown,
according to some embodiments. As described above with reference to
FIG. 2, moving outwards from the center of the container 100 to the
sidewall 104, the bottom wall 114 is shown to include the inner
surrounding portion 118 and the outer surrounding portion 120. In
some embodiments, such as the embodiment depicted in FIGS. 2 and 3,
the inner surrounding portion 118 and the outer surrounding portion
120 are not coplanar. Instead, the inner surrounding portion 118
may be situated vertically above the outer surrounding portion
120.
[0017] The curved or sloped region 122 is shown to include a first
curved portion 126 and a second curved portion 128. Again, moving
outwardly from the center of the container 100, the first curved
portion 126 is shown to slope upwardly and the second curved
portion 128 is shown to slope downwardly before merging or
intersecting with the sidewall 104. In an exemplary embodiment, the
intersection between the second curved portion 128 and the sidewall
104 is substantially perpendicular. When the container 100 is
subjected to a drop test, the portion of the sidewall 104 below the
second curved portion 128 may be permitted to flex. This flexure
prevents energy from driving up the sidewall 104 and across the
bottom wall 114, which might otherwise result in fracture. Although
the second curved portion 128 is specifically shown to intersect
with the sidewall 104, the sloped region 122 may extend around the
entire perimeter of the container 100, and thus the second curved
portion 128 may intersect with the sidewalls 106 and the corner
walls 108 in the same way as the sidewall 104 as depicted in FIG.
3.
[0018] In an exemplary embodiment, the first curved portion 126 and
the second curved portion 128 slope in opposite directions. Stated
differently, the first curved portion 126 has a radius of curvature
134 and a center of curvature 136 located on a first side 130 of
the bottom wall 114 (i.e., within the interior region 102,
described above with reference to FIG. 1). The second curved
portion 128 has a radius of curvature 138 and a center of curvature
140 located on a second side 132 of the bottom wall 114. The second
side 132 may be opposite the first wall 130. In an exemplary
embodiment, the radius of curvature 134 of the first curved portion
126 is greater than the radius of curvature 138 of the second
curved portion 128. In other embodiments, the radius of curvature
138 may be greater than or approximately equal to the radius of
curvature 140.
[0019] The reinforcing ribs 124 are shown to be disposed below the
curved region 122 such that the height of each rib may be at a
minimum near the first curved portion 126, specifically near a
transition region between the outer surrounding portion 120 and the
first curved portion 126. The height of each rib may be at a
maximum near the second curved portion 128, specifically near a
transition region or intersection between the second curved portion
128 and the sidewall 104. In an exemplary embodiment, a top surface
142 of each of the reinforcing ribs 124 is coincident with the
first curved portion 126 and the second curved portion 128, while a
bottom surface 144 of each of the reinforcing ribs 124 is
substantially coplanar with a bottom surface 146 of the outer
surrounding portion 120. In other embodiments, the reinforcing ribs
124 may have any other desired geometry.
[0020] In an exemplary embodiment, the container 100 is fabricated
from polypropylene (PP) resin using an injection molding process.
In other embodiments, a different material (e.g., polyethylene
(PE), polyethylene terephthalate (PET), polylactic acid (PLA),
high-density polyethylene (HDPE)) may be utilized. The injection
molding process may include providing a mold with features
configured to form the container 100 and pouring or injecting
molten material (e.g., PP resin) into the mold. After a curing or
cooling period elapses and the material solidifies, the container
100 may be removed from the mold.
[0021] In some embodiments, the container 100 includes one or more
labels (not shown). For example, the label(s) may be affixed to one
or more of the sidewalls 104, 106 and the corner walls 108. In an
exemplary embodiment, the label may be affixed to the sidewalls
104, 106 and the corner walls 108 using an in-mold labeling
process. In-mold labeling can provide several advantages over other
methods of affixing a label to the container 100, including shorter
production times and costs, quick tooling changeover when the label
design is updated, good label resistance to humidity and
temperature damage, and better container recycling opportunities.
In an exemplary embodiment, the in-mold label may be fabricated
from a polypropylene voided OPP film, although any suitable label
material (e.g., paper, polystyrene) may be utilized. During the
molding process, the label is inserted into the mold before
injecting the molten material. The label may be retained in a
proper position within the mold using a variety of methods,
including a static charge, a vacuum, or compressed air. After the
molten material has been injected and the curing period has
elapsed, the label is inseparable from the formed container.
[0022] The features of the bottom wall 114 may aid in the
successful completion of an in-mold labeling process. For example,
the substantially perpendicular intersection between the second
curved portion 128 and the sidewalls 104, 106 and corner wall 108
may drive the sidewalls 104, 106 and the corner walls 108 into the
walls of the mold to ensure proper adhesion between the label and
the sidewalls 104, 106 and the corner walls 108. The presence of
the reinforcing ribs 124 beneath the second curved portion 128 may
further aid label adhesion.
Configuration of Exemplary Embodiments
[0023] The construction and arrangement of the systems and methods
as shown in the various exemplary embodiments are illustrative
only. Although only a few embodiments have been described in detail
in this disclosure, many modifications are possible (e.g.,
variations in sizes, dimensions, structures, shapes and proportions
of the various elements, values of parameters, mounting
arrangements, use of materials, colors, orientations, etc.). For
example, the position of elements may be reversed or otherwise
varied and the nature or number of discrete elements or positions
may be altered or varied. Accordingly, all such modifications are
intended to be included within the scope of the present disclosure.
The order or sequence of any process or method steps may be varied
or re-sequenced according to alternative embodiments. Other
substitutions, modifications, changes, and omissions may be made in
the design, operating conditions and arrangement of the exemplary
embodiments without departing from the scope of the present
disclosure.
[0024] In the present disclosure, the word "exemplary" is used to
mean serving as an example, instance, or illustration. Any
embodiment or design described herein as "exemplary" is not
necessarily to be construed as preferred or advantageous over other
embodiments or designs. Rather, use of the word "exemplary" is
intended to present concepts in a concrete manner. Accordingly, all
such modifications are intended to be included within the scope of
the present disclosure.
[0025] The terms "coupled," "connected," and the like as used
herein mean the joining of two members directly or indirectly to
one another. Such joining may be stationary (e.g., permanent) or
moveable (e.g., removable or releasable). Such joining may be
achieved with the two members or the two members and any additional
intermediate members being integrally formed as a single unitary
body with one another or with the two members or the two members
and any additional intermediate members being attached to one
another.
[0026] As used herein, the terms "approximately," "about,"
"substantially," and similar terms are intended to have a broad
meaning in harmony with the common and accepted usage by those of
ordinary skill in the art to which the subject matter of this
disclosure pertains. It should be understood by those of skill in
the art who review this disclosure that these terms are intended to
allow a description of certain features described and claimed
without restricting the scope of these features to the precise
numerical ranges provided. Accordingly, these terms should be
interpreted as indicating that insubstantial or inconsequential
modifications or alterations of the subject matter described and
claimed are considered to be within the scope of the invention as
recited in the appended claims.
[0027] Although the figures show a specific order of method steps,
the order of the steps may differ from what is depicted. Also two
or more steps may be performed concurrently or with partial
concurrence. Such variation will depend on the software and
hardware systems chosen and on designer choice. All such variations
are within the scope of the disclosure. Likewise, software
implementations could be accomplished with standard programming
techniques with rule based logic and other logic to accomplish the
various connection steps, processing steps, comparison steps and
decision steps.
* * * * *