The present disclosure relates to transporting fluid product in individual bottles or containers that are stacked and/or bundled together, and more particularly to a bottle and associated method that increases stability in dynamic conditions associated with such bottles and shipping of same. The disclosure finds particular application in connection with transporting liquid product such as dairy (e.g., milk), water, juices and related products (e.g., soy milk), although it may also find application in non-food and liquid products, e.g., liquid detergents, soaps, oil, etc.
It is generally known to transport fluid product stored in individual bottles that are disposed in a stacked array, for example, on a pallet for shipping purposes. A commercially successful system, as shown and described in commonly owned U.S. Pat. Nos. 6,068,161; 6,247,507; and 6,371,172—Soehnlen, et al., eliminates use of external cases (e.g., milk crates) by providing strengthening ribs or flutes in the bottle that extend in a substantially vertical direction from adjacent a first or upper wall or surface to a location adjacent a second or lower wall or surface. The strengthening ribs are designed to carry vertical loads in the sidewall from the top wall to the bottom wall. The ribs are designed to be rigid structures to carry the load much like columns in a building. In this way, loads are transferred through the bottles from an upper stacked layer of filled bottles to a lower stacked layer of filled bottles, and/or directly to a pallet without the use of cases.
As a part of the design of the system, substantially planar regions are formed in the top and bottom walls or surfaces of the bottle that cooperate with vertically extending ribs/flutes, the handle, and corners formed between adjacent sidewalls to transfer the load from the top to the bottom wall of each bottle. This parallelepiped design allows the bottles to be stacked one atop the other and more effectively convey vertical forces or loads through the sidewalls. Oftentimes, one of the ribs extends from the top surface and terminates in the sidewall just above the bottom wall of the bottle.
A container opening is formed in the top wall for introducing fluid content into the bottle and also dispensing a fluid therefrom, and the container opening is preferably located adjacent one of the corners, typically opposite from the location of the handle located in an opposite corner. Because the bottle container opening is located adjacent one of the corners i.e. adjacent the perimeter, conventional filling equipment is modified to reposition the filler over the bottle opening. This can lead to a significant capital expenditure to modify or substitute conventional filling equipment to accommodate this arrangement.
The caseless shipping system has proved to be a substantial and commercially successful improvement in the dairy industry, for example, where substantial cost has been eliminated over a bottle design and system that has existed for over 60 years. The incorporation of the load carrying ribs/flutes into the plastic bottle has limited the use of cases, and simultaneously reduced the amount of resin used per unit volume.
The need exists for continued improvement. For example, reduced resin content is always desirable. Increased stability for both static and particularly dynamic conditions is also desirable, and specifically the ability to improve handling of lateral load and pressure. Adaptation of a system to conventional filler would also result in a substantial cost savings.
An improved bottle is obtained from designing a bottle that is divided into first and second portions that flex relative to one another.
A mechanical arrangement imposes a lateral load on the bottle that urges the first and second portions toward one another in a lateral direction and thereby pressurizes the closed bottle.
In a preferred arrangement, the mechanical hinge extends all the way around the bottle.
In one embodiment, the lateral load is provided by a wrap that surrounds the array of bottles, for example, a shrink or stretch wrap around the stacked array of bottles received on a pallet.
Locating the bottle opening in an offset position more closely positioned toward a geometric center of the upper surface of the bottle allows for use of a traditional filler.
A number of other benefits are associated with the present disclosure including increased stability (particularly in a dynamic situation), a stronger bottle and therefore a corresponding reduction in a required amount of plastic material required to achieve a selective level of strength and rigidity for the bottle than could be achieved with prior designs.
The hinge in the filled, closed/sealed bottle defines first and second compartments that move toward one another in response to an imposed preload, and as a result makes the bottle stronger and more rigid so that increased load can be conveyed vertically through the bottle with less plastic material.
The new bottle is designed to flex, e.g., the bottle will flex outwardly and not leave a depression (plastic deformation) in the bottle.
The location of flexing on the bottle can be selectively altered/changed.
Pouring the fluid contents from the bottle is also improved with the new bottle of the present disclosure.
The new bottle permits use of a smaller diameter cap (e.g., from 48 mm to 43 mm) and the bottle can therefore hold more pressure.
The bottle arrangement is easy to manufacture, and has a reduced weight when compared to a conventional bottle used for the same purposes.
Another advantage is the ability to use less expensive associated equipment (e.g., a conventional filler can be used) since the offset bottle opening is closer to a central axis of the bottle.
Purposefully creating or providing a pleat or hinge to form first and second compartments of the bottle allows movement between the first and second compartments without plastic deformation when the bottle is filled, sealed, and subject to a preload, and the sealed/capped bottle advantageously builds pressure since the bottle volume is reduced in response to the bottle being subjected to a preload.
Purposefully reducing a surface area of the upper wall of the bottle improves pouring and there is no longer a need to be concerned with the same levels of load carrying capabilities since the bottle is under increased pressure (a concept that is the exact opposite of the previous caseless bottle where there is a desire to maximize the surface area of the top wall).
In addition, the new bottle also handles lateral load and pressure better than the previous caseless bottle.
Still other benefits and advantages of the present disclosure will become more apparent from reading and understanding the following detailed description.
Turning to
The sidewall portions 106a, 106b are adjacent one another and together with the region of cavity 108 enclosed by these sidewall portions 106a, 106 and those portions of the upper (top) and lower (bottom) walls 102, 104 joining them, form a first compartment or front portion 130 of the bottle 100. Likewise, sidewall portions 106c, 106d are adjacent one another and together with that region of cavity 108 enclosed by these sidewall portions 106c, 106d and those portions of the top and bottom walls 102, 104 interconnecting the sidewall portions 106c, 106d, form a second compartment or rear portion 132 of bottle 100. The front and rear portions or compartments 130, 132 of the bottle 100 are in fluid communication with one another to form the single, continuous internal volume or cavity 108 enclosed or defined by the first, second, and third walls 102, 104, 106 (i.e., the top wall, bottom wall, and sidewall) of the bottle 100. The walls enclosing the first and second compartments 130, 132 are separated/joined by a compliant pleat or hinge 140 (sometimes referenced herein as a mechanical arrangement) that when collapsed in response to a lateral load imposed on the bottle 100 urges the first and second portions/compartments 130, 132 toward one another and thereby pressurizes the bottle when the opening 110 is sealed or closed by cap 120.
In a preferred arrangement, the mechanical hinge 140 extends all the way around the bottle 100. More specifically, sidewall portion 106a is joined to the sidewall portion 106d via the hinge 140 and likewise sidewall portion 106b is joined to the sidewall portion 106c via the hinge. Similarly, the hinge 140 divides the top wall 102 into first and second portions 102a, 102b, and the bottom wall 104 is similarly divided into first and second portions 104a, 104d by the hinge. As will be described in greater detail below, the hinge/pleat 140 is substantially continuous or in a preferred arrangement is continuous around the bottle 100 and allows the top, bottom, and sidewall portions 102a/102b, 104a/104b; 106b/106c, and 106a/106d forming the first and second compartments 130, 132 to be spaced apart when the bottle is formed and originally filled with fluid under ambient pressure conditions. As evident in the top plan view of
Once a predetermined amount of the fluid is introduced into the bottle 100 through the opening 110, the bottle is sealed or closed by the cap 120. The cap 120 is threaded onto the externally threaded neck 112 around the opening 110 and the cap forms a fluid tight seal of the opening, and/or a foil seal may be heat fused or sealed around the perimeter of the opening. A preload or lateral force is then imposed on the sealed, filled bottle 100 to collapse the pleat 140 and allow the top, bottom, and sidewall portions forming the first and second compartments 130, 132 of the bottle to move toward one another and thereby reduce the volume of the internal cavity 108. Since the filled bottle 100 is sealed, the lateral force increases pressure inside the bottle as a consequence of the internal volume of the cavity 108 being reduced as the first and second compartments 130, 132 are moved toward one another when the pleat/hinge 140 is collapsed. The increased internal pressure adds further strength and rigidity to the sealed bottle 100.
A preferred manner of increasing the internal pressure of the sealed bottle 100 by collapsing the first and second compartments 130, 132 relative to one another is to apply a preload or lateral force by tightly bounding a group or array of sealed bottles with a surrounding stretch or shrink wrap 150. As a result of this preload or lateral force applied by the wrap 150 on the bottle 100, pressure above ambient is created in the sealed bottle. A pre-stretch can be induced in the wrap 150 whereby the wrap wants to relax to its original stretch length thereby shrinking the internal cavity 108 of the bottle by urging the first and second compartments 130, 132 together as the hinge/pleat 140 is collapsed.
The bottle 100 may further include a flexible label (not shown) that extends about the third wall or sidewall 106 and is dimensioned to impose a second preload force on each bottle and increase the pressure in the bottle.
To facilitate the movement of the first and second compartments 130, 132, the wall thickness of the bottle 100 in the hinge/pleat 140 is different than a wall thickness of other portions of the bottle, e.g., wall thickness of the wall portion 106. In a preferred arrangement, the wall thickness of the pleat/hinge is approximately 0.020 inches while the associated wall thickness of the sidewall 106 (or sidewall portions) is approximately 0.015 inches, of course other dimensions may be used without departing from the scope and intent of the present disclosure but a relative percentage differences wall thickness facilitates initial movement of the first and second compartments 130, 132 in response to a lateral load applied to a filled, sealed bottle 100 that results in increased pressure in the sealed bottle.
The bottle 100 of the present disclosure has improved pouring features. Specifically, the opening 110 is moved away from the sidewall 106 and closer to a central axis of the bottle. As particularly evident in
A handle 170 is provided in the bottle 100. The handle 170 is a non-pass-through handle in the embodiment of
The unique configuration or shape of the handle 170 is dimensioned to conform to a generally C-shape contour formed by a user's thumb and index finger when the fingers of a user's hand are stretched and shaped over a virtual cylindrical or hemispherical surface. Thus, the thumb and index finger (as well as the remaining fingers) are received over the cylindrical conformation portion 172 of the handle 170. The palm of the user's hand is received over the circumferential region 174 of the handle 170, and likewise conforms to the convex contour 124b of the handle defined along the apex of the sidewall portions 106c, 106d. The fingers and thumb of the user grip the handle 170 along the cylindrical conformation 172 disposed in each of the first and third sidewall portions 106c, 106d, respectively,—depending on whether the user grips the handle 170 with the right or left hand. Interconnecting portions 190, 192 of the first and third sidewall portions 106c, 106d each have a compound, curvilinear conformation in a generally horizontal plane where the sidewall curves outwardly from the respective depressed regions 178, 180 toward the sidewall 106 and where the curvilinear conformation smoothly merges into the large planar sidewall portions 106c, 106d, respectively.
The upper wall 102 has an arch shape (see
The upper wall 102 has a stepped configuration in which a first portion 102a includes the externally threaded neck 112 extending outwardly therefrom. The upper perimeter edge of the neck 112 is essentially flush or even in a horizontal plane with a second portion 102b of the upper wall (see
A diameter of the opening 110 is also substantially reduced in the present disclosure over that of the caseless bottle of the prior art shown and described in commonly owned U.S. Pat. Nos. 6,068,161; 6,247,507; and 6,371,172. For example, the diameter of the opening in the prior art is 48 mm whereas the new diameter is 43 mm. Although the precise dimensions can vary, by reducing the diameter of the opening 110 and the cap 120, a greater amount of pressure can be held in the bottle 100. Of course the ability to hold greater pressure in the bottle 100 allows the lateral force to be applied or increased to the sidewall 106 which, in turn, allows the first and second compartments 130, 132 to move toward one another, i.e. the hinge/pleat 140 collapses. The individual bottle 100 and array of bottles preclude plastic deformation of the bottle walls and allow the sealed bottles to build pressure and advantageously and effectively carry the vertical.
These various arrangements provide for increased stability of the bottles 100, particularly when in a stacked array and subjected to a dynamic situation such as shipping and handling. The various designs shown and described above provide for a stronger bottle 100 and therefore allow for a reduction in material since the sealed bottle is able to handle increased pressure. Since the thickness of the walls 102, 104, 106 of the bottle 100 are controlled via the blow molding operation, the walls can flex as desired in response to the lateral or vertical loads which reduces the interior volume of the cavity 108 and increases the pressure of the sealed bottle. Moreover, the walls 102, 104, 106 will not encounter a permanent change in the conformation of the bottle 100, i.e., when the bottle is subsequently opened for use, the bottle will reshape to its original contour since the elastic yield strength of the plastic will not have been exceeded. The hinge/pleat 140 is designed to form first and second compartments 130, 132 that can move relative to one another under load when the bottle 100 has been sealed by the cap 120. Moreover, the design provides for improved pouring, the smaller diameter cap 120 allows greater pressure to be held, and less resin or plastic material is required to form the new bottle. For example, the ratio of resin (measured in grams) per bottle volume (measured in gallons) is on the order of 75 grams/gallon. The bottle 100 can also be advantageously used with a conventional filler with only minor modification thereto.
This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims. Moreover, this disclosure is intended to seek protection for a combination of components and/or steps and a combination of claims as originally presented for examination, as well as seek potential protection for other combinations of components and/or steps and combinations of claims during prosecution.
This application claims the priority benefit of U.S. provisional application Ser. No. 62/261,144, filed Nov. 30, 2015, the entire disclosure of which is expressly incorporated herein by reference.
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Number | Date | Country | |
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20170152095 A1 | Jun 2017 | US |
Number | Date | Country | |
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62261144 | Nov 2015 | US |