Patent Application
20190322406
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Preferably, the deflection of the center panel of the base does not exceed 0.029 inches when the container is fully loaded.
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.
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.
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.
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.
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.
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.
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.
The disclosed method can further include the step of forming vents in the container to promote airflow therethrough.
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:
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.
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.
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.
Referring now to
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
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
In the embodiment shown in
Referring now to
Referring now to
As shown in
As shown in
As shown in
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.
Referring now to
1. Place an empty container into the test fixture;
2. Zero out the dial indicator;
3. Pour 2 lbs of water into the container; and
4. Record the measurement on the dial indicator.
The prior art container of
This data was converted into a BOX PLOT which is shown in
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
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.
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:
1. Forming a lid from a portion of a single sheet of at least partially transparent plastic material;
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
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.
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.
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.
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.
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.
