CONTAINER WITH NON-CYLINDRICAL UPPER BODY PORTION

Abstract

A one-piece, unitary molded plastic container includes a neck portion; a base portion; and a sidewall extending upwardly from the base portion toward the neck portion. The sidewall includes an upper body portion and a lower body portion. The lower body portion is substantially cylindrical, extends from the base portion toward the upper body portion, and has a height that is from about 0.10 to about 0.60 of the total height of the container. The upper body portion is substantially non-cylindrical, extends upwardly from the lower body portion toward the neck portion, and has a height that is from about 0.30 to about 0.80 of the total height of the container; and includes a curved label-receiving portion. In embodiments, a label—e.g., a directly-applied ink label or separately applied composite label—is applied to the label-receiving portion.

Description

TECHNICAL FIELD

The present invention relates in general to plastic containers, including plastic containers with non-cylindrical portions.

BACKGROUND

Plastic containers may include various integrated structural and ornamental features. Most commercial containers that package contents include, and even require, some form of labeling. Consequently, various known labeling techniques have been employed in the art. In a number of conventional applications, a label panel is included, and the label panel is intended to be flat, or include significant portions that are flat. However, such a constraint can limit available positioning and/or design configurations. Moreover, commercial containers are commonly grouped for shipping, so their lower/base configurations are often intended to facilitate such grouping.

SUMMARY

The present disclosure provides, inter alia, a one-piece, unitary molded plastic container including a neck portion; a base portion; and a sidewall extending upwardly from the base portion toward the neck portion. The sidewall includes an upper body portion and a lower body portion. The lower body portion is substantially cylindrical, extends from the base portion toward the upper body portion, and has a height that is from about 0.10 to about 0.60 of the total height of the container. The upper body portion is substantially non-cylindrical, extends upwardly from the lower body portion toward the neck portion, and has a height that is from about 0.30 to about 0.80 of the total height of the container; and includes a curved label-receiving portion. In embodiments, a label—e.g., a directly-applied ink label or separately applied composite label—is applied to the label-receiving portion.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, wherein:

FIGS. 1A and 1B are perspective views of embodiments of containers formed in accordance with aspects or teachings of the invention;

FIGS. 2A and 2B are left side elevational view of embodiments of the containers shown in FIGS. 1A and 1B, respectively;

FIG. 3 is a right side elevational view of the embodiment of a container shown in FIG. 1B;

FIG. 4 is a rear elevational view of the embodiment of a container shown in FIG. 1B;

FIG. 5 is a front elevational view of the embodiment of a container shown in FIG. 1B;

FIG. 6 is a top plan view of the embodiment of a container shown in FIG. 1B;

FIG. 7 is a side view of an embodiment of a container similar to that illustrated in FIG. 2B;

FIG. 8 is a representation of a cross section of the container taken at cut A-A in FIG. 7;

FIG. 9 is a representation of a cross section of the container taken at cut B-B in FIG. 7;

FIG. 10 is a representation of a cross section of the container taken at cut C-C in FIG. 7;

FIG. 11 is a representation of a cross section of the container taken at cut D-D in FIG. 7; and

FIG. 12 is a representation of a cross section of the container taken at cut E-E in FIG. 7.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments of the present invention, examples of which are described herein and illustrated in the accompanying drawings. While the invention will be described in conjunction with embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims.

By way of example, and without limitation, embodiments of a container 10 provided in accordance with aspects and teachings of the invention are shown in FIGS. 1A and 1B. The container may be a single, one-piece, unitary molded plastic container. The illustrated containers 10 include, inter alia: a neck portion 20, with a dispensing opening 30, a closure-receiving (e.g., threaded) portion 40, and a support flange 50; a base portion 60 (which may be round or substantially round); and a sidewall 70.

As illustrated in FIGS. 2A and 2B, the sidewall 70 extends upwardly from the base portion 60 toward the neck portion 20, and includes an upper body portion 80 and a lower body portion 90. In embodiments, the lower body portion 90 extends from the base portion 60 toward the upper body portion 80, is substantially cylindrical, and may have a vertical height that is from about 0.10 to about 0.60 of the total height H of the container. In an embodiment, the lower body portion 90 extends from the base portion 60 toward the upper body portion 80, is substantially cylindrical, and may have a vertical height that is from about 0.25 to about 0.50 of the total height H of the container. Further, in embodiments, the upper body portion 80 is substantially non-cylindrical, extends upwardly from the lower body portion 90 toward the neck portion 20, has a vertical height that is from about 0.30 to about 0.80 of the total height H of the container, and includes a curved label-receiving formation 100. In an embodiment, the upper body portion 80 is substantially non-cylindrical, extends upwardly from the lower body portion 90 toward the neck portion 20, has a vertical height that is from about 0.40 to about 0.60 of the total height H of the container, and includes a curved label-receiving formation 100.

The label-receiving portion 100 may itself take the overall form of one or more decorative features (e.g., a leaf). In embodiments, the label-receiving portion 100 is curved—i.e., such that a portion, which may include all or a significant portion of the label-receiving portion, is not flat or planar, but rather includes a radius or a plurality of radii. With reference to FIG. 3, in an embodiment, the label-receiving portion 100 has a vertical length VL that is greater than a horizontal length HL. Without limitation, for embodiments, the vertical length VL of the label-receiving portion 100 is at least 1.25 times the horizontal length HL of the label-receiving portion 100, and for a number of embodiments may be more than 1.6 times the horizontal length HL.

For some embodiments, such as that illustrated, the label-receiving portion 100 may have a vertical length VL that is at least about 0.60 of the vertical length of the entire upper body portion 80. In some embodiments, the label-receiving portion 100 has a vertical length VL that is at least about 0.70 of the vertical length of the entire upper body portion 80.

The invention is not limited to the inclusion of a single label-receiving portion 100 and, in embodiments, may include a plurality of label-receiving portions. For some embodiments, label-receiving portions may be provided on opposing sides of the container, and may be similar to (and even minor images of) each other. In the illustrated embodiment, the container includes two curved label-receiving portions 100 (generally illustrated in FIGS. 4 and 5 as 100a and 100b).

As generally illustrated in the figures, the label-receiving portions may be generally convex relative to a central axis CA of the container 10. Additionally, as generally illustrated in FIG. 6, for embodiments, the label-receiving portion 100 may remain substantially, and even entirely, within the plan “footprint” of the container (viewed in FIG. 6 from the top view)—which may, overall, be circular or substantially circular, as shown.

With reference to FIG. 3, the label-receiving portion 100 may include at least one reinforcing formation, generally indicated as element 110. In embodiments, the reinforcing formation may, for example, include a rib (e.g., curved rib 120), which may extend radially inwardly (although it may also extend radially outwardly). As generally illustrated, the reinforcing formation 100 may also include a plurality of extensions (e.g., curved extensions 130), which may be small ribs of varying lengths, and which may cross or extend from a primary rib. The ribs and/or extensions may be configured to provide additional strength (e.g., to resist internal or external pressures). If desired, for some embodiments, the at least one reinforcing formation 110 may have a length that is at least 0.70 of the vertical length VL of the label receiving portion 100. Moreover, for some embodiments, the at least one reinforcing formation 100 may have a vertical length that is at least 0.25 of the total height H of the container. As also generally illustrated in FIG. 3, the lower body portion 90 may also include one or more lower reinforcing formations—such as ribs 92—which may extend radially inward and may extend circumferentially around the container, whether in the form of annular rings, or in a spiral-like formation such as illustrated in FIG. 3.

FIG. 7 includes a side view of an embodiment of a container 10 similar to that illustrated in FIG. 2B. FIGS. 8 through 12 include representations of cross-sections of the container taken at A-A, B-B, C-C, D-D, and E-E, respectively. For example, without limitation, the aforementioned cross sections may be taken at the following positions/indicated distances:

Section Cut Distance/Height from Bottom
A-A         D1 = 4.500 in. (114.30 mm)
B-B         D2 = 5.000 in. (127.00 mm)
C-C         D3 = 5.500 in. (139.70 mm)
D-D         D4 = 6.000 in. (152.40 mm)
E-E         D5 = 6.500 in. (165.10 mm)

With embodiments, the wall thickness of the label-receiving portion may be about 10 mil or less and, for some embodiments, may be about 7 mil or less. In that regard, while FIGS. 8-12 generally represent cross sections, such lines may, for instance, be considered median lines for the aforementioned thicknesses.

By way of example only, and without limitation, embodiments of containers provided in accordance with aspects and teachings of the invention may have measurements/dimensions of the type set forth in the following table (which includes three different embodiments—i.e., Emb #1, Emb #2, and Emb #3):

	Emb #1	Emb #2	Emb #3
Container Height	5.7	in.	8.201	in.	8	in.
Sidewall Height	5.028	in.	7.529	in.	7.529	in.
Neck Portion Height	0.672	in.	0.672	in.	0.471	in.
Base Portion Height	0.473	in.	0.473	in.	0.473	in.
Lower Body Portion	1.094	in.	2.859	in.	2.859	in.
Height
Combined Base	1.567	in.	3.773	in.	3.773	in.
Portion and Lower
Body Portion Height
Upper Body Portion	3.461	in.	3.923	in.	3.924	in.
Height
Base Portion	2.557	in.	2.79	in.	2.557	in.
Maximum Diameter
Container Volume	10	fl oz	20	fl oz	500	ML
Container Weight	10	g.	15.3	g.	10	g.
Label-Receiving
Portion Height	2.709	in.	2.874	in.	2.874	in.
Label-Receiving	1.691	in.	1.785	in.	1.817	in.
Portion Width
Neck Portion Internal	26.7	mm	26.7	mm	26	mm
Diameter
Lower Body Portion	19%	35%	36%
Height to Container
Height
Combined Base	27%	41%	42%
Portion and Lower
Body Portion Height to
Container Height
Upper Body Portion	61%	48%	49%
Height to Container
Height
Label-Receiving	48%	35%	36%
Portion Height to
Container Height
Label-Receiving	78%	73%	73%
Portion to Upper Body
Portion Height

It is noted that, when a container is in an upstanding position, the label-receiving portion 100 may provide a visual that is generally perpendicularly oriented with respect to the central axis CA. That is, rather than being a significant part of a shoulder portion of a container—which would convey a visual impression angled “upwardly,” the visual impression to an observer would be directed radially outwardly in a substantially perpendicular direction.

In embodiments, the container may include a label that is applied to the label-receiving portion. It is noted, though, that as used herein a “label” may include a conventional label that is affixed to the label-receiving portion by conventional means, such as in-mold labeling, pressure sensitive, heat transfer, and/or adhesion applications, but may also include the application of ink directly to all or portions of the label-receiving portions (for example, by digital printing and/or screen printing). Moreover, the content of the “label” may comprise text, designs, colors, or various combinations of the forgoing. For example, with respect to FIGS. 2A and 2B, a label may include ink-applied text (e.g., “TEXT” 140 in FIG. 2A) and/or may include one or more colors applied to a portion (or portions) of the label-receiving portion (e.g., 150).

In embodiments in which the label is comprised of ink, the ink may be applied so as to be in direct contact with the outer surface of the label-receiving portion. Moreover, if desired, several coats of ink may be applied (e.g., a base coat and one or more coats thereon). For example, without limitation, the ink(s) may comprise a curable ink used for printing on plastic containers. Moreover, examples of techniques for printing on non-planar surfaces are disclosed in U.S. Pat. No. 7,736,713 and U.S. patent application Ser. Nos. 12/490, 564, filed Jun. 24, 2009, and 12/604,557, filed Oct. 23, 2009, which are commonly owned, and which are hereby incorporated by reference as though fully set forth herein.

Without limitation, the container 10 may, for example, comprise a plastic injection molded or blow molded container. The container may also, without limitation, be comprised of a wide variety or monolayer or multilayer plastic materials, such as polyethylene terephthalate (PET) or high density polyethylene (HDPE). The container 10 may comprise a biaxially oriented injection stretch blow molded container. Further, embodiments of an empty container 10 may have a minimum top load capability of at least about 2 lbs, preferably at least about 5 lbs, and more preferably at least about 10 lbs. Moreover, a lightweight embodiment of container 10 may have a wall thickness throughout the container of about 10 mil or less.

If desired, a rotary system may provide for printing on curved surfaces at relatively high production speeds. However, alternative embodiments for a rotary system may be incorporated or employed. For example, and without limitation, a system may be configured so that containers move along a substantially linear path, and individual containers are rotated in front of one or more print heads/stations (e.g., about a central container axis) so as to provide or maintain a substantially constant distance or radius between the print head and the surface to be printed. In another embodiment of a system, a container path—at least in front of one or more print heads—may be configured with a radius or curved portion to facilitate providing a substantially constant distance between the print head and the print area on the container. It is noted that the print heads associated with the various disclosed embodiments may optionally be movable. Such movability can facilitate providing or maintaining a substantially constant distance (e.g., offset distance) between a print head and the print area or surface to be printed. Moreover, the ability to provide or maintain such a distance can be used in connection with non-round containers or containers that have surface portions with non-constant radii.

It is noted that a pre-treatment device may provide a form of heat treatment to the label-receiving portion. Such heating may be accomplished using known techniques including, without limitation, flame, plasma jet, or corona heating/treatment processes. Further, following application of a label to a label-receiving portion, a curing device/station (or multiple devices/stations) may be provided, and may comprise a number of forms of curing devices including, for example, ultraviolet (UV) lamps and/or LED devices.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and various modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to explain the principles of the invention and its practical application, to thereby enable others skilled in the art to utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims and their equivalents.

Claims

1. A one-piece, unitary molded plastic container, comprising: a neck portion;a base portion;a sidewall extending upwardly from the base portion toward the neck portion, the sidewall including an upper body portion and a lower body portion;wherein the lower body portion is substantially cylindrical, extends from the base portion toward the upper body portion, and has a height that is from about 0.10 to about 0.60 of the total height of the container; the upper body portion is substantially non-cylindrical, extends upwardly from the lower body portion toward the neck portion, has a height that is from about 0.30 to about 0.80 of the total height of the container; and includes a curved label-receiving portion.

2. The container of claim 1, wherein the container is biaxially oriented.

3. The container of claim 1, wherein the container comprises polyethylene terephthalate (PET).

4. The container of claim 1, wherein the vertical length of the label-receiving portion is at least about 0.6 the vertical length of the upper body portion.

5. The container of claim 1, wherein the vertical length of the label-receiving portion is at least about 0.70 the vertical length of the upper body portion.

6. The container of claim 1, wherein the upper body portion includes two opposing sides, each opposing side including a label-receiving portion.

7. The container of claim 6, wherein the label-receiving portion of each opposing side are substantially minor images of each other.

8. The container of claim 1, wherein the label-receiving portion is generally convex relative to a central axis.

9. The container of claim 1, wherein the label-receiving portion includes at least one reinforcing formation.

10. The container of claim 9, wherein the at least one reinforcing formation includes a curved rib.

11. The container of claim 10, wherein the curved rib extends radially inwardly.

12. The container of claim 9, wherein the at least one reinforcing formation includes a curved rib and a plurality of curved extensions, the curved extensions extending from the curved rib.

13. The container of claim 9, wherein the at least one reinforcing formation has a vertical length that is at least 0.70 of the vertical length of the label receiving portion.

14. The container of claim 9, wherein the at least one reinforcing formation has a vertical length that is at least 0.25 of the total height of the container.

15. The container of claim 1, including a label applied to the label-receiving portion.

16. The container of claim 15, wherein the label is comprised of ink in direct contact with the outer surface of the label-receiving portion.

17. The container of claim 15, wherein the label is comprised of one of an in-mold label, a pressure sensitive label, and a heat transferred label affixed or applied to the outer surface of the label-receiving portion.

18. The container of claim 1, further comprising a grip area located between the upper body portion and the lower body portion, wherein the grip area comprises a concave recess to facilitate handling.

19. The container of claim 1, wherein the container has a minimum top load capability of 5 lbs.

20. The container of claim 1, wherein the container is produced by injection stretch blow molding.

21. The container of claim 1, wherein the lower body portion includes a plurality of generally horizontal ribs.