Conventional wide mouth containers are often used to store solid items that may be too large to pour. These containers may also be used to store viscous or semi-solid materials that must be scooped from a container rather than poured. As a result, these containers may have mouths large enough for a person's hand to enter the container.
Further, these containers are often formed of plastic. Plastic manufacturing techniques allow for virtually any shape, size, and configuration of container that is easy to use and often targeted to a specific material to be stored or use of that container and material within. However, when a wide mouth container contains dense objects or materials, thick walls are conventionally used to provide sufficient structural strength. Thick walls increase manufacturing costs, however, and increase the container weight, thereby increasing shipping costs. Conversely, some traditional containers rely on thinner walls to reduce material costs. However, these thin wall containers may be unable to withstand certain external forces and therefore may be unsuitable for certain applications. As a result, thin wall containers may be unable to be stacked, reducing shipping options and increasing costs.
Consequently, there is a need for improved containers that allow for storage and easy access to goods, while reducing costs by providing versatile shipping options and reducing manufacturing costs.
A container according to various embodiments of the present disclosure includes an outlet defining an opening that is in fluid communication with an interior portion of the container, the outlet having a central axis. The container also a neck portion having an upper structural ring lying in a first plane that is substantially perpendicular to (e.g., perpendicular to) the central axis, and a lower structural ring lying in a second plane that is substantially perpendicular to (e.g., perpendicular to) the central axis, wherein the first plane and the second plane are separated by a vertical distance. The neck portion may have a gusset extending between the upper structural ring and the lower structural ring, and the gusset may have a plane of symmetry, wherein the central axis lies in the plane of symmetry. The container further includes a shoulder beneath the neck portion, a waist section beneath the shoulder, and a base beneath the waist section.
In additional embodiments, a mold for forming a container includes a top portion having a top horizontal recess configured to form a top rib of a container; a lower horizontal recess configured to form a lower rib of the container; a middle protrusion disposed between the top horizontal recess and the lower horizontal recess; and a plurality of gusset recesses configured to form a plurality of gussets extending between the top rib and the lower rib. The mold also includes a middle portion having a cylindrical section configured to form a panel section of the container; and at least one horizontal rib protrusion having a radius less than a radius of the cylindrical section. The mold further includes a bottom section configured to form a base of the container.
Further, according to various embodiments of the present disclosure, a method of manufacturing a wide mouth container includes heating a tube of a material until the material is above a glass transition temperature of the material and surrounding the tube with a mold. The mold includes a top portion having a top horizontal recess configured to form an upper structural ring; a lower horizontal recess configured to form a lower structural ring; a middle protrusion disposed between the top horizontal recess and the lower horizontal recess; and a plurality of gusset recesses configured to form a plurality of gussets extending between the upper structural ring and the lower structural ring. The mold also includes a middle portion having a cylindrical section configured to form a panel section of the wide mouth container; and at least one horizontal rib protrusion having a radius less than a radius of the cylindrical section. Further, the mold includes a bottom section configured to form a base of the wide mouth container. The method also includes pressing the tube against the mold using a pressurized gas; and releasing the wide mouth container from the mold.
Various embodiments are described below. In the course of this description, reference will be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
Various embodiments will now be described more fully hereinafter with reference to the accompanying drawings. It should be understood that the concepts disclosed herein may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like numbers refer to like elements throughout.
Wide mouth containers may be used to store and ship items that a person may desire to dispense individually. For instance, food products like snacks (e.g., pretzels, candy, cookies, etc.) may be shipped in wide mouth containers that allow a person to take one unit at a time (e.g., one pretzel at a time). Wide mouth containers may also store varieties of an item, such as varieties of candy, and the wide opening may allow a person to select a desired flavor. Further, wide mouth containers may be useful in bulk shipment and purchases of goods by having a large volume that is easily accessed by a consumer. For instance, a wide mouth container may include a dense substance (e.g., ice cream, peanut butter, shortening, etc.) that is too viscous to be poured from a narrow opening, and which a consumer may scoop out with a utensil, thus requiring a wide opening for the consumer's hand and utensil. In certain cases, manufacturers may store heavy items in wide mouth containers, such as screws or other hardware items, as well.
However, in order to benefit from the economies of scale of shipping bulk goods, as well as maximizing storage density in warehouses and stores, merchants and shippers may desire to stack wide mouth containers. In cases where the wide mouth containers hold dense, heavy goods, the stacking height of the wide mouth containers may be limited by the container's material strength. However, adding more material to the container to increase strength may increase costs as well by increasing raw material consumption and shipping weight. Thus, various embodiments of the present disclosure provide structural reinforcement designs for wide mouth containers that improve stacking height and container durability without significant addition of raw material or weight.
The container 10 also includes an outlet having an opening 102 that is in fluid communication with an interior portion of the container. The opening may be substantially circular about a central axis, for instance. Further, the opening may be sized to allow suitable contents (e.g., one or more food items or other items) to be transferred to and from the container's interior. The opening may also be sized to allow a human hand to fit into the container, or, in some embodiments, a hand holding a utensil (e.g., spoon, knife, etc.). In certain embodiments, the outlet opening may be so dimensioned so that a consumer may grip a lid secured to the opening with a single hand. Accordingly, the opening may be, for example, less than about six inches in diameter in some embodiments (e.g., between about four inches and about 6 inches in diameter).
The container 10 may also include a substantially circular neck portion 110 below the outlet 100. The neck portion 110 may have a diameter greater than a diameter of the outlet. In certain embodiments, a lid secured on the thread of the outlet may rest on a rim forming a transition from a smaller outlet diameter to the greater neck portion diameter. Further details of the neck portion will be discussed with reference to
As shown in
The shoulder 120 may include a bumper 130 at the bottom of the shoulder 120. The top bumper 130 may be substantially circular and concentric with the outlet. Further, the top bumper 130 may have an outside wall with a diameter at least as large as a largest diameter of the shoulder 120. The top bumper 130 may provide an upper boundary to a waist section 140 disposed beneath the shoulder. Thus, a maximum radius of the bumper 130 may be greater than a maximum radius of the waist section 140. For example, in some embodiments, the waist section 140 may have a diameter slightly smaller than the top bumper 130 (e.g., the waist section diameter may be about 99%, 95%, etc., of the bumper diameter). In this manner, a label adhered to a portion of the waist section 110 may be protected from abrasion damage should the container 10 rub against an adjacent container during shipping and handling. In other words, the top bumper 130 may impact adjacent containers, rather than a label or other markings on the waist section. In some embodiments, the top bumper 130 may have a thicker wall than adjacent container sections to help provide additional durability against side impacts and abrasion.
The container 10 may have a large opening in comparison to a diameter of the waist section in order to allow a consumer to access goods that fall to the bottom or adhere to the sides of the container 10. For example, a ratio of a diameter of the outlet opening to a diameter of the waist section 140 may be greater than 0.5 in some embodiments. As a result, a consumer may be able to insert a tool to scrape a viscous product off of interior walls of the container 10.
In some cases, large compressive loads pushing downward on a container may cause unreinforced walls to buckle. This may be especially problematic for container having thin container walls with a large surface area. Such walls may be unable to provide a radial force counteracting bending moments resulting from off-center vertical loads, such as those experienced during shipping and handling. Additionally, when a thin wall buckles, the buckling movement may give rise to stress raisers, which could focus forces on a small area and cause material failure. If the container holds a liquid or a food, a hole in a wall may be unacceptable for a consumer.
Thus, a container 10 according to various embodiments of the present disclosure may include reinforcement ribs to help prevent buckling. As may be understood from
Further, the ribs 150A-150C may be grouped in a region of the waist section 140. For example, the waist section may include a panel portion having the shape of a wall of a cylinder. The panel portion may secure a label, or may include printed identification material of a product within the container 10. A bottom edge of the panel portion may lie substantially on a plane that is substantially perpendicular to (e.g., perpendicular to) the central axis of the outlet, such that the panel portion lies on a first side of the plane. Further, at least one structural rib may be disposed on a second side of the plane. For instance, as shown in
Further, because the container may hold a large volume of a good (e.g., 1 gallon), the container 10 may cause a large spill if tipped. Additionally, any spills from a tipped container may grow rapidly due to the large opening of the container 10. To help avoid spills, the base 170 may have a diameter that is greater than 0.5 times a height of the container 10. For example, the container 10 may have a height of 9 inches, and a base diameter of 6 inches. Further, the force of gravity on the container contents may provide a force downward along the central axis of the container 10. As a result of the base diameter being at least half of the height of the container, a significant fraction (e.g., at least ⅓) the force of gravity on the contents may be directed substantially perpendicular to a moment arm along by a line between a rim of the base and the center of gravity of the contents of a full container. That is, decreasing an angle between the base and the center of gravity about a particular point on the rim also increases the fraction of the gravitational force that is substantially perpendicular to the moment arm, as well as increasing the moment. As a result, the moment about a particular point on the rim due to gravity increases, thereby increasing a force required to tip the container and cause a spill. Thus, the dimension of the container 10 may decrease the likelihood of incidental bumps during shipping and consumer handling causing a spill.
In certain embodiments, the base 170 may include gradually tapering lower portion 180, as illustrated further in
Turning to
The upper and lower structural rings 112, 116 may be connected by a first, substantially-circular connecting portion 114 having a concave exterior profile as shown in
The upper and lower structural rings are also connected by a plurality of elongated gussets 118A-118D that, respectively, extend from the upper structural ring 112 to the lower structural ring 116 in a direction that is substantially perpendicular to both the upper structural ring 112 and the lower structural ring 116. As shown in
In particular embodiments, such as the embodiment shown in
Further, the gussets 118A-118D may be symmetric about a plane. For example, the gusset 118C is symmetric about a plane of symmetry running vertically. Further, the plane of symmetry of the gusset 118C substantially bisects the container 10. Thus, the central axis of the outlet may lie in the plane of symmetry of the gusset 118C. This symmetry may help disperse pressure that may otherwise be localized and cause material failure. Additionally, each gusset 118A, 118B, and 118D may also be symmetric, and have respective planes of symmetry. The central axis may lie in each respective plane of symmetry, such that the respective planes of symmetry substantially intersect along the central axis.
As stated above, in certain embodiments, the container 10 may be formed by a blow molding process. For instance, manufacturing of the container 10 may begin with heating a tube of material until the material is above particular temperature. For example, the temperature may be a glass transition temperature of the material, such that the material transitions from a crystalline or semi-crystalline structure into a malleable form, but is not sufficiently heated to cause the material to become liquid or burn. The material may be heated by heated air, radiative heating elements, or any other suitable heating method.
The heated tube may be substantially surrounded by a mold configured to form the features of the container 10. The mold may have multiple pieces (e.g., a left and right side). The mold may also have multiple portions, each corresponding to a portion of the container. For example, the mold may comprise a top portion configured to form the outlet 100, neck portion 110, and shoulder 120. Accordingly, the top portion may comprise a top horizontal recess configured to form an upper structural ring (e.g., the upper structural ring 112), and a lower horizontal recess configured to form a lower structural ring (e.g., the lower structural ring 116). The mold may also comprise a middle protrusion disposed between the top horizontal recess and the lower horizontal recess, which may correspond to the circular connection portion 114 described above. Further still, the mold may comprise a plurality of gusset recesses configured to form a plurality of gussets extending between the upper structural ring and the lower structural ring.
The mold may also comprise a middle portion having a cylindrical section configured to form a panel section of the container and at least one horizontal rib protrusion having a radius less than a radius of the cylindrical section (e.g., the waist section 140 and the ribs 150A-150C). The mold may further comprise a bottom section configured to form a base of the container (e.g., the base 170). The bottom section of the mold may also include markings to be formed in the material of the container (e.g., material properties, recycling category, branding, etc.).
After the tube of material is substantially surrounded by the mold, the tube may be pressed against the mold, for instance using a pressurized gas to inflate the tube of malleable material. The pressure may cause the tube of malleable material to expand and substantially take on the shape of the mold. In some embodiments, the mold may be spun, for instance about a central axis, to force the material against the mold walls. Further, the mold may be cooled, such that heat from the tube of material may be removed causing the material to resolidify. After the material has resolidified, the material, now in the shape of the container 10, may be released from the mold, for instance by blowing the container off the mold walls, or by cooling the container 10 such that the material contracts and releases.
The concepts and technologies described herein are related to various embodiments of a container, which may, for example, be made of a suitable polymer. While the particular examples shown in
Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for the purposes of limitation.
This application claims priority to U.S. Provisional Patent Application Ser. No. 63/197,940, filed Jun. 14, 2021, entitled “CONTAINER,” the disclosure of which is hereby incorporated by reference in its entirety.
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