LIGHTWEIGHT CONTAINER

Abstract

A container for fluids. The container having a hollow body with an octo-rectangular cross-sectional shape. The octo-rectangular cross-sectional shape being defined by the hollow body having an elongated rectangular cross-sectional shape with four side walls and four corners. each of the four corners being further defined by two rounded sub-corners and an intermediate wall. The container further includes a spout defining an opening into the container. a transition section located between and connecting the body to the spout. and a base closing one end of the body opposite of the spout.

Description

BACKGROUND

1. Field of the Invention

The present invention generally relates to containers for the housing of liquids, and more specifically to blow molded plastic containers for liquids. Even more specifically, the invention relates to plastic containers for liquids, such as automotive motor oils, exhibiting both reduced material usage and improved top load capabilities.

2. Description of Related Art

Blow molded plastic container are available in a wide variety of shapes and volumes. Those provided for automotive liquids, such as motor oils, in one quart/liter and greater capacities, were initially provided as either cylindrical containers with centrally oriented spouts, cylindrical containers with offset spouts. Cylindrical containers, while having various structural and manufacturing advantages, are not efficient when packaged for shipping on standard sized pallets. When multiple containers are packaged for shipping, open or void spaces are present between the adjacent containers, as well as the packaging, such as the walls of a box. More recently, such containers have been provided as either rectangular containers with centrally oriented spouts or rectangular containers with offset spouts. Rectangular containers are much more efficiently packaged because the void space between adjacent individual containers is significantly reduced. Accordingly, rectangular shaped containers are currently the most common, particularly, but not exclusively, in the United States.

In manufacturing the above mentioned plastic containers, typically, a high density polyethylene (HDPE) material is used in an extrusion blow molding process. In producing the containers, a significant portion of the overall cost of the container is a direct result of the amount of plastic resin used to form the container. Efforts to reduce the amount of plastic resin, however, are challenging.

One challenge is for the container to withstand industry standard, and often times company specific, top load requirements. The top load requirements ensure that the container will withstand the expected forces experienced during filling, capping, transporting and warehouse stacking. Reductions in the amount of plastic used in a given container are known to translate to a reduction in the top load capabilities of the container. Typical weights and top load capabilities of today's rectangular, off-set neck, one quart/one liter (1 Qt/1 L) containers are in the range of about 48 grams to 56 grams HDPE and about 45 to 65 lbf of top load (unvented and unfilled) capability. Top load testing is conducted under ASTM D2659-11.

Since millions of containers are produced annually, it will be readily appreciated that any reduction in the weight of the plastic used to form the container, by even a few percentage points, that does not compromise the container's top load capability, translates into enormous cost saving to the manufacturer.

SUMMARY

In overcoming the various drawbacks and limitations of the related art, the present invention provides a container for automotive or other fluids having an octo-rectangular cross-sectional shape that allows for light weighting of the container while improving top load capabilities of the container.

In one aspect of the invention, a container for automotive or other fluids comprising: a hollow body, the hollow body having an octo-rectangular cross-sectional shape, the octo-rectangular cross-sectional shape of the hollow body is defined by the hollow body having an elongated rectangular cross-sectional shape with four side walls and four corners, each of the four corners being defined by two rounded sub-corners and an intermediate wall; a spout defining an opening into the container; a transition section located between and connecting the body to the spout; and a base closing one end of the body opposite of the spout.

In another aspect, the intermediate walls and the four side walls are substantially planar.

In a further aspect, the four side walls include two major side walls and two minor side walls, when measured in transverse cross-section the major side walls having an overall width substantially greater than an overall width of the minor side walls as measured in transverse cross-section.

In an additional aspect, the four side walls include two major side walls and two minor side walls, when measured in transverse cross-section the major side walls having an overall width that is fifty percent greater than an overall width of the minor side walls as measured in transverse cross-section.

In yet another aspect, the four side walls include major side walls and minor side walls, when measured in transverse cross-section the minor side walls having an overall width that substantially the same as an overall width of the intermediate walls as measured in transverse cross-section.

In still a further aspect, the transition section has an octo-rectangular cross-sectional shape, the octo-rectangular cross-sectional shape of the transition section being defined as having an elongated rectangular cross-sectional shape with four side walls and four corners, each of the four corners of the transition section being defined by two rounded sub-corners and an intermediate wall.

In an additional aspect, the two rounded sub-corners and intermediate wall of the transition section are extensions of the two rounded sub-corners and intermediate wall of the hollow body.

In another aspect, the four side walls of the transition section include major side walls and minor side walls, the minor side walls and intermediate walls of the transition section decreasing in width as measured in transverse cross-section when proceeding from the hollow body toward the spout.

In yet a further aspect, the four side walls of the transition section include major side walls and minor side walls, the minor side walls of the transition section having an overall width measured in transverse cross-section that is less than an overall width measured in transverse cross-section of the intermediate walls of the transition section.

In still an additional aspect, the four side walls include two major side walls and two minor side walls, an average wall thickness ratio of the thickness of the intermediate walls to the thickness of the major sides of the container being greater than 0.66.

In yet another aspect, the average wall thickness ratio is in the range of 0.63 to 0.77.

In a further aspect, the container is a container having a one quart/one liter nominal volume.

In yet an additional aspect, in a 1 Qt/1 L volume container configuration the container has a surface area of less than 107 sq. in.

In a further aspect, in a ten liter volume container configuration the container has a surface area of less than 465 sq. in.

In an additional aspect, in a twenty liter volume container configuration the container has a surface area of less than 823 sq. in.

In another aspect, the container has a weight of less than 48 grams and a top load capability of greater than 45 lbf.

In still a further aspect, the container has a weight of in the range of 40 to 42 grams and a top load capability of greater than 45 lbf.

In an additional aspect, the four side walls include two major side walls and two minor side walls, an average wall thickness ratio of the thickness of the intermediate walls to the thickness of the major sides of the container being greater than 0.

In yet another aspect, the average wall thickness ratio defines a variance of less than 23% from a uniform wall thickness ratio.

In a further aspect, the average wall thickness ratio defines a variance of less than 13% from a uniform wall thickness ratio.

In an additional aspect, the container is a container having a 2.5 gallon/10 liter nominal volume.

In another aspect, where the container is a container having a 2.5 gallon/10 liter nominal volume, a weight of less 360 grams and a top load capability of greater than 90 lbf.

In a further aspect, the container is a container having a 2.5 gallon/10 liter nominal volume, a weight of less 300 grams and a top load capability of greater than 120 lbf. Accordingly, in one aspect the invention provides

Further objects, features and advantages of the invention will become readily apparent to persons skilled in the art after review of the following description, including the claims, and with reference to the drawings that are appended to and form a part of this specification

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view of a container embodying the principles of the present invention.

FIG. 2 is a left side elevational view of the container seen in FIG. 1.

FIG. 3 is a right side elevational view of the container seen in FIG. 1.

FIG. 4 is a top plan view of the container seen in FIG. 1.

FIG. 5 is a cross-sectional view of the container seen in FIG. 1, generally taken along line 5-5 in FIG. 1.

FIG. 6 is a cross-sectional view of the container seen in FIG. 1, generally taken along line 6-6 thereof.

FIG. 7 is a graph presenting a mapping of the wall thickness of a conventional container and the container seen in FIG. 1.

FIG. 8 is a schematic representation comparing the wall thicknesses, at various locations, of a conventional 1 Qt/1 L container against those of a 1 Qt/1 L container according to the present invention.

FIG. 9 is a front elevational view of 2.5 gallon/10 liter (2.5 Gal/10 L) container embodying the principles of the present invention.

FIG. 10 is a cross-sectional view of the container seen in FIG. 9, generally taken along line 9-9 in FIG. 10.

FIG. 11 is a graph presenting a mapping of the wall thickness of a conventional 2.5 Gal/10 L container and the container seen in FIG. 9.

FIG. 12 is a schematic representation comparing the wall thicknesses, at various locations, of a conventional 2.5 Gal/10 L container against those of a 2.5 Gal/10 L container according to the present invention.

DETAILED DESCRIPTION

As used in the description that follows, directional terms such as “upper” and “lower” are used with reference to the orientation of the elements as presented in the figures. Accordingly, “upper” indicates a direction toward the top of the figure and “lower” indicates a direction toward the bottom of the figure. The terms “left” and “right” are to be similarly interpreted. The terms “inward” or “inner” and “outward” or “outer” indicate a direction that is generally toward or away from a central axis of the referred to part, whether or not such an axis is designated in the figures. An axial surface is a surface that faces in the axial direction, a direction along or parallel to the central axis. A radial surface faces radially, generally away from or toward the central axis.

Referring now to the drawings, a blow molded plastic container embodying the principles of the present invention is generally illustrated in FIG. 1 and designated at 10. The container 10 incorporates many novel structural features that provide enhanced strength and rigidity. As a result, for like-sized containers, the present container 10 can be formed from a reduced amount of plastic resin, while being able to provide a similar or greater top load capacity.

As used in the initial discussion and comparisons of the present disclosure, both the conventional containers and the present container are containers intended to hold about one quart (32 fl. oz.)/one liter of liquid and have an overflow volume of about 36.9 +/−0.5 fl. oz. the containers as sized so that the same container may be used for either quantity of liquid. For conventional containers, the weight of the container is in the range of 48 to 56 grams and the top load capability of the container is in the range of 45 to 65 lbf. Top load testing for all containers discussed herein is conducted under ASTM D2659-11.

Referring now to FIGS. 1-4, seen therein is a container 10 embodying the principles of the present invention. The container 10 includes a hollow body 12, generally located between lines A and B, that is closed on its lower end by a base 14. At the opposing end of the body 12, the upper end, a tapered transition section or shoulder 16 extends to a spout 18. The spout 18 may be threaded allowing it to receive a correspondingly threaded closure cap (not shown).

As seen in FIGS. 4 and 5, the body 12 of the container 10, when viewed from the

top or bottom or from a transverse plane, has an elongated, generally rectangular shape. The cross-sectional shape of the body 12 is generally rectangular in that it has two sets of directly opposing and generally parallel sides 20, 22 that are themselves oriented approximately ninety degrees from each other. A first set of the sides 20 of the rectangular cross-sectional shape exhibits a width/dimension (measured across the body 12 of the container 10 in a direction transverse to the longitudinal axis of the container) that is substantially greater, at least double, than the dimension of the second set of opposing sides 22. Thus, the two sets of opposing sides 20, 22 may be referred to as major sides 20 and minor sides 22. The body 12 is thus generally provided as an elongated rectangle, as opposed to being substantially square While the major and minor sides 20, 22 are described and/or shown as being parallel with respect to themselves, it will be appreciated that in practice, because of the nature of the plastic material forming the container 10, the sides 20, 22 may not be exactly parallel with themselves and may each exhibit a slightly outwardly (convex) or inwardly (concave) bowed shape.

Unlike conventional rectangular containers, which have rounded corners connecting corresponding major and minor sides, the major and minor sides 20, 22 of the present container 10 are connected by four corners 24 that are not rounded corners. Rather, each corner 24 is comprised of an intermediate side 26 disposed between two sub-corners 28. As will be appreciated from FIGS. 4 and 5, the intermediate sides 26 are generally planar. Accordingly, the body 12 of the container 10, while being generally rectangular, more specifically has an elongated octagonal shape. The eight generally planar sides of the elongated octagonal shape are thus defined by the two major sides 20, the two minor sides 22 and the four intermediate sides 26, and with each adjacent side being connected by one of the eight, slightly rounded sub-corners 28. The cross-sectional shape of the body 12 of the container 10 is therefore herein referred to as being octo-rectangular. Like the major and minor sides 20, 22, while the intermediate sides 26 are shown and/or referred to as being planar and parallel to the intermediate wall 26 of the diagonally opposing corner 24, although not directly opposing, in practice the intermediate sides 26 may exhibit a slightly bowed (convex or concave) shape.

Optionally formed within each of the intermediate walls 26 is a rib 30. The ribs 30 may extend axially along the intermediate walls 26 from adjacent the base 14, just above line B, past the upper extend of the body 12 at line A and into the transition section 16. Alternatively, the ribs 30 may extend from adjacent the base 14 substantially completely through the transition section and terminate adjacent to the spout 18. In another alternative, the ribs 30 extend from adjacent the base 14 and terminate at a location within the body 12 before the upper extent thereof at line A. In any of the above variations, the ribs may extend completely to the base 14 instead of terminating in the intermediate wall 26 adjacent to the base 14 and above line B. Viewed axially, as seen in FIG. 4, the ribs 30 are centrally located within the intermediate walls 28 and are formed as concave recesses within the intermediate walls 28. As such, the ribs 30 may be referred to as outwardly concave ribs 30. The terminal ends of the ribs 30 may take a variety shapes, including a tapered end 32 or a rounded end, the latter having a common radius of curvature both axially and transversely and the former having different radii of curvature axially and transversely.

FIG. 5 is a cross-sectional view of the container 10, generally taken along line 5-5 in FIG. 1, illustrating the container 10 without the ribs 30 discussed above. As seen in FIG. 5, the minor walls 22 and the intermediate walls 26 each define a width/dimension, designated as D in FIG. 5. Preferably, the width D of the minor walls 22 and the width D of the intermediate walls 26 are identical or substantially the same (within +/−10%).

Optionally, the major sides 20 of the body 12 may be formed with a defined label area 34. As shown the label area 34 is slightly recessed in the major side 20, laterally terminating at the sub-corners 28 and axially terminating at upper and lower shoulders 36, 38 formed in the major side 20, generally adjacent to the transition section 16 and the base 14, respectively.

The transition section 16, when viewed in transverse cross-section, as shown in FIG. 6, also has shape that may be described as an elongated, generally rectangular shape. Like the body 12, the transition section 16 has two sets of direct opposing and parallel sides that are oriented ninety degrees from each other and which may also be referred to as major or long sides 40 and minor or short sides 42, with the major sides 40 having a dimension/width (measured in the transverse direction) that is substantially greater (at least double) than the minor sides 42. Also when viewed in cross section, the major sides 40 are generally parallel with each other and the minor sides 42 are generally parallel with each other. It will be appreciated that, in practice, the sides 40, 42 may not be exactly parallel with themselves when viewed in cross-sectionally in the transverse plane and may each exhibit a slightly outwardly or inwardly bowed shape, similarly to that described above in connection with the major and minor sides 20, 22 and the intermediate walls 26 of the body 12. In the axial direction, as seen in FIGS. 1-3, the major and minor sides 40, 42 of the transition section 16 exhibit a curvature and their transverse widths decreasingly taper in the direction proceeding from the body 12 to the spout 18.

Also like the body 12, the transition section 16 does not include the round corners of existing containers, but instead is formed with corners 44 that include an intermediate wall 46 disposed between two sub-corners 48. As seen in FIG. 6, in a given transverse cross-section, the intermediate walls 46 are generally planar and, as such, the transition section 16, while being considered an elongated rectangular shape, also may be considered as having an elongated octagonal shape. The eight sides of the transition section's elongated octagonal shape are thus defined by the two major sides 40, the two minor sides 42 and the four intermediate walls 46, with the adjacent sides and walls being connected by one of the eight rounded sub-corner 48

Like the major and minor sides 40, 42, while the intermediate walls 46 are shown in the transverse cross-section as being substantially planar and parallel to the intermediate wall 46 of the diagonally opposing corner 44, in practice the intermediate walls 46 may exhibit a slightly bowed shape. Also like the major and minor sides 40, 42 of the transition section 16, in the axial direction the intermediate walls 46 of the transition section 16 are curved surfaces that decrease in width proceeding from the body 12 to the spout 18. This decreasing width is similar seen in the sub-corners 48 of the transition section. The decreasing width of the various portions of the transition section 16 are best understood by collectively considering FIGS. 1-4.

In a given transverse cross-section, such as seen in FIG. 6, the minor walls 42 and intermediate walls 46 each define a dimension/width, designated as d₁ and d₂, respectively. As will be appreciated from FIG. 6, the dimension/width d₁ of the minor walls 42 and the dimension/width d₂ of the intermediate walls 46 change as the given transverse cross-sections proceeds from body 12 to the spout 18. In each cross-section, however, the with width d₁ is smaller than the width d₂.

As noted above, the optional ribs 30 may extend from the intermediate walls 26 of the body 12 into the transition section 16, or more specifically, into the intermediate walls 46 of the transition section 16.

In forming the container 10, heated thermoplastic resin, which may be HDPE as noted above, is forced into an extrusion mechanism that operates as part of a blow molding machine. The extrusion mechanism includes a circular mandrel positioned in a circular die defining a predetermined die gap between the mandrel and the die a predetermined die angle. The resin is caused to flow about the mandrel through the die gap where it exits the extrusion mechanism and forms an extruded parison, which is in the form of a semi-molten, generally circular or oval hollow tube extending from the extrusion mechanism. By controlling the shape of the die angle and the size of the die gap with respect to the mandrel, the shape and proportions of the parison can be controlled.

With the parison in its tube-shaped form, a mold, having a mold cavity corresponding to the shape of the container 10, is closed about the parison. As the mold is closed, the shape of the parison is caused to change from a circular shape to an elliptical shape. With this change in shape, and in combination with the octagonal cross-sectional shape of the body 12 of the present container 10, the parison more closely corresponds with the shape of the container 10 and may be kept closer to the walls of the mold cavity that define the shape of the container 10. The above is representatively shown in FIG. 4 where the elliptical shape of the parison is designated by dashed line 50 and it will be appreciated that the surfaces defining the walls of the mold cavity correspond to the periphery of the container 10 shown therein.

Once the mold is closed, air is introduced into the parison, which may be through the mandrel, to inflate the parison into conformity with the shape defined by the mold cavity. Replacing the rounded corners of conventional rectangular containers with the intermediate walls 26 and the sub-corners 28 reduces the amount of stretch required of the parison to form these corner replacements. As a result, a thinner parison of less material may be used while resulting thicker and stronger walls in the corners 24 of the container 10. With the addition of the optional ribs 30, the distance may be further reduced, resulting in thicker intermediate walls 26 combined with structural enhancement that may be provided by the ribs 30. With the parison 50 more closely corresponding to the shape of the container 10, the thickness of the wall forming the body 12 and the transition section 16 is more uniform and, therefore, stronger.

An extrusion blow molding machine having three mold cavities was utilized to form containers 10 embodying the principles of the present invention. Presented in Tables 1 and 2 are results of forming and testing containers 10 incorporating the principles of the present invention. Three mold cavities were identically constructed of the shape and volume described above and with a 38 mm (outer diameter) spout 18. Two samples of containers were molded in each of the three mold cavities. The two samples employed two different amounts of thermoplastic material, 38 grams and 40 grams, in forming the containers 10. The results for the 38 gram containers 10 are presented in Table 1, and the results for the 40 gram containers 10 are presented in Table 2.

As seen in Table 1, the actual average weight for the 38 gram containers 10 was 38.1 grams with an average overflow volume of 35.7 fl. oz. The 38 gram containers 10 also exhibited an average top load capability of 45.45 lbf. and all passed a 6 ft. drop test. When compared with heavier 48 and 56 gram, 1 Qt/1 L containers of a conventional rectangular construction with four rounded corners, the 38 gram containers 10 embodying the principles of the present invention were approximately 20% to 32% lighter in weight, while still providing top load and drop test capabilities consistent with the conventional container and industry standards (a top load of 45 to 65 lbf).

TABLE 1
New 1 Qt/1 L (38 mm
neck) container	Cavity 1	Cavity 2	Cavity 3	Average
Weight (grams)	38.1	38.0	38.1	38.1
Overflow Vol. (fl. oz.)	35.9	35.9	35.9	35.9
Top Load (lbf.)	47.05	44.26	45.04	45.45
Drop Test (6 ft.)	Pass	Pass	Pass	Pass
20.6% less plastic resin than conventional 48 gram 1 Qt/1 L container
32.0% less plastic resin than conventional 56 gram 1 Qt/1 L container

As seen in Table 2, the average weight for the 40 gram containers 10 was 40.1 grams with an average overflow volume of also 35.7 fl. oz. The 40 gram containers 10 exhibited an average top load capability of 51.67 lbf. and passed a 6 ft. drop test. When compared with heavier, 48 to 56 gram, 1 Qt/1 L containers of a conventional rectangular construction with four rounded corners, the 40 gram containers 10 embodying the principles of the present invention were approximately 16% to 28% lighter in weight, while still providing top load and drop test capabilities consistent with the conventions container and industry standards (a top load of 45 to 65 lbf).

TABLE 2
New 1 Qt/1 L (38 mm
neck) Container	Cavity 1	Cavity 2	Cavity 3	Average
Weight (grams)	40.2	40.2	40.1	40.1
Overflow Vol. (fl. oz.)	35.7	35.7	35.7	35.7
Top Load (lbf.)	52.84	50.56	51.61	51.67
Drop Test (6 ft.)	Pass	Pass	Pass	Pass
16.5% less plastic resin than conventional 48 gram 1 Qt/1 L container
28.4% less plastic resin than conventional 56 gram 1 Qt/1 L container

As a result of the shape of the container 10 discussed above, a lighter weight container 10, on average about 25% lighter, can be formed with comparable top load capabilities to those of the heavier conventional containers. The present container may thus have a weight less than a conventional container at 48 grams, while still achieving a top load capability of greater than 45 lbf. As seen above, containers 10 having a weight between 40 and 41 grams exhibit a top capability significantly greater than 45 lbf. This is believed to be in part the result of the present design enabling the molding process to providing a more consistent, yet similar wall thickness about the body 12 of the container. The difference in top load capability may therefore be seen as derived from less of a variance in the wall thickness of the container 10.

Presented in the graph of FIG. 7 is a wall thickness map of the body of a conventional, existing rectangular 1 Qt/1 L container formed using 55 grams of thermoplastic resin and the body of a 1 Qt/1 L container 10 according to the principles of the present invention formed using 41 grams of thermoplastic resin, the latter using over 25% less resin to form the container 10. The lower line beginning at map position A represents the wall thickness measurements of the conventional container at various locations about the body of the container. The upper line beginning a map position A represents the wall thickness measurements of the container 10 according to the principles of the present invention. Map position measurements were taken in corresponding location on each container and are presented in thousandths of an inch.

Progressing counter clockwise about a central position on the body 12 of the container 10:

• • map position H (0.024 in.) corresponds to a central location (beneath the spout 18) on minor side 22;
  • (while not presented in FIG. 7, but seen in FIG. 8, it is noted that the adjacent intermediate wall 26, located between the minor side 22 at map position H and the next major side 20 at map position J, has a wall thickness of 0.022 in.)
  • map position I (0.019 in.) corresponds to the sub-corner 28 adjacent to the major side 20;
  • map position J (0.032 in.) corresponds to a central location on major side 20 as the container is presented in FIG. 1;
  • map position K (0.025 in.) corresponds to the sub-corner 28 adjacent to the major side 20;
  • (while not presented in FIG. 7, but seen in FIG. 8, it is noted that the adjacent intermediate wall 26, located between the major side 20 at map position J and the next minor side 22 at map position L, has a wall thickness of 0.026 in.)
  • map position L (0.027 in.) corresponds to a central location on minor side 22 opposite of the spout 18;
  • (while not presented in FIG. 7, but seen in FIG. 8, it is noted that the adjacent intermediate wall 26 located between the minor side 22 opposite of the spout 18 at map position L and the opposing major side 20 at map position N, has a wall thickness of 0.027 in.)
  • map position M (0.026 in.) corresponds to the next sub-corner 28 adjacent the opposing major side 20;
  • map position N (0.035 in.) corresponds to a central location on the opposing major side 20;
  • map position O (0.023 in.) corresponds to the sub-corner 28 that that forms the transition from the opposing major side 20 to the next intermediate wall 26, which is adjacent to minor side 22 exhibiting map position H;
  • (while not presented in FIG. 7, but seen in FIG. 8, it is noted that the remaining intermediate wall 26 located between the opposing major side 20 at map position N and the minor side 22 at map position H has a wall thickness of 0.024 in.); and
  • Map positions A-G and P-W represent similar wall thickness measurements taken in the transition section 16 and base 14, respectively, above and below lines A-A and B-B of FIG. 1.

Corresponding to the above, wall thickness measurements on the conventional 1 Qt/1 L container are:

• • map position H (0.027 in.);
  • map position I (0.022 in.), corresponding to rounded corner between positions H and J;
  • map position J (0.043 in.);
  • map position K (0.026 in.), corresponding to rounded corner between positions J and L;
  • map position L (0.029 in.);
  • map position M (0.024 in.), corresponding to rounded corner between positions L and N;
  • map position N (0.046 in.); and
  • map position O (0.022 in.), corresponding to rounded corner between positions N and H.
  • Map positions A-G and P-W represent similar wall thickness measurements taken in the transition section and base, above and below the body of the conventional container.

FIG. 8 is a schematic comparison of the wall thicknesses of a conventional 1 Qt/1 L container (55 grams) and a 1 Qt/1 L octo-rectangular container 10 (41 grams) according to the present invention, taken at a location generally corresponding to line 5-5 in FIG. 1. As demonstrated therein, using the geometry of container 10 allows for an increase in the wall thickness (0.022 to 0.027 inches; an average of 0.0248 in.) of the intermediate walls 26 of the corners 24, as compared to the wall thickness (0.022 to 0.00.26 inches; an average of 0.0235 in.) of the rounded corners of a conventional rectangular container. Simultaneously, the thicknesses of the corresponding major and minor sides 20, 22 of the present container 10 can be reduced. This wall thickness increases in the intermediate sides 26 translates into greater top load capabilities for the present container 10. It follows that the weight of the present container 10 can be reduced relative to a similarly sized conventional container while still achieving comparable top load capabilities, as was noted above.

TABLE 3
Corresponding Wall Thickness Comparison (inches)
	Existing 1 Qt/1 L
	(55 gram)		New 1 QT/1 L
	conventional		(41 gram)
	container		container
Map position H	0.027		0.024
Map position I	0.022	Intermediate wall	0.022
Map position J	0.043		0.032
Map position K	0.026	Intermediate wall	0.026
Map position L	0.029		0.027
Map position M	0.024	Intermediate wall	0.027
Map position N	0.046		0.035
Map position O	0.022	Intermediate wall	0.024

As seen from Table 3, at map position H, the 55 gram conventional container has a wall thicknesses of 0.043 in. versus 0.032 in. for the 41 gram container 10 hereof. At map position J, the wall thicknesses are 0.043 in. versus 0.032 in. At map position L, the wall thicknesses are 0.029 in. versus 0.027 in. And at map position N, the wall thicknesses are 0.046 on. versus 0.035 in. In all instances of the major and minor sides 20, 22, the wall thickness in the body of the present container 10 is less than that of the conventional container. In comparing the wall thicknesses in rounded corners (map positions I, K, M, O) of the conventional container with the intermediate walls 26 of the present container 10, it is seen that the average wall thickness is increased in the present container 10. As a result, even while reducing the amount of plastic resin used in forming comparable volume containers (by 25%), the top load capability (58 lbf) of the present container 10 is greater than the top load capability (52 lbf) of the conventional container. (See FIG. 7)

The ratio of the wall thickness of the intermediate walls 26 to the major sides 20 of the present container 12 is a measure of wall thickness uniformity, and seen as varying from 0.63 to 0.77 (1.0 being a uniformly thick wall). When compared to the ratio of the rounded corners and corresponding major sides of a conventional container, which varies from 0.51 to 0.55, it is seen that wall thickness of the present container 10 is significantly more uniform, increasing from an average uniformity of about one-half (53%) to an average uniformity of greater than two-thirds (70%).

The above wall thickness ratios, while presented for a 1 Qt/1 L container 10 having a weight of 41 grams, are similarly true for 1 Qt/1 L containers 12 of lesser and greater weight and volumes.

Referring now to FIG. 9, seen therein is a 2.5 Gal/10 L container 110, embodying the principles of the present invention. The container 110 includes a hollow body 112, generally located between lines A and B, that is closed on its lower end by a base 114. At the opposing end of the body 112, the upper end, a transition 116 extends to a spout 118 and includes a handle 119. The spout 18 may be threaded allowing it to receive a correspondingly threaded closure cap (not shown).

As seen in FIGS. 9 and 10, the body 112 of the container 110, when viewed from a transverse plane, has an elongated, generally rectangular shape. The cross-sectional shape of the body 12 includes opposing major and minor sides 120, 122, wherein the major sides 120 are substantially greater, at least double, than the dimension of the minor sides 22, similar to the 1 Qt/1 L container discussed above. While the major and minor sides 120, 122 may be described and/or shown as being parallel with respect to themselves, it will again be appreciated the sides 120, 122 may not be exactly parallel with themselves and may each exhibit a slightly outwardly (convex) or inwardly (concave) bowed shape.

The major and minor sides 120, 122 of the container 110 are connected by four corners 124, which are not rounded corners like conventional 2.5 Gal/10 L containers. Rather, each corner 124 is comprised of a generally planar, intermediate side 126 disposed between two sub-corners 128. In practice the intermediate sides 126 may exhibit a slightly bowed (convex or concave) shape. Preferably, the width D of the minor walls 122 and the width D of the intermediate walls 126 are identical or substantially the same (within +/−10%).

As seen from the above, the body 112 of the container 110 also exhibits an octo-rectangular shape having eight generally planar sides (the two major sides 120, the two minor sides 122 and the four intermediate sides 126) being connected by one of the eight, slightly rounded sub-corners 128.

Presented in FIG. 11 is a wall thickness map of the body of a conventional rectangular 2.5 Gal/10 L container formed using 361 grams of thermoplastic resin and the body of a 2.5 Gal/10 L container 110 according to the principles of the present invention formed using 280 grams of thermoplastic resin, the latter using over 22% less resin to form the container 110. The lower line of the two lines drawn initially from map position A to map position B represents the wall thickness measurements of the conventional container at various locations about the body of the container, and the upper line proceeding from map position A to map position B represents the wall thickness measurements of the container 110 according to the principles of the present invention. Map position measurements were taken in corresponding location on each container and are presented in thousandths of an inch.

Progressing counter clockwise about a central position on the body 112 of the container 110, the map positons may be defined as follows:

• • map position I (0.039 in.) corresponds to a central location (beneath the spout 118) on minor side 122;
  • map position J (0.033 in.) corresponds to a central location in the adjacent intermediate wall 126;
  • map position K (0.032 in.) corresponds to a central location on major side 120 as the container is presented in FIG. 9;
  • map position L (0.037 in.) corresponds to a central location on the next intermediate wall 126;
  • map position M (0.032 in.) corresponds to a central location on minor side 122 opposite of the spout 118;
  • map position N (0.036 in.) corresponds to a central location of the next adjacent intermediate wall 126;
  • map position O (0.034 in.) corresponds to a central location on the opposing major side 120; and
  • map position P (0.041 in.) corresponds to a central location on the next intermediate wall 126, which is adjacent to minor side 122 exhibiting map position I.

Map positions A-H and Q-X represent similar wall thickness measurements takin in the transition section 116 and base 114, respectively, slightly above and below lines A-A and B-B of FIG. 9.

Corresponding to the above, wall thickness measurements on the conventional 2.5 Gal/10 L container are:

• • map position I (0.055 in.);
  • map position J (0.045 in.);
  • map position K (0.060 in.);
  • map position L (0.049 in.);
  • map position M (0.046 in.);
  • map position N (0.042 in.);
  • map position O (0.058 in.); and
  • map position P (0.047 in.).

Map positions A-H and Q-X represent similar wall thickness measurements taken in the transition section and base, just above and below the body of the conventional container.

TABLE 4
Corresponding Wall Thickness Comparison (inches)
	Conventional
	2.5 Gal/10 L		New 2.5 Gal/10 L
	(361 gram)		(280 gram)
	container		container
Map position I	0.055		0.039
Map position J	0.045	Intermediate wall	0.033
Map position K	0.060		0.032
Map position L	0.049	Intermediate wall	0.037
Map position M	0.046		0.032
Map position N	0.042	Intermediate wall	0.036
Map position O	0.058		0.034
Map position P	0.047	Intermediate wall	0.041

As seen from the above and Table 4, the wall thicknesses of the present 2.5 Gal/10 L container 110 have been reduced in all map positions relative to a conventional 2.5 Gal/10 L container. While the reduction in thickness may have been expected because of the reduction in the thermoplastic resin used to form the container 10 (361 grams to 280 grams, a 23% reduction), unexpected is the resulting increase in top load capability, an increase from 87.7 lbf to 128.7 lbf, an increase of 47%.

The ratio of the wall thickness of the intermediate walls 126 to the major sides 120 of the present container 112, the wall thickness uniformity, and seen as varying from a maximum of 1.28 to a minimum of 0.97 (1.0 being a uniformly thick wall), an average of 1.125 and a variance of only 12.5% from uniform. When compared to the ratio of the rounded corners and corresponding major sides of a conventional container, which varies from 0.70 to 0.84, and average of 0.77 and a variance of 23% from uniform. Accordingly, the wall thickness of the present container 10 is significantly more uniform, by a factor of 1.8, almost double.

In addition to providing for a reduction in the weight of the container 10 without sacrificing top load capabilities, the configuration described herein also reduced the surface area of the container 10 (the surface of the container exclusive of the finish and threads) as compared to a conventional shaped rectangular container. Examples of surface area reductions include the following: 1 Qt/1 L containers 10 according to the disclosed configuration exhibited a 4.9 to 5.0% reduction in surface areas as compared to the surface area of a 1 Qt/1 L conventionally shaped rectangular container, 102.212 to 102.258 sq. in. versus 107.302 sq. in.; 2.5 Gal/10 L containers 10 according to the disclosed configuration exhibited a 3.9 to 4.1% reduction in surface areas as compared to the surface area of a 2.5 Gal/10 L conventionally shaped rectangular container, 446.821 to 447.616 sq. in. versus 465.192 sq. in.; and a 5 gallon/20 L container 10 according to the disclosed configuration exhibited a 4.5% reduction in surface area as compared to the surface area of a 5 gallon/20L conventionally shaped rectangular container, 788.255 sq. in. versus 823.774 sq. in.

While principally described above in connection with a 1 Qt/1 L container 10 and a 2.5 Gal/10 L container 110, the container 10 is not intended to be limited to a 1 Qt/1 L or 2.5 Gal/10 L containers. It will be readily appreciated that the disclosed containers 10, 110 are scalable and may be manufactured in volumes larger or smaller than those discussed herein, while still achieving the benefits discussed above.

The above description is meant to be illustrative of at least one preferred implementation incorporating the principles of the invention. One skilled in the art will really appreciate that the invention is susceptible to modification, variation and change without departing from the true spirit and fair scope of the invention, as defined in the claims that follow. The terminology used herein is therefore intended to be understood in the nature of words of description and not words of limitation.

Claims

1. A container for automotive or other fluids comprising: a hollow body, the hollow body having an octo-rectangular cross-sectional shape, the octo-rectangular cross-sectional shape of the hollow body is defined by the hollow body having an elongated rectangular cross-sectional shape with four side walls and four corners, each of the four corners being defined by two rounded sub-corners and an intermediate wall;a spout defining an opening into the container;a transition section located between and connecting the body to the spout; anda base closing one end of the body opposite of the spout.

2. The container according to claim 1, wherein the intermediate walls and the four side walls are substantially planar.

3. The container according to claim 1, wherein the four side walls include two major side walls and two minor side walls, when measured in transverse cross-section the major side walls having an overall width substantially greater than an overall width of the minor side walls as measured in transverse cross-section.

4. The container according to claim 1, wherein the four side walls include two major side walls and two minor side walls, when measured in transverse cross-section the major side walls having an overall width that is fifty percent greater than an overall width of the minor side walls as measured in transverse cross-section.

5. The container according to claim 1, wherein the four side walls include major side walls and minor side walls, when measured in transverse cross-section the minor side walls having an overall width that substantially the same as an overall width of the intermediate walls as measured in transverse cross-section.

6. The container according to claim 1, wherein the transition section has an octo-rectangular cross-sectional shape, the octo-rectangular cross-sectional shape of the transition section being defined as having an elongated rectangular cross-sectional shape with four side walls and four corners, each of the four corners of the transition section being defined by two rounded sub-corners and an intermediate wall.

7. The container according to claim 6, wherein the two rounded sub-corners and intermediate wall of the transition section are extensions of the two rounded sub-corners and intermediate wall of the hollow body.

8. The container according to claim 6, wherein the four side walls of the transition section include major side walls and minor side walls, the minor side walls and intermediate walls of the transition section decreasing in width as measured in transverse cross-section when proceeding from the hollow body toward the spout.

9. The container according to claim 6, wherein the four side walls of the transition section include major side walls and minor side walls, the minor side walls of the transition section having an overall width measured in transverse cross-section that is less than an overall width measured in transverse cross-section of the intermediate walls of the transition section.

10. The container according to claim 1, wherein the four side walls include two major side walls and two minor side walls, an average wall thickness ratio of the thickness of the intermediate walls to the thickness of the major sides of the container being greater than 0.63.

11. The container according to claim 1, wherein the average wall thickness ratio is in the range of 0.63 to 0.77.

12. The container according to claim 11, wherein the container is a container having a one quart/one liter nominal volume.

13. The container according to claim 1, wherein in a 1 Qt/1 L volume container configuration the container has a surface area of less than 107 sq. in.

14. The container according to claim 1, wherein in a ten liter volume container configuration the container has a surface area of less than 465 sq. in.

15. The container according to claim 1, wherein in a twenty liter volume container configuration the container has a surface area of less than 823 sq. in.

16. The container according to claim 1, where the container has a weight of less than 48 grams and a top load capacity of greater than 45 lbf.

17. The container according to claim 1, where the container has a weight of in the range of 40 to 42 grams and a top load capacity of greater than 45 lbf.

18. The container according to claim 1, wherein the four side walls include two major side walls and two minor side walls, an wall thickness ratio of greater than 0.85.

19. The container according to claim 18, wherein the average wall thickness ratio defines a variance of less than 23% from a uniform wall thickness ratio.

20. The container according to claim 18, wherein the average wall thickness ratio defines a variance of less than 13% from a uniform wall thickness ratio.

21. The container according to claim 18, wherein the container is a container having a 2.5 gallon/10 liter nominal volume.

22. The container according to claim 1, where the container is a container having a 2.5 gallon/10 liter nominal volume, a weight of less 360 grams and a top load capability of greater than 90 lbf.

24. The container according to claim 1, where the container is a container having a 2.5 gallon/10 liter nominal volume, a weight of less 300 grams and a top load capability of greater than 120 lbf.