LIGHTWEIGHT CONTAINERS WITH IMPROVED LOAD RESISTANCE

BACKGROUND

The present disclosure generally relates to containers. More specifically, the present disclosure relates to lightweight containers having improved stability as well as side- and top-load resistance.

Currently, the market comprises many different shapes and sizes of containers capable of housing fluids. The shape and size of fluid containers can depend, among other things, on the amount of fluid to be housed, the type of fluid to be housed, consumer demands and desired aesthetics. For example, lightweight containers for beverages are known in the art that are made of a semi-crystalline polyethylene terephthalate (PET) for good transparency and processability properties. Such lightweight containers are typically blow-molded using an injected preform, and can have a wall thickness, at least in the middle-height region of the container body that is less than or equal to 100 μm. These lightweight containers are, therefore, manufactured with a substantially lower amount of plastic material compared to containers of similar volume content, but made using traditional processes. Accordingly, these containers are cheaper to produce and are also particularly environment-friendly.

Examples of prior art lightweight containers include those described, for example, in International Patent Application WO 03/033361 A1 or WO 2005/04 7120 A1. These containers are known to be of generally ovoid or spherical shape, which provides for good volume/weight ratios. However, these containers also exhibit several drawbacks in that they are sometimes difficult to store and to pile in pallets for transportation. Lightweight container should be able to withstand different environmental factors encountered during manufacturing, shipping and retail shelf stocking or storage. One example of such an environmental factor includes top-loading forces. In this regard, containers may be stacked one on top of another during packaging, shipping and display. Thus, the containers should be manufactured so as to withstand the compressive forces applied by one or more filled containers placed on top of the container without buckling.

Additionally, due to the generally ovoid or spherical shape, the sides of the container body are very flexible and a risk exists that once the container is open, the contents splash out of the container when grabbed or squeezed by the consumer. Accordingly, a need exists for a fluid container having improved structural features as well as desirable aesthetic characteristics.

SUMMARY

The present disclosure relates to lightweight, stable, load-bearing containers for housing liquid products. In a general embodiment, the present disclosure provides a container having a first body portion comprising a plurality of ribs with a constant depth and a constant width. The container further includes a second body portion connected to the first body portion and having a plurality of undulating ribs, each undulating rib having a constant depth, a constant inner width, and a constant outer width, and at least one bridge member located within its corresponding rib. The container also includes a third body portion connected to the second body portion and having at least one rib having a constant depth, a constant inner width, and a constant outer width.

In an embodiment, the first body portion includes three ribs having a constant depth and a constant width, each rib includes a width of about 1 mm to about 5 mm, and a depth of about 1 mm to about 4 mm.

In an embodiment, the second body portion comprises at least three ribs having a constant depth, a constant inner width, and a constant outer width, each rib having an inner width of about 0.5 mm to about 3 mm, an outer width of about 2 mm to about 5 mm, and a depth of about 0.5 mm to about 2.5 mm.

In an embodiment, the third body portion includes one rib having a constant depth, a constant inner width, and a constant outer width, each rib having an inner width of about 1.0 mm to about 4 mm, an outer width of about 5 mm to about 15 mm, and a depth of about 0.5 mm to about 2.5 mm.

In an embodiment, the container includes at least six undulating ribs, each undulating rib comprising a peak-to-peak amplitude of about 1 mm to about 10 mm.

In an embodiment, each undulating rib completes two wave periods around a circumference of the container.

In an embodiment, the bridge members are projections having a depth that is less than a depth of corresponding rib. In an embodiment, each undulating rib has at least two bridge members and each bridge member comprises a substantially semi-circular shape that projects outward from an inner-most portion of its corresponding rib. In an embodiment, each undulating rib has at least ten bridge members evenly spaced from each other.

In an embodiment, each of the plurality of ribs of the first body portion includes at least ten bridge members evenly spaced from each other, and wherein each undulating rib of the second body portion includes at least ten bridge members evenly spaced from each other.

In an embodiment, the first connecting portion tapers from a first container diameter to a second container diameter in a downward direction over a distance from about 3 mm to about 7 mm, and with a first inward radius of curvature of about 8 mm, and with a second outward radius of curvature of about 1 mm.

In an embodiment, the second connecting portion tapers from a first container diameter to a second container diameter in an upward direction over a distance from about 0.5 mm to about 3.5 mm, and with a first inward radius of curvature of about 2 mm, and with a second outward radius of curvature of about 1 mm.

In another embodiment, a container is provided and includes a first connector portion connecting (i) a first body portion having at least one rib with a constant width and a constant depth and (ii) a second body portion having at least one undulating rib having a constant inner width, a constant outer width, and a constant depth, the first connector portion tapering downward from a first container diameter to a second container diameter over a distance from about 3 mm to about 7 mm. The container further includes a second connector portion connecting (i) the second body portion and (ii) a third body portion having at least one rib with a constant inner width, a constant outer width and a constant depth, the second connector portion tapering upward from a first container diameter to a second container diameter over a distance from about 0.5 mm to about 3.5 mm.

In an embodiment, a tangential line intersecting a bottom inner width and a bottom outer width of the undulating rib and a tangential line intersecting an upper inner width and an upper outer width of the undulating rib form an angle θ therebetween. In an embodiment, the angle θ is from about 25° to about 75°.

In an embodiment, a tangential line intersecting a bottom inner width and a bottom outer width of the at least one base rib and a tangential line intersecting an upper inner width and an upper outer width of the at least one base rib form an angle θ therebetween. In an embodiment, the angle θ is from about 45° to about 135°.

In an embodiment, the first connector portion comprises a first inward radius of curvature of about 8 mm, and a second outward radius of curvature of about 1 mm. The second connector portion includes a first inward radius of curvature of about 2 mm, and a second outward radius of curvature of about 1 mm.

In still another embodiment, a container is provided and includes an internal volume of about 500 mL, an empty weight that is less than 10.0 g, and a characteristic selected from the group consisting of over-splashing between 17.0 and 18.0 mm with a force between 1.0 and 1.5 kg; a prehension sinking between 2.5 mm and 4.0 mm, a level after breaking between 21.0 and 23.0, or combinations thereof.

In yet another embodiment, a container is provided comprising a neck; a shoulder connected to the neck; a label portion connected to the shoulder, the label portion comprising at least two ribs having a constant width and a constant depth; a prehension portion connected to the label portion via a first connecting portion, the prehension portion comprising at least five undulating ribs, each undulating rib comprising a plurality of bridge members; and a base portion connected to the prehension portion via a second connecting portion, the base portion comprising at least one rib having a constant width and a constant depth.

An advantage of the present disclosure is to provide an improved, lightweight container.

Another advantage of the present disclosure is to provide a container having improved stability.

Yet another advantage of the present disclosure is to provide a container with improved side- and top-load resistance properties.

Still another advantage of the present disclosure is to provide a container having connector portions that help to improve load-resistance.

Another advantage of the present disclosure is to provide a container having a plurality of ribs having varying depths and radii of curvature that aid in improving load-resistance of the container.

Yet another advantage of the present disclosure is to provide a container that is so constructed and arranged for ease of handling by a consumer.

Additional features and advantages are described herein, and will be apparent from the following Detailed Description and the Figures.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a front plan view of a prior art container.

FIG. 2A is a front plan view of a container in an embodiment of the present disclosure.

FIG. 2B is a side plan view of a container in an embodiment of the present disclosure.

FIG. 3A is an enlarged, partial view of the container of FIG. 2A in an embodiment of the present disclosure.

FIG. 3B is an enlarged, partial view of the container of FIG. 2B in an embodiment of the present disclosure.

FIG. 4A is an enlarged, partial view of the container of FIG. 2A in an embodiment of the present disclosure.

FIG. 4B is an enlarged, partial view of the container of FIG. 2B in an embodiment of the present disclosure.

FIG. 5 is a cross-sectional view of the container of FIG. 2A in an embodiment of the present disclosure.

FIG. 6 is an enlarged, partial view of the container of FIG. 5 in an embodiment of the present disclosure.

FIG. 7 is an enlarged, partial view of the container of FIG. 5 in an embodiment of the present disclosure.

FIG. 8 is an enlarged, partial view of the container of FIG. 5 in an embodiment of the present disclosure.

FIG. 9 is an enlarged, partial view of the container of FIG. 5 in an embodiment of the present disclosure.

FIG. 10 is an enlarged, partial view of the container of FIG. 5 in an embodiment of the present disclosure.

FIG. 11 is a cross-sectional view of the container of FIG. 2A in an embodiment of the present disclosure.

FIG. 12 is a front plan view of a container in an embodiment of the present disclosure.

FIG. 13 is a side plan view of a container in an embodiment of the present disclosure.

FIG. 14 is a front plan view of a container in an embodiment of the present disclosure.

FIG. 15 is a side plan view of a container in an embodiment of the present disclosure.

FIG. 16 is a cross-sectional view of a preform for a container in an embodiment of the present disclosure.

FIG. 17 is a graphical representation of the results obtained from an experiment performed with a container of the present disclosure and two prior art containers.

DETAILED DESCRIPTION

The present disclosure relates to lightweight, stable, load-bearing containers for providing consumable products and, in particular, fluids. The containers are constructed and arranged to be stable and load-bearing to provide a container having not only improved structural features, but also desirable aesthetics.

As described above, lightweight containers for housing liquids are known to have problems transmitting vertical loads efficiently. Specifically, during packaging, distribution and retail stocking, containers or bottles can be exposed to large amounts of top-loading and can buckle at any existing points of weakness on the container. Indeed, top-loading, as well as side-loading, can be especially problematic for lightweight containers.

Additionally, due to the generally ovoid or spherical shape of known containers, the sides of the container body are very flexible and a risk exists that once the container is open, the contents splash out of the container when grabbed or squeezed by the consumer.

Further, during packaging, distribution, and retail stocking, containers can be exposed to widely varying temperature and pressure changes, as well as external forces that jostle and shake the container. These types of environmental factors can contribute to rises in internal pressure that affect the overall quality of the product purchased by the consumer.

A prior art container 10 is illustrated by FIG. 1. Container 10 includes ribs that traverse a circumference of the bottle and may be used to provide added hoop strength, rigidity and resistance to bending, leaning, crumbling and/or stretching. Container 10 also includes a neck portion 12, a shoulder portion 14, a label portion 16, a grip portion 18 and a base 20. Label portion 16 includes several ribs 22 that traverse a circumference of the container and have constant width and depth. Grip portion 18 includes two ribs 24 of constant width and depth, as well as one rib 26 having a first curvature, one rib 28 having a second curvature that is greater than the first curvature, and one rib 30 having a third curvature that is greater than the second curvature. Grip portion 18 is also substantially V-shaped along a side wall of container 10 that is parallel to a vertical axis of container 10, with rib 30 being the vertex of the V-shape. Container 10 further includes an integrally formed shape 32 on an upper, transition portion of the grip portion 18, as well as integrally formed shapes 34 oriented substantially vertically on shoulder portion 14. Although container 10 includes ribs, container 10 may not necessarily be configured to deliver optimized stability or optimized side- and top-load resistance for a lightweight container.

In contrast, Applicants have surprisingly found that the configuration of the containers disclosed herein provides improved stability, improved side-load resistance, and improved top-load resistance. In this regard, Applicants have surprisingly found that the specifically disclosed geometry of the container's ribs in combination with its specifically configured transition or connecting portions provides improved stability and load resistance for lightweight containers.

As shown in FIG. 2A, container 40 of the present disclosure includes a mouth 41, a neck portion 42, a shoulder portion 44, a label portion 46, a grip portion 48 and a base portion 50, all of which combine to form an interior of container 40 that is capable of housing a liquid. As is further shown by FIG. 2A, a vertical cross-section of container identified by line V-V is illustrated in FIG. 5, which will be discussed further below with respect to its various sectional views provided by FIGS. 6-10.

Containers of the present disclosure may be configured to house any type of liquid therein. In an embodiment, the containers are configured to house a consumable liquid such as, for example, water, an energy drink, a carbonated drink, tea, coffee, milk, juice, etc. In an embodiment, the containers are configured to house water. Containers 40 may hold any suitable volume of a liquid such as, for example, from about 50 to 5000 mL including 100 mL, 200 mL, 300 mL, 400 mL, 500 mL, 600 mL, 700 mL, 800 mL, 900 mL, 1000 mL, 1500 mL, 2000 mL, 2500 mL, 3000 mL, 3500 mL, 4000 mL, 4500 mL and the like. In an embodiment, containers 40 are configured to hold about 500 mL of a liquid.

Suitable materials for manufacturing containers of the present disclosure can include, for example, polymeric materials. Specifically, materials for manufacturing bottles of the present disclosure can include, but are not limited to, polyethylene (“PE”), low density polyethylene (“LDPE”), high density polyethylene (“HDPE”), polypropylene (“PP”) or polyethylene terephthalate (“PET”). In an embodiment, the containers are lightweight containers manufactured from PET, which has viscoelastic properties of creep and relaxation. Further, the containers of the present disclosure can be manufactured using any suitable manufacturing process such as, for example, conventional extrusion blow molding, stretch blow molding, injection stretch blow molding, and the like.

Mouth 41 may be any size and shape known in the art so long as liquid may be introduced into container 40 and may be poured or otherwise removed from container 40. In an embodiment, mouth 41 may be substantially circular in shape and have a diameter ranging from about 10 mm to about 50 mm, or about 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, or the like. In an embodiment, mouth 41 has a diameter that is about 25 mm.

Neck portion 42 may also have any size and shape known in the art so long as liquid may be introduced into container 40 and may be poured or otherwise removed from container 40. In an embodiment, neck portion 42 is substantially cylindrical in shape having a diameter that corresponds to a diameter of mouth 41. The skilled artisan will appreciate that the shape and size of neck portion 42 are not limited to the shape and size of mouth 41. Neck portion 42 may have a height (from mouth 41 to shoulder portion 44) from about 5 mm to about 45 mm, or about 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, or the like. In an embodiment, neck portion 42 has a height of about 15 mm.

Container 40 can further include an air tight cap 43 attached to neck portion 42, as shown in FIG. 2B. Cap 43 can be any type of cap known in the art for use with containers similar to those described herein. Cap 43 may be manufactured from the same or a different type of polymeric material as container 40, and may be attached to container 40 by re-closeable threads, or may be snap-fit, friction-fit, etc. Accordingly, in an embodiment, cap 43 includes internal threads (not shown) that are constructed and arranged to mate with external threads 45 of neck portion 42.

Shoulder portion 44 of container 40 extends from a bottom of neck portion 42 downward to a top of label portion 46. Shoulder portion 44 comprises a shape that is substantially a conical frustum. As used herein, a “conical frustum” means that shoulder portion 44 has a shape that very closely resembles a cone having a top portion (e.g., the apex) of the cone lopped-off. Shoulder portion 44 has a lopped-off apex since shoulder portion 44 tapers into neck portion 42 for functionality of container 40. Further, the “conical frustum” shape also includes a rounded edge 47 wherein shoulder portion 44 curves downward in a substantially vertical orientation to meet label portion 46.

Shoulder portion 44 may have a height (from a bottom of neck portion 42 to a top of label portion 46) ranging from about 15 mm to about 50 mm, or about 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, or the like. In an embodiment, shoulder portion 44 has a height that is about 43 mm. At a bottom portion (e.g., before label portion 46), shoulder portion 44 may have a diameter ranging from about 40 mm to about 80 mm, or about 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, or the like. In an embodiment, the diameter of a bottom, widest portion of shoulder portion 44 is about 66 mm.

Label portion 46 of container 40 includes a plurality of ribs 52 having a constant width (W) and depth (D), as shown more clearly in FIG. 6. In this regard, ribs 52 have a constant width because the ribs do not increase or decrease in width as the ribs traverse the circumference of container 40. Ribs 52 have a constant depth because the ribs do not change the distance between an inner most portion of the rib and an adjacent portion of an outer wall of container 40 as the ribs traverse the circumference of container 40. In general, ribs 52 are curved ribs that provide a spring effect allowing for increase of pressure within the container, which is typical, for example, during storage and transport of lightweight, liquid-filled containers.

Container 40 may include any number of straight and/or constant ribs 52 having any size that provides improved stability and load resistance. Container 40 may include 1, 2, 3, 4, 5, 6, 7, 8, 9 or 10 ribs 52. In an embodiment, container 40 includes a plurality of ribs 52. In another embodiment, container 40 includes 2-5 ribs 52, or 3-4 ribs 52, or 3 ribs 52. Ribs 52 may have a width from about 1 to about 5 mm, for from about 2 to about 4 mm, or about 3 mm. In an embodiment, ribs 52 have a width that is about 3 mm. Ribs 52 may also have a depth that is from about 1 mm to about 4 mm, or from about 2 to about 3 mm. In an embodiment, ribs 52 have a depth that is about 1.5 mm.

At a widest point of ribs 52, container 40 may have a diameter ranging from about 40 mm to about 80 mm, or about 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, or the like. In an embodiment, the diameter of container 40 at the widest portion of rib 52 is about 65 mm.

Additionally, ribs 52 may have a first radius of curvature, or a bend radius, where a substantially vertical side wall of container 40 curves inward to form rib 52. This radius of curvature is indicated by the arrow in combination with (R₁), and is also present where a bottom portion of rib 52 curves to meet the substantially vertical side wall of container 40 located below rib 52. Ribs 52 may also include a second radius of curvature at a depth (D) of rib 52. This second radius of curvature is indicated by the arrow in combination with the (R₂) indicator. In an embodiment, the radii of curvature (R₁, R₂) of ribs 52 are the same and are 3 mm.

Grip portion 48 of container 40 also includes a plurality of ribs 54, which are different than the straight and/or constant width/depth ribs 52 of label portion 46. Instead, ribs 54 of grip portion 48, while possibly having a constant width and depth, undulate or swirl around container 40 as they traverse its circumference. Ribs 54 provide the container with reinforced side-load resistance (i.e., lateral resistance of the container) in part due to the number of ribs, and in part due to the trapezoidal geometry of the ribs. The specific wave shape arrangement of the ribs also helps top-load resistance in comparison to ribs 52.

As used herein, “undulating” ribs or the “undulation” of ribs means that the ribs move in a wavy, sinuous, curved, or rising and falling manner as the ribs oscillate and traverse a circumference of the present containers. Accordingly, the presently disclosed undulating ribs may be described in terms of a wave. In this regard, undulating ribs may have, for example, a peak-to-peak amplitude (e.g., as measured from crest to adjacent trough) and a wave period (e.g., as measured from crest to crest or from trough to trough). In an embodiment, undulating ribs may have a peak-to-peak amplitude from about 1 mm to about 10 mm, or 2 mm, or 3 mm, or 4 mm, or 5 mm, or 6 mm, or 7 mm, or 8 mm, or 9 mm. In an embodiment, undulating ribs have a peak-to-peak amplitude of about 7 mm. In an embodiment, undulating ribs complete one to three wave periods as undulating ribs traverse a circumference of the container. In an embodiment, undulating ribs complete two wave periods as undulating ribs traverse a circumference of the container.

As used herein, “grip portion” may be used interchangeably with “prehension portion.” As used herein, “prehension” means the act of taking hold, seizing or grasping. Accordingly, a prehension portion, or grip portion, of the container may be a portion of the container intended for seizing or grasping by the consumer during handling of the container.

As shown in greater detail in FIG. 8, ribs 54 may include a constant inner width (W_I) and a constant outer width (W_O) that is greater than inner width (W_I). Inner width (W_I) may range from about 0.5 mm to about 3 mm, or about 1 mm to about 2.5 mm, or about 1.5 mm to about 2 mm. In an embodiment, inner width (W_I) is about 2 mm. Outer width (W_O) may range from about 2 mm to about 5 mm, or from about 3 mm to about 4 mm. In an embodiment, outer width (W_O) is about 3.5 mm. In anther embodiment, outer width (W_O) is about 3.6 mm. An upper portion of inner width (W_I) and an upper portion of outer width (W_O) may be connected via a theoretical first line. Similarly, a lower portion of inner width (W_I) and a lower portion of outer width (W_O) may be connected via a theoretical second line. Because inner width (W_I) is smaller than outer width (W_O), the theoretical first and second lines form an angle θ therebetween. Angle θ may be from about 25° to about 75°, or from about 30° to about 70°, or from about 35° to about 65°, or from about 40° to about 60°, or from about 45° to about 55°, or about 50°, as shown by FIG. 8. In an embodiment, angle θ is about 50°.

Ribs 54 may have a depth (D) from about 0.5 mm to about 2.5 mm, or about 1.0 mm to about 2.0 mm, or about 1.5 mm, or about 1.7 mm.

Additionally, ribs 54 may have a first radius of curvature, or a bend radius, where a substantially vertical side wall of container 40 curves inward to form rib 54. This radius of curvature is indicated by the arrow in combination with (R₃), and is also present where a bottom portion of rib 54 curves to meet the substantially vertical side wall of container 40 located below rib 54. In an embodiment, radius of curvature R₃is about 1 mm. Ribs 54 may also include a second radius of curvature at a depth (D) of rib 54 where inwardly curved radius R₃meets a substantially vertical inner portion of rib 54. The second radius of curvature is also present where the substantially vertical inner portion of rib 54 curves outward toward radius R₃located at a bottom of rib 54. This second radius of curvature is indicated by the arrow in combination with (R₄). In an embodiment, radius of curvature R₄is about 1 mm.

A bottom portion of container 40 comprises base portion 50, which may be of any suitable design, including those known in the art and as illustrated. Importantly, however, base portion 50 of the present containers includes a base rib 56, which is an opened trapezoidal rib that helps to ensure good rigidifying structure of the container. Although the present disclosure depicts base portion 50 as having one rib 56, the skilled artisan will appreciate that base portion 50 may include more or less than one rib 56 so long as the container is able to provide the desired stability and improved side- and top-load resistance.

As shown in more detail in FIG. 10, and similar to swirling ribs 54, rib 56 may include a constant inner width (W_I) and a constant outer width (W_O) that is greater than inner width (W_I). Inner width (W_I) may be from about 1 mm to about 4 mm, or about 1.5 mm to about 3.5 mm, or about 2 mm to about 3 mm. In an embodiment, inner width (W_I) is about 2.5 mm. In another embodiment, inner width (W_I) is about 2.6 mm. Outer width (W_O) maybe from about 5 mm to about 15 mm, or from about 6 mm to about 14 mm, or from about 7 mm to about 13 mm, or from about 8 mm to about 12 mm, or from about 9 mm to about 11 mm, or about 10 mm. In an embodiment, outer width (W_O) is about 9 mm. In another embodiment, outer width (W_O) is about 9.5 mm. An upper portion of inner width (W_I) and an upper portion of outer width (W_O) may be connected via a theoretical first line. Similarly, a lower portion of inner width (W_I) and a lower portion of outer width (W_O) may be connected via a theoretical second line. Because inner width (W_I) is smaller than outer width (W_O), the theoretical first and second lines form an angle θ therebetween. Angle θ may be from about 45° to about 135°, or from about 55° to about 125°, or from about 65° to about 115°, or from about 75° to about 105°, or from about 85° to about 95°, or about 90°.

Rib 56 may have a depth (D) from about 0.5 mm to about 2.5 mm, or about 1.0 mm to about 2.0 mm, or about 1.5 mm, or about 1.7 mm.

Additionally, rib 56 may have a first radius of curvature, or a bend radius, where a substantially vertical side wall of container 40 curves inward to form rib 56. This radius of curvature is indicated by the arrow in combination with (R₅). This radius of curvature is also present where a bottom portion of rib 56 curves to meet the substantially vertical side wall of container 40 located below rib 56. In an embodiment, radius of curvature R₅is about 2.5 mm. Rib 56 may also include a second radius of curvature at a depth (D) of rib 56 where inwardly curved radius R₅meets a substantially vertical inner portion of rib 56, which is also present where the substantially vertical inner portion of rib 56 curves outward toward radius R₅located at a bottom of rib 56. This second radius of curvature is indicated by the arrow in combination with (R₆). In an embodiment, radius of curvature R₆is about 1 mm.

FIG. 2B illustrates a side view of container 40 of the present disclosure. As can be seen from the figure, the difference between the side (FIG. 2B) and front (FIG. 2A) views of container 40 lies in grip portion 48 of the container. In this regard, and due to the undulating or swirling nature of ribs 54, side view of container 40 illustrates that an upper portion of grip portion 48 includes truncated rib 58 that is unable to traverse an entire circumference of container 40 due to the undulation of rib 54 located immediately below rib 58. Further, the bottom-most rib 54 of grip portion 48 is interrupted by an undulating or swirling lip, that forms a transition or connecting portion 60 between base portion 50 and grip portion 48, as will be discussed further below.

FIG. 3A is an enlarged view of portion 3A-3A of FIG. 2A. As seen in the figure, label portion 46 includes a bottom-most rib 52 that is adjacent to a first substantially vertical portion 62 of container 40. First vertical portion 62 is immediately adjacent to a second substantially vertical portion 64 that has a slightly larger diameter than first vertical portion 62. As such, first vertical portion 62 tapers slightly outward at the bottom to meet the larger diameter vertical portion 64. At the bottom of vertical portion 64, label portion 46 includes a transition or connecting section 66 that connects label portion 46 to grip portion 48. As discussed previously, Applicants believe that the advantages and benefits derived from the presently disclosed containers is due, at least in part, to the combination of the specific geometries of the different ribs of the container with the specific geometry of connecting portion 66. Indeed, Applicants believe that his combination of structural features aids in improvement of stability and load resistance of the containers of the present disclosure when compared to known prior art containers.

As is better illustrated in FIG. 7, connecting portion 66 has a container diameter that is greater than a diameter of grip portion 48. The diameter of connecting portion 66, however, tapers from its largest container diameter at a top of connecting portion 66, which is approximately the same as the diameter of vertical portion 64, to meet the smaller container diameter of grip portion 48 at a bottom of connecting portion 66. This taper may be quantified in terms of a distance, or height (e.g., a linear measurement) and a radius of curvature. For example, connecting portion 66 requires a certain distance or height, when measured along a substantially vertical plane that runs parallel to a vertical axis of container 40, to complete its taper. In this regard, the “h” indicator of FIG. 7 quantifies the measurement from where connecting portion 66 has a substantially vertical orientation and a diameter that is substantially the same as vertical portion 64, to completion of its taper at a diameter approximately the same as grip portion 46. This distance, or height or may anywhere from about 3 mm to about 7 mm, or from about 4 mm to about 6 mm, or about 5 mm.

The diameter of container 40 at the widest portion of connecting portion 66 may range from about 40 mm to about 80 mm, or about 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, or the like. In an embodiment, the diameter of container 40 at the widest portion of connecting portion 66 is about 66 mm.

Connecting portion 66 also includes a depth (D) as shown by FIG. 7 that extends from a substantially vertical side wall of container 40 horizontally outward to the widest portion of connecting portion 66. The depth of connecting portion 66 may be from about 0.5 mm to about 3 mm, or from about 1.0 mm to about 2.5 mm, or from about 1.5 mm to about 2.0 mm. In an embodiment, the depth of connecting portion 66 is about 1.5 mm. In another embodiment, the depth of connecting portion 66 is about 2.0 mm.

Connecting portion 66 may also include at least one radius of curvature to define its taper toward grip portion 48. In an embodiment, connecting portion 66 includes two radii of curvature. A first radius of curvature defines its taper from a substantially vertical orientation inward toward grip portion 48 such that the inward curve is convex with respect to an exterior of container 40. This radius of curvature is indicated in FIG. 7 by the arrow and (R₇). In an embodiment, radius of curvature R₇is about 8 mm. In FIG. 7, connecting portion 66 also includes a second radius of curvature to define a slight concave curve joining the convex curve to a substantially vertical side wall of grip portion 48. This radius of curvature is indicated by the arrow and (R₈). In an embodiment, radius of curvature R₈is about 1 mm.

As is also shown by FIG. 3A, grip portion 48 includes a number of bridge members 68 or semi-circle-shaped projections in ribs 54 from an exterior of container 40. Bridge members 68 will be discussed further below. In general, however, bridge members 68 serve as reinforcing pins and are material local elements forming a link between two mechanical elements (vertically-adjacent ribs, for example) having strengthening function. Bridge members 68 serve to compensate for the spring effect obtained with ribs 54, and increase mechanical resistance of ribs 54 in connection with top loading. In this regard, it is important to keep top-loading capabilities as high as possible due to the fact that the lightweight containers of the present disclosure are typically assembled in packs and are palletized for storage and delivery.

FIG. 3B is an enlarged view of portion 3B-3B of FIG. 2B. As previously discussed, the difference between the side (FIG. 2B) and front (FIG. 2A) views of container 40 lies in grip portion 48. In this regard, and due to the undulating or swirling nature of ribs 54, a side view of container 40 illustrates that an upper portion of grip portion 48 includes truncated rib 58 that is unable to traverse an entire circumference of container 40 due to the undulation of rib 54 located immediately below rib 58. In this regard, undulating rib 54 located immediately below rib 58 undulates in an upward direction on either side of truncated rib 58 at approximately 90° from truncated rib 58 so that it nearly reaches connecting portion 66. In this manner, rib 54 limits the circumferential traverse of rib 58 around container 40. Although rib 58 does not completely traverse the circumference of container 40, rib 58 still aids in providing additional stability and load resistance to the presently disclosed containers.

FIG. 4A is an enlarged view of portion 4A-4A of FIG. 2A. As previously discussed, bottom-most rib 54 of grip portion 48 is interrupted by an undulating or swirling lip, that forms a transition or connecting portion 60 between base portion 50 and grip portion 48. As shown by FIG. 4A, a bottom-most rib 54 undulates in an upward manner on a front (and correspondingly, a back) of container 40 so as to avoid contact with an upwardly undulating portion of connecting portion 60.

As is more clearly illustrated in FIG. 9, connecting portion 60 has a diameter that is greater than a diameter of grip portion 48. The diameter of connecting portion 60, however, tapers from its largest diameter at a bottom of connecting portion 60, which is approximately the same as the diameter of a top portion of base portion 50, to meet the smaller diameter of grip portion 48 at a top of connecting portion 60. This taper may be quantified in terms of a distance or height (e.g., a linear measurement) and a radius of curvature. For example, connecting portion 60 requires a certain distance or height, when measured along a substantially vertical plane that runs parallel to a vertical axis of container 40, to complete its taper. In this regard, the “h” indicator of FIG. 9 quantifies the measurement from where connecting portion 60 has a substantially vertical orientation and a container diameter that is substantially the same as (or slightly less than) a top portion of base portion 50, to completion of its taper at a container diameter approximately the same as grip portion 46. This distance, or height or may anywhere from about 0.5 mm to about 3.5 mm, or from about 1 mm to about 2.5 mm, or from about 1.5 mm to about 2.5 mm, or about 2 mm.

Connecting portion 60 may have a depth (D) as shown in FIG. 9 that is from about 0.2 mm to about 1.2 mm, or about 0.3 mm to about 1.1 mm, or about 0.4 mm to about 1.0 mm, or about 0.5 mm to about 0.9 mm, or about 0.6 mm to about 0.8 mm. In an embodiment, connecting portion 60 has a depth of about 0.7 mm. In another embodiment, connecting portion 60 has a depth of about 0.8 mm.

The diameter of container 40 at the widest portion of base portion 50 may range from about 40 mm to about 80 mm, or about 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, or the like. In an embodiment, the diameter of container 40 at the widest portion of base portion 50 is about 66 mm.

Connecting portion 60 may also include at least one radius of curvature to define its upward taper toward grip portion 48. In an embodiment, connecting portion 60 includes two radii of curvature. A first radius of curvature defines the upward taper of connecting portion 60 from a substantially vertical orientation inward toward grip portion 48 such that the curve is convex with respect to an exterior of container 40. This radius of curvature is indicated in FIG. 9 by the arrow and (R₉). In an embodiment, radius of curvature R₉is about 2 mm. In FIG. 9, connecting portion 60 also includes a second radius of curvature to define a slight concave curve joining the convex curve to a substantially vertical side wall of grip portion 48. This radius of curvature is indicated by the arrow and (R₁₀). In an embodiment, radius of curvature R₁₀is about 1 mm.

FIG. 4B further illustrates that connecting portion 60 undulates in much the same manner as ribs 54. In this regard, connecting portion 60 includes a substantially horizontal bottom portion that is substantially parallel to a bottom surface of container 40. A top portion of connecting portion 60, however, undulates as connecting portion 60 traverses a circumference of container 40. As with ribs 54, connecting portion 60 may complete one to three wave periods as connecting portion 60 traverses a circumference of container. In an embodiment, connecting portion 60 completes two wave periods as it traverses the circumference.

Additionally, as shown by FIG. 4A, bottom-most rib 54 undulates upwardly at a front (and correspondingly, a back) of container 40 such that bottom-most rib 54 does not contact top-most undulating portions 70 of connecting portion 60. This is in direct contrast to FIG. 4B, which is an enlarged view of portion 4B-4B of FIG. 2B, which depicts a side view of container 40. In FIG. 4B, bottom-most rib 54 undulates downwardly at a side of container 40 such that bottom-most rib 54 is intersected by top-most undulating portions 70 of connecting portion 60.

A cross-sectional view of grip portion 48 of FIG. 2A is provided in FIG. 11, which will aid in further describing bridge members 68. As mentioned above, grip portion 48 includes a number of bridge members 68 that are projections in ribs 54 extending toward an exterior of container 40. In an embodiment, bridge members 68 are semi-circular in shape when viewed from a cross-section, but the skilled artisan will appreciate that bridge members 68 need not be limited to such shape. In this regard, bridge members 68 may also have a square, rectangular, oval, triangular, or any other shape known in the art, so long as bridge members 68 are capable of providing the desired reinforcement. In this regard, bridge members 68 serve as reinforcing pins and are material local elements forming a link between two mechanical elements (vertically-adjacent ribs, for example) having strengthening function. Bridge members 68 serve to compensate for the spring effect obtained with ribs 54, and increase mechanical resistance of ribs 54 in connection with top loading. In this regard, it is important to keep top-loading capabilities as high as possible due to the fact that the lightweight containers of the present disclosure are typically assembled in packs and are palletized for storage and delivery.

More specifically, and as shown in FIG. 11, each bridge member 68 includes a semi-circular projection 72 in a slightly flattened wall portion 74 of container 40. As the skilled artisan would appreciate, bridge members 68 serve to compensate for the spring effect obtained with ribs 54, and increase mechanical resistance of ribs 54 in connection with top loading. It is believed that this may be due, at least in part, to the connecting function that bridge members 68 provide between vertically-adjacent ribs 54. In this regard, bridge members 68 can help to transfer top-loading from one rib 54 to the next lowest rib 54 to more efficiently distribute the top-loading.

As with the different types of ribs discussed herein above, semi-circular projection 72 may have a depth (D) and a radius of curvature as depicted by FIG. 11. For example, semi-circular projection 72 may have a depth from about 0.25 mm to about 2.75 mm, or from about 0.5 mm to about 2.5 mm, or from about 0.75 mm to about 2.25 mm, or from about 1.0 mm to about 2.0 mm, or from about 1.25 mm to about 1.75 mm, or about 1.5 mm. In an embodiment, semi-circular projection 72 has a depth of about 1.6 mm.

Further, semi-circular projection 72 has a radius of curvature as the slightly flattened wall portion 74 curves outward to form the semi-circular projection 72. This radius of curvature is indicated in FIG. 11 by the arrow and (R₁₁). In an embodiment, radius of curvature R₁₁is about 1.6 mm.

As is also illustrated by FIG. 11, and in an embodiment, slightly flattened wall portion 74 of the container's wall may be oriented at 90° from each other. For example, the cross-sectional view provided by FIG. 11 indicates that the bridge member 68 intersected by cross-sectional line XI-XI on the front of container 40 corresponds to a second bridge member 68 located on the back of container 40, both of which are located about 180° from each other on an upwardly undulating portion of rib 54. Similarly, FIG. 2A also illustrates that the same rib 54 that is intersected by the cross-sectional line XI-XI includes bridge members 68 located on both sides of container 40 at 90° from the front and back bridge members 68.

The widest diameter of container 40 at the cross-sectional line XI-XI of FIG. 2A may range from about 30 mm to about 80 mm, or about 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, or the like. In an embodiment, the widest diameter of container 40 at the cross-sectional line XI-XI is about 59 mm.

Further, FIG. 2A also illustrates that location of bridge members 68 container 40 may alternate with adjacent rib members 54. In this regard, top-most rib 54 includes bridge member 68 located in a vertical plane that intersects the center of a front of container 40. The second rib 54 away from label portion 46 includes two bridge members 68, each located in a separate vertical plane and each separate vertical plane is offset 45° in opposite directions from the vertical plane containing bridge member 68 of top-most rib 54. The third rib 54 away from label portion 46 includes a bridge member 68 located in the same vertical plane as the first bridge member 68, and so on.

The skilled artisan will appreciate that the embodiment depicted in FIGS. 2A and 2B includes four bridge members 68 per undulating rib 54. The skilled artisan will also appreciate, however, that the containers of the present disclosure need not be limited to this particular configuration of bridge members 68, and more or less bridge members 68 may be included on each undulating rib 54.

For example, FIGS. 12-13 illustrate a second embodiment of the present disclosure where each rib 54 includes more than four bridge members 68 evenly spaced from each other along rib 54. Specifically, FIGS. 12-13 illustrate an embodiment wherein each rib 54 includes twelve bridge members 68 evenly spaced form each other along rib 54. Accordingly, the skilled artisan will appreciate that each rib 54 may include any number of bridge members 68 (e.g., 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15) so long as the number of bridge members 68 is able to provide the desired improved stability and side- and top-load resistance. The skilled artisan will also appreciate that bridge members 68 need not be evenly spaced from each other along rib 54, so long as the spacing of bridge members 68 is able to provide the desired improved stability and side- and top-load resistance.

FIGS. 14-15 illustrate a third embodiment of the present disclosure where each straight and/or constant width rib 52 also includes bridge members 68. Ribs 52 may include the bridge member 68 orientation described with respect to ribs 54 of FIGS. 2A and 2B, or a configuration described with respect to FIGS. 12-13, or any other configuration that is able to provide the desired improved stability and side- and top-load resistance. Similarly, ribs 52 may have the same or a different number of, or the same or a different configuration of bridge members 68 when compared to ribs 54 of a same container.

FIG. 16 shows an example preform 76 that may be used to manufacture a lightweight container of the present disclosure. Preform 76 includes a thin wall neck 12 that can help, for example, to efficiently blow-mold lightweight containers, protect critical dimensions of the bottle, stabilize the blow-molding process, and utilize less resin during manufacturing.

The foregoing may be better understood by reference to the following Example(s), which are presented for purposes of illustration and are not intended to limit the scope of the present disclosure.

EXAMPLES

To demonstrate improved stability and side- and top-load resistance, Applicants performed several experiments using the prior art containers of FIG. 1 and containers according to the present disclosure, both of which were tested while filled with liquid at 10.9 g, 9.9 g and 9.0 g container weights (i.e., each empty container weighed either 10.9 g, 9.9 g, or 9.0 g). The volume of the containers was 500 mL.

Initially, Applicants calculated a minimum top-load requirement for the heaviest, filled containers of the present disclosure at break as being 27.6 kg force. This calculation was performed in consideration of palletization of a plurality of containers for shipment and/or storage and included the following input information: product (liquid) weight, container material weight, closure weight, weight per container per filled, containers per case, cases per layer, layers per pallet, pallet weight, number of pallets high, and safety factor. The calculation further included the following output information: total weight of product and containers per pallet, weight of wooden pallet's above first pallet, weight per case, weight of one layer of filled containers, number of containers per layer, predicted force applied to each container on the lowest layer of the bottom pallet by the filled containers, predicted force applied by the wooden pallets to each container on the lowest layer of the bottom pallet, and total force applied to each container on the lowest layer of the bottom pallet.

As shown by FIG. 17, a filled, top-load comparison of a 10.9 g prior art container, a 9.9 g prior art container, and a 9.9 g container of the present disclosure illustrates that the 9.9 g container of the present disclosure outperformed both of the prior art containers, even when the prior art container had a greater amount of material used to form the container (i.e., the 10.9 g prior art container).

Further, Table 1 below shows the lab results obtained from several experiments performed by Applicants to compare the prior art containers of FIG. 1 and containers according to the present disclosure, both of which were tested while filled with liquid at 10.9 g and 9.9 g container weights. The volume of the containers was 500 mL.

As used herein, “over-splashing” refers to an amount of contained liquid that is displaced upon squeezing a grip portion of the container with a known amount of force. As used herein, “prehension sinking” refers to a depression amount of a grip portion of the container when the grip portion is squeezed with a known amount of force. As used herein, “level after breaking” is used in connection with a side-loading of the container; when the container presents irreversible deformation, the level of liquid in the container is measured. As used herein, a “drop test” refers to an experiment wherein the container is dropped on the floor from a height of 1 meter and then the number of surviving bottles (not burst) is counted.

As shown by Table 1 below, the 9.9 g container of the present disclosure again outperformed both of the prior art containers, even when the prior art container had a greater amount of material used to form the container (i.e., the 10.9 g prior art container). Additionally, Table 1 also illustrates that even the 9.0 g container of the present disclosure was able to satisfactorily withstand the tested level of top-loading.

TABLE 1

Prior Art
Claimed
Prior Art
Claimed
Claimed

Container
Container
Container
Container
Container

10.9 g/
10.9 g/
9.9 g/
9.9 g/
9.0 g/

66.7 mm
66.7 mm
66.7 mm
66.7 mm
63 mm

Height (mm)
199.7
202.2
200.9
202.5
202.4

Capacity
516
514
520
516.7
515.2

(ml) at

23 mm

Base Weight
1.29
1.53
1.35
1.59
1.37

(g)

Lower Body
3.23
3.25
2.36
2.47
2.05

Weight (g)

Label
1.64
1.38
1.48
1.14
0.84

Weight

(g)

Shoulder
4.93
4.88
4.96
4.88
4.71

Weight

(g)

Filled Top
21.3
31.3
12.6
24.1
18.9

Load at

5 mm (kg)

Filled Top
47.6
55.1
42.2
55.6
40

Load at

break (kg)

Empty Top
4.8
2.2
2.4
1.7
0.6

Load (kg)

Over-
1.6
1.46
0.93
1.05
0.72

splashing

Force (kg)

Prehension
2.57
2.99
3.79
3.86
6.01

Sinking

(mm)

Drop Test
0/4
0/5
1/5
0/5
1/5

Applicants further performed testing on both the prior art containers of FIG. 1 and containers according to the present disclosure, both of which were tested while filled with liquid with at least 10.9 g and 9.9 g container weights. The volume of the containers was 500 mL. The containers were tested for prehension resistance on an open bottle with varying forces until over-splashing occurred. The containers were tested for prehension depression on a closed bottle with 0.5 kg lateral force.

As shown by Table 2 below, the 9.9 g container of the present disclosure outperformed both of the prior art containers, even when the prior art container had a greater amount of material used to form the container (i.e., the 10.9 g prior art container). Additionally, Table 2 also illustrates that even the 9.0 g container of the present disclosure demonstrated satisfactory prehension resistance.

TABLE 2

Prehension
Level After

Over-Splashing
Sinking
Breaking

(mm)
(kg)
(mm)
(mm)

Prior Art Container (10.9 g)
14.88
1.6
2.57
22.2

Claimed Container (10.9 g)
17.86
1.46
2.99
22.6

Prior Art Container (9.9 g)
14.81
0.93
3.79
21.6

Claimed Container (9.9 g)
17.35
1.05
3.86
21.8

Claimed Container (9.0 g)
17.22
0.72
6.01
19.9

The structural features of the present containers described herein advantageously allow for the manufacture of lightweight, yet stable containers. In this regard, the disclosed geometries of the different ribs in combination with the at least two different connecting portions provide advantageous improvements in stability and side- and top-loading resistance when compared to prior art containers.

Further, a reduced use of resin in the containers provides the advantage of a lower cost per unit and increased sustainability when compared to a bottle without such structural features. By manufacturing the containers of the present disclosure using lower amounts of raw materials, the bottles can provide lower environmental and waste impact. Along the same lines, the bottles can be constructed to use less disposal volume than other plastic bottles designed for similar uses.

Additionally, the containers of the present disclosure can also improve the ease of use and handling by manufacturers, retails and consumers. In this regard, the structural features described herein provide for improved stability and improved side- and top-loading resistance to help achieve a lightweight container that is desirable by consumers.

It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.

LIGHTWEIGHT CONTAINERS WITH IMPROVED LOAD RESISTANCE

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

PRIORITY CLAIM

Provisional Applications (1)