1. Field of the Invention
The present invention relates to a method for designing a container, and more particularly to a container comprising a handle and a sidewall, the handle creating a hole between itself and the sidewall of the container. The invention relates even more particularly to a container having a three-dimensional image applied on the handle and sidewall of the container.
2. Description of the Related Art
Blow-molded plastic containers have become commonplace in packaging products using hot-fill and cold-fill processes such as beverages including juice, for example. Such a container normally has a dome, an annular sidewall extending from a base, and a waist connecting the dome to the sidewall. Typically, the containers have a horizontal cross section which is substantially circular or rectangular or is multi-faceted. Blow-molded plastic containers can provide a package with sufficient flexure to compensate for pressure and temperature, while maintaining structural integrity and aesthetic appearance. In addition, the plastic used in the containers is recyclable. In order to increase the sales of beverages or other products, there is a need to produce aesthetically appealing containers.
Other containers, particularly those designed for larger volumes of liquids, can have a more substantially rectangular cross-section. Such containers frequently have a handle molded into the container to make it easier to lift and to pour the contents from the container. These containers are also generally blow-molded by, for example, stretch blow-molding, extrusion blow-molding, and injection blow-molding. It is often desirable to place designs or a relief on a container for either functional reasons, such as to improve gripability, or ornamental reasons, for example by placement of a logo or some other means that promotes “brand identity.”
Making molds that create relief structures on containers is known. However, conventional mold-making and design methods are limited by how the designs are created and the intricacies of the mold-making process. Generally, these conventional methods have limited the scope of designs that can be created and the placement of designs. As a result of these limitations, designs are generally placed in relatively open spaces on a container. As used herein, an “open” space is one that readily accessible and can be on an outer tubular surface. These open spaces can be, for example, on the dome or sidewall of a round container or a flat surface of a rectangular container.
An example of a typical conventional method is a means for making a mold to create a sculpture to appear on a container. As shown in
The above-mentioned shortcomings are overcome by a method in a computer system for generating an image for producing an electrode as disclosed in co-pending U.S. Patent Application No. 60/384,166 to Yourist filed May 31, 2002, which is incorporated herein by reference in its entirety. As disclosed therein, such a method may comprise the steps of generating a virtual sculptural relief; projecting the virtual sculptural relief onto a virtual mold cavity surface to form a virtual sculptural relief on the virtual mold cavity surface, the projected virtual sculptural relief having a profile; removing the virtual mold cavity surface outside the profile of the virtual projected sculptural relief; extending the virtual projected sculptural relief profile to a predetermined plane to form a virtual extension of the virtual projected sculptural relief; and combining the virtual projected sculptural relief with the virtual extension, which together form a virtual image of the electrode. The virtual image is converted into a numerical control language and a material is machined, based on the numerical control language, to form an electrode. The electrode is then used to impress a mold.
While such a method is useful and precise, it is still limited to placing designs on open portions of the mold.
While the above-mentioned co-pending U.S. Patent Application overcomes several of the shortcomings discussed above, the method disclosed therein does not attempt to meet the challenge of applying a three-dimensional textured image to more intricate non-open areas of a container, for example the handle and sidewall, particularly when the handle forms a hole between itself and the sidewall of the container. Therefore, among other advantages, such a method would provide a container with a better grip for the user as well as enhancing the appearance of the container compared to conventional containers. It would be aesthetically and ergonomically advantageous if there existed a method and a device for applying a three-dimensional textured image to less open areas. A particular area would be, for example, the handle and sidewall of a container when the handle forms a hole between itself and the sidewall of the container. Challenges arise in such situations because the handle and sidewall of the container are offset angularly with respect to one another, thereby making the design and application of a textured image extremely time-consuming, expensive, and inefficient using existing techniques. What is needed, therefore, is a method and a device for designing and applying a three-dimensional textured image to more than one surface of a container when the surfaces are angularly offset from one another.
An exemplary embodiment of the present invention provides the above-mentioned and other advantages through the provision of a method and device for providing a container comprising a handle and a sidewall, a three-dimensional sculptural image being applied on the handle and sidewall. The container may be a beverage container, for example, and the three-dimensional image may be in the form of a leaf of a fruit tree, for example. The handle may form a hole between itself and the sidewall of the container. According to an exemplary embodiment of the present invention, the above-mentioned advantages are met through the provision of a method for designing a three-dimensional textured image for being applied to more than one surface of a container when the surfaces are angularly offset from one another. The image may be projected onto the handle at an oblique angle. The angle at which the image is applied may be such that the image is applied to multiple surfaces of the handle and the sidewall of the container simultaneously.
A computer system can be used to design a relief, a container, or place a relief design on a container. In a typical use of such systems, a design is placed on a container in an open region of the container.
Forming a continuous design on such a surface using conventional techniques, if possible at all, is difficult. Preparing a mold for such a container using conventional techniques would require burning the design into a mold using multiple electrodes that approach at multiple angles including, for example, an oblique angle (i.e., an angle other than a right angle). Aligning such multiple electrodes to prepare a continuous design using such conventional techniques is a tedious and time-consuming task. For example, failure to properly align the electrodes would result in unacceptable design incontinuities. Alternatively, such molds could be hand-tooled. This, however, adds undesirable time and expense to the mold-making process. The present invention uses design software and automated tooling software to (a) generate a design, and (b) make a mold from the design. Further, according to an exemplary embodiment of the present invention, when projecting an image on the virtual surface of the container, there may be some distortion in the projected image. According to an exemplary embodiment of the present invention, the projected image may be corrected (for example, by modifying the boundary of the projected image by drawing 3-D bspline curves), flattened (projected) to a plane in virtual space, the image may be used to form a new virtual sculptural relief, and the new virtual sculptural relief may be reprojected onto the virtual container surface to form a new virtual projected sculptural relief to obtain the design of the container.
Although it is preferable that all of the images shown in
In another exemplary embodiment of the invention, a boundary image may be created on a virtual container. For example, the virtual container of
In a step for forming a virtual sculptural relief image (step 402), as seen in the exemplary illustration of
Steps 400 and 402 may be implemented using commercial software packages such as, for example, ArtCam sold by Delcam plc of Birmingham, England. A sculptural relief is a three-dimensional image formed in an otherwise planar surface. A sculptural relief may be either positive (protruding from the plane toward an observer) or negative (receding from the plane relative to the observer). A virtual sculptural relief is a graphically created sculptural relief as may be shown on a display.
After the virtual sculptural relief image 600 is formed (step 402), it may be projected onto a simulated or “virtual” container surface 1002 (step 404), as shown in
As illustrated in
After the virtual sculptural relief is projected onto the simulated container surface (step 404), and suitably manipulated (step 406), the virtual sculptural relief may be preferably triangulated (step 408) to differentiate the surface of the virtual sculptural relief projected onto the simulated container from the simulated container surface, which does not contain the projected surface of the sculptural relief. In effect, a digital data set is formed defining points of the sculptural relief relative to points defining the surrounding simulated container surface. Triangulation of shapes or images is a well known process, which involves using a plurality of triangles in a coordinate system to define a shape or image. Any other method for ascertaining the surface of the sculptural relief on the simulated mold cavity can be used.
When projecting the virtual sculptural relief onto the virtual container surface, around the hole formed by the handle, for example, distortions in the projected relief may be created by the hole. According to an exemplary embodiment of the present invention, where boundary lines have been distorted, an operator of the graphical software application program may correct the distorted lines of the boundary image, by, e.g., drawing lines on the virtual surface, such as one or more bspline curves, in 3-D on the 3-D surface. The corrected bspline curves may then be projected to a 2D plane in 3D space, flattening the curves. The plane may be at an oblique angle to the surface of the projected relief. The resulting new 2D image may be used to develop a new virtual sculptural relief. The new virtual sculptural relief, may then be reprojected onto the virtual container surface to obtain the design of the container.
After the surface of the projected sculptural relief on the simulated container is ascertained, the simulated mold cavity surface outside boundary of the projected sculptural relief image may be trimmed away or removed (step 410).
The resulting boundary or profile (step 410) may provide one or more digital files to a tooling shop in a digital format familiar to the shop such as, for example, IGES or STL files. The digital images created according to an exemplary embodiment of the present invention may be transformed into images for creating a mold. The tooling shop can then use these files to tool the desired image into the mold. Thus, in contrast to conventional methods that may impress a design into an existing mold, an exemplary embodiment of the present invention may use the combination of design software and tooling software to directly tool a pattern into a mold. Using this combination in this way may allow a designer to incorporate features not contemplated nor attainable using conventional methods.
After the tooling shop has made the mold from an image generated through a method according to an exemplary embodiment of the present invention, the mold can be used to make a container having the relief image thereon. The container may be made of a plastic material, such as nylon; polyolefins, such as, e.g., but not limited to, polypropylene, high density polyethylene and low density polyethylene; and polyesters, such as polyethylene terephthalate, for example. The container may be made according to methods known to those skilled in the art such as injection blow-molding, stretch blow-molding, or extrusion blow-molding, for example.
While the invention has been described in detail with reference to specific and preferred embodiments, it will be appreciated that various modifications and variations will be apparent to the artisan. All such modifications and embodiments as may occur to one skilled in the art are intended to be within the scope of the appended claims.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US04/13593 | 5/3/2004 | WO | 9/26/2005 |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 10428035 | May 2003 | US |
| Child | 10550680 | Sep 2005 | US |