A container, customized to defined specifications, and a method of creating the container are disclosed. Container specifications are provided and evaluated against attributes of various plastic materials, such as polypropylene and polyethylene. A core material and one or more skin materials and thicknesses of each are chosen such that the combination of materials and thicknesses provides the defined specifications. The one or more skin materials are injected into a container mold one at a time. The core material is then injected into the container mold so that the core material is substantially surrounded by the one or more skin materials.
Description
DESCRIPTION OF THE DRAWINGS
The invention is best understood from the following detailed description when read with the accompanying drawings.
FIG. 1 depicts a dual-material pail according to an illustrative embodiment of the invention.
FIG. 2 depicts a co-injection apparatus that can be used to create containers according to illustrative embodiments of the invention.
Claims
1. A method of customizing a container to defined specifications comprising:
providing container specifications;choosing a core material and one or more skin materials and thickness of each such that the combination of materials and thicknesses provides the defined specifications;injecting the one or more skin materials into a container mold one at a time; andinjecting the core material into the container mold so that the core material is substantially surrounded by the one or more skin materials.
2. The method of claim 1 wherein the specifications include wall thickness.
3. The method of claim 1 wherein the specifications include stack strength.
4. The method of claim 1 wherein the core material and one or more skin materials are polymers.
5. The method of claim 4 wherein the core material is a polypropylene.
6. The method of claim 4 wherein at least one of the one or more skin materials is a high density polyethylene.
7. The method of claim 4 wherein the core material is a polypropylene and at least one of the one or more skin materials is a high density polyethylene.
8. The method of claim 1 wherein the specifications include a wall thickness between about 70 mil and about 100 mil.
9. The method of claim 1 wherein the specifications include a stack strength of greater than about 3600 lbs.
10. The method of claim 1 wherein the ratio of wall thickness to stack strength is less than about 0.024.
11. The method of claim 10 wherein the ratio of wall thickness to stack strength is less than about 0.023.
12. The method of claim 1 wherein the container is a pail having a capacity of between about 1 gallon and about 7 gallons.
13. The method of claim 12 wherein the container is a pail having a capacity of about 5 gallons.
14. The method of claim 1 comprising:
providing a core loading between about 35% and about 65%.
15. The method of claim 1 wherein the specifications include impact strength.
16. The method of claim 1 further comprising injecting additional skin material into the mold after the core material injection is complete so the core material is fully surrounded by the skin material.
17. A multi-material container comprising:
a polymer core;at least one polymer skin disposed around the core:wherein the ratio of wall thickness to stack strength is less than about 0.024.
18. The container of claim 17 wherein the core material is a polypropylene.
19. The container of claim 17 wherein at least one of the one or more skin materials is a high density polyethylene.
20. The container of claim 17 wherein the core material is a polypropylene and at least one of the one or more skin material is a high density polyethylene.
21. The container of claim 17 wherein the wall thickness is between about 70 mil and about 100 mil.
22. The container of claim 17 wherein the stack strength is greater than about 3600 lbs.
23. The container of claim 17 wherein the ratio of wall thickness to stack strength is less than 0.023.
24. The container of claim 17 wherein the container is a pail having a capacity of between about 1 gallon and about 7 gallons.
25. The container of claim 17 wherein the container is a pail having a capacity of about 5 gallons.
26. The container of claim 17 comprising a core loading between about 35% and about 65%.
27. A multi-material container comprising:
a polymer core;one or more polymer skins disposed around the core;wherein the wall thickness is less than about 100 mil; andthe stack strength is greater than about 3600 lbs.
28. The container of claim 27 wherein the core material is a polypropylene.
29. The container of claim 27 wherein at least one of the one or more skin materials is a high density polyethylene.
30. The container of claim 27 wherein the core material is a polypropylene and at least one of the one or more skin material is a high density polyethylene.
31. The container of claim 27 wherein the stack strength is greater than about 3800 lbs.
32. The container of claim 27 wherein the ratio of wall thickness to stack strength is less than 0.023.
33. The container of claim 27 wherein the container is a pail having a capacity of between about 1 gallon and about 7 gallons.
34. The container of claim 27 wherein the container is a pail having a capacity of about 5 gallons.
35. The container of claim 27 comprising a core loading between about 35% and about 65%.
36. A method of customizing a container to defined specifications comprising:
(a) providing a targeted cost of container materials and one or more additional container specifications;(b) choosing container materials including a core material and one or more skin materials and thickness of each such that the combination of materials and thicknesses provides the defined specification(s) and the targeted cost;(c) forming the container so the core material is substantially surrounded by the one or more skin materials; and(d) performing step b again when one or more container material costs change.
Patent Application
20070212503
