1. Field of the Inventions
The field of the invention relates generally to storage containers, and more particularly, to an improved injection molded container that can be used for the transport of dangerous goods and hazardous materials.
2. Background Information
Containers such as buckets and pails are known and used in a variety of shapes and sizes to store various materials. A conventional container is comprised of a cylindrical structure with an interior cavity that is closed at one end. The container may also include a removable cover to secure or close the upper opening of the container. A tubular gasket can also be disposed between the upper bead of the container and the cover to provide an improved seal. A handle may also be attached to the container to help facilitate the carrying and handling of the container.
Despite the broad array of containers that exist, current containers, including plastic containers made through an injection molding process, present numerous shortcomings. These shortcomings become particularly evident when current containers are manufactured for use in transporting dangerous goods and hazardous materials. During transport the containers are often stacked on top of each other several containers high. As a result, it is imperative that each container be able to hold within itself the contents of the materials to be transported and stored as well as support the weight of several containers and their respective contents.
The advent of modern transportation by rail and highway, along with the development of more and more hazardous materials, has increased the need to develop safe containers and packaging to safely transport these materials from one destination to another. Design specifications have become a hallmark to ensure that a company's product can be handled and transported safely and arrive intact at its customer's facility.
While the adoption of specification packaging in the United States ensured a level of safety, other countries did not have to accept the United States' standards. In fact, as other countries adopted their own specifications, it became evident that without international standards, incompatible regulations could hinder the free flow of hazardous materials between countries. A solution to this incompatibility and, in some cases, to the lack of regulations, came from the United Nations' (UN) Committee of Experts on the Transport of Dangerous Goods. This included the adoption of standards that could be used by all nations which based packaging not so much on design as the ability of a given package to pass performance tests. By passing a series of tests, a package design proves itself acceptable for both international and domestic transportation of hazardous materials. For example, a container designed to contain liquids is required to pass a drop test, leakproof test, hydrostatic pressure test and a stacking test. The details of such tests are known or are accessible to those of ordinary skill in the art.
Not surprisingly, the designs of current containers, including plastic containers made through known injection molding techniques, typically attempt to increase the strength and rigidity of the container by adding additional material and thickness to regions of the container that are likely to fail. However, in some cases, this design approach can actually lead to increases in the likelihood of a failure. For example, the junction of two or more wall portions of a container made through injection molding techniques leads to a thick cross section. The thick sections found at the wall junctions of the container often experience a region of increased stress and an increased chance of structural failure when the container is subjected to a performance test or while in actual use. This is due to the fact that during the injection molding process, the regions of increased thickness experience increased heating which, in turn, requires an increased amount of time to cool. In addition, the plastic on the outer portion of the wall junction typically cools faster than the plastic at the inside of the wall junction. This often leads to weakness in the plastic that forms the wall junction.
Therefore, the sections of increased thickness found at the wall junction and other regions of the container can be prone to failure during performance tests or while in actual use. Accordingly, the wall junction and other components found in such containers can actually be strengthened by implementing design features that reduce the amount of material that is used to form the wall junction, while at the same time designing the components of the container to absorb or otherwise withstand the stresses the container is subjected to during performance tests or while in actual use.
Reducing the amount of material that is used to form components of the container can provide other benefits in addition to strengthening the product and its components. For example, reducing the amount of material that is used to form the container can provide a plastic container that is more environmentally friendly. In addition, reducing the amount of material required to produce the container simplifies and speeds up the manufacturing process while reducing the ultimate cost of the container. Such benefits that result from using a reduced amount of material to produce the container cannot be realized, however, without design features that ensure the container can meet the standards required by the United Nations' regulations for dangerous goods and hazardous materials and thereby provide the safe transport of such materials.
A container comprises a body that comprises a proximal end, a distal end and a floor sealing the distal end of the body to define an internal cavity. In one aspect, the body further comprises a shock absorbing wall section. In another aspect, the container also comprises an angled bead formed circumferentially around the proximal end of the body. The angled bead comprises a rim that extends radially outward and toward the distal end of the body.
In another aspect, the container comprises a cover that is configured to be removably coupled to the proximal end of the body. The cover comprises a gripping flange that is configured to interlock with the angled bead. The cover also comprises an angled cover chime that is substantially parallel to the angled bead when the cover is coupled to the body.
In another aspect, the container comprises a gasket positioned in a cavity formed between the gripping flange and the angled bead. The angled cover chime further comprises a gasket retainer bead that extends into the cavity and contacts the gasket.
In another aspect, the container comprises a plurality of satellite rings extending circumferentially around the body and a bail ear connecting at least two satellite rings to form an opening between the bail ear and the body of the pail.
In another aspect, the wall junction formed by the satellite ring and the body comprises a substantially constant wall thickness throughout the wall junction.
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Angled bead 24 comprises a projecting rim or lip that extends circumferentially around the proximal end of body 14 and extends radially outward and downward from the proximal end of body 14. In another embodiment, angled bead 24 comprises one or more projecting rim segments that extend radially outward and downward from the proximal end of body 14. This particular embodiment of the invention illustrates first, second and third satellite rings 25, 26 and 27 which protrude circumferentially around body 14 to form three respective ridges which extend away from the external face of body 14. Although satellite rings 25, 26 and 27 are illustrated in a position that is angled downward toward the distal end of body 14, satellite rings 25, 26 and 27 can also be positioned perpendicular to body 14, or angled upward toward the proximal end of body 14. Satellite rings 25, 26 and 27 comprise respective proximal ends which are attached to and extend from body 14 to form a one-piece construction during the injection molding process. Satellite rings 25, 26 and 27 function to absorb forces that the external surface of pail 12 may be subjected to as container 10 undergoes a performance test or is transported from one location to another in actual use.
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Gripping flange 52 comprises a circumferential upper portion 60, a circumferential lower portion 62, and central member 61 that couples upper portion 60 to lower portion 62. Upper portion 60 is formed to connect gripping flange 52 to cover surface 48 this particular embodiment of the invention illustrates lower portion 62 which comprises a ring pull 64. Ring pull 64 comprises a substantially circular ring coupled to lower portion 62 with at least one connection member 66.
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Gasket 22 comprises an outer tube made of vinyl or rubber, for example, that defines an internal cavity. Gasket 22 is disposed between and conforms to essentially fill the cavity defined by upper portion 60 of gripping flange 52 and angled bead 24. In operation, when cover 20 is coupled to pail 12, gasket retainer bead 70 exerts increased tension on gasket 22. Gasket retainer bead 70 thereby functions to help maintain the position of gasket 22, particularly with respect to pressure increases inside of container 10. In addition, angled bead 24 and angled cover chime 68 operate in conjunction to force gasket 22 outward against support member 69. Thus, as pressure builds within container 10, for example, angled bead 24 and angled cover chime 68 help prevent gasket 22 from releasing and forming a leak. Instead, as pressure builds within container 10, the additional pressure is forced onto gasket 22 which, in turn, is retained by support member 69, angled cover chime 68 and angled bead 24.
Angled bead 24 is also formed to define cover rest area 82 at the top portion of the junction of angled bead 24 and body 14 of pail 12. Cover rest area 82 comprises a substantially flat surface that is configured to contact a corresponding substantially flat surface formed on an interior surface of upper portion 60 of gripping flange 52. Cover rest area 82 functions as a support member as cover 20 is subjected to external forces, for example, when one or more containers are stacked on top of the cover 20 of container 10.
Angled cover chime 68 is connected to central member 61 with support member 69. Central member 61 comprises engagement member 84 and wall section 86. Engagement member 84 comprises a projection that extends toward body 14 of pail 12 between satellite ring 26 and angled bead 24, thereby defining an indent that extends circumferentially around the external surface of central member 61. The formation of engagement member 84 reduces the amount of plastic necessary to form gripping flange 52 resulting in a faster production cycle and at a reduced cost. In addition, the reduced amount of material used during the injection molding process facilitates a more rapid, even cooling of the plastic, thereby helping to promote consistent and improved strength throughout the component.
In order to place cover 20 onto pail 12, a portion of gripping flange 52 is flexed slightly outward as cover 20 is lowered onto pail 12, such that engagement member 84 is able to clear angled bead 24. Once engagement member 84 has cleared angled bead 24, engagement member 84 returns to its pre-flexed configuration allowing a portion of engagement member 84 to be snapped into place to position a portion of engagement member 84 in contact with the bottom lip or edge formed by angled bead 24. Once cover 20 has been engaged with pail 12, cover 20 is effectively locked in place and a hermetic seal is formed. Conversely, to remove cover 20, lower portion 62 of gripping flange 52 functions as a tear strip that can be removed from central portion 61 along a circumferential tear line by exerting a force on ring pull 64. The tear strip also functions as a tamper evidence feature and enables end users to remove cover 20 without any tools.
Satellite ring 26 comprises a proximal end which is attached to and protrudes from body 14 to form a single piece construction during the injection molding process. In the embodiment of the invention that is illustrated, body 14 of pail 12 is molded to form an indent 90 on the inner surface of body 14 of pail 12. Indent 90 allows the wall junction of satellite ring 26 and body 14 to have a substantially constant thickness through their wall junction. By providing indent 90 on the inner surface of body 14 at the wall junction of satellite ring 26 and body 14, a reduced amount of plastic is used to form the wall junction of satellite ring 26 and body 14 during the injection molding process. This allows the component to be produced with a faster production cycle and at a reduced cost. In addition, the substantially uniform thickness of the wall junction of satellite ring 26 and body 14 facilitates a more rapid, even cooling of the plastic throughout the wall junction, thereby helping to promote consistent strength throughout the pail.
While certain embodiments of the inventions have been described above, it will be understood that the embodiments described are by way of example only. Accordingly, the inventions should not be limited based on the described embodiments. Rather, the scope of the inventions described herein should only be limited in light of the claims that follow when taken in conjunction with the above description and accompanying drawings.
This application is a continuation of U.S. patent application Ser. No. 11/250,589, filed Oct. 14, 2005, entitled “PERFORMANCE ORIENTED PAIL.”
Number | Date | Country | |
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Parent | 11250589 | Oct 2005 | US |
Child | 13489631 | US |