Single-Serve Beverage Container

Abstract

An improved plastic container including a bottom strengthening formation. The strengthening formation assists in reducing deformation of the bottom of the container when the container is pierced during the beverage brewing process. In a preferred embodiment, the strengthening formation includes a generally gear-shaped path to evenly distribute dynamic forces from a piercing needle or stylus to the spokes or gear teeth of the strengthening formation. The gear-shaped path includes the features of gear design and includes an outer diameter, and inner diameter, and a pitch diameter. In some embodiments, a depression defining and encircling the piercable area further enhances the even distribution of dynamic forces.

Description

BACKGROUND OF THE INVENTION

Single-serve coffee containers for use in single-serve beverage makers have drawbacks which occur due to changes in container materials, filling percentages, filter media, etc. One such problem or drawback is the collapse or deformation of the container base when the coffee maker needle or stylus punctures the base. When such deformation occurs, the filter holding the associate beverage material (coffee, tea, chocolate mix, etc.) may be torn or perforated causing coffee grounds, tea leaves or other beverage material to pass through the maker and into the brewed beverage. Additionally, when a liquid is added to the container, the contents can spill or leak in unpredictable locations.

SUMMARY OF THE INVENTION

The present invention provides for a pierceable plastic container. The container includes a circular top flange that extends between an outside edge and a circular inside edge centered on a longitudinal, central axis. The circular inside edge has an edge diameter. The flange couples to a tapered sidewall that extends from the circular inside edge to an edge diameter that defines a transition area. The edge diameter of the transition area defines a strengthening wall that extends from the edge diameter to a bottom edge. The strengthening wall defines a gear-shaped path about the central axis. The gear-shaped path includes an outer diameter and an inner diameter. The inner diameter has a ratio relative to the outer diameter that is greater than 75%. The outer diameter of the gear-shaped path is less than the top edge diameter of the circular top flange. The strengthening wall couples to a bottom wall formed from the bottom edge of the strengthening wall. The bottom wall, the strengthening wall, and the tapered sidewall are molded together from plastic to form a fluid-tight vessel.

Another embodiment of the disclosure relates to a pierceable plastic container. The container includes a circular top flange that extends between an outside edge and a circular inside edge centered on a longitudinal, central axis. The circular inside edge has an edge diameter. The circular top flange couples to a tapered sidewall that extends from the circular inside to an edge diameter that defines a transition area. The transition area couples to a strengthening wall that extends from the edge diameter of the transition area to a bottom edge. The strengthening wall defines an outer gear-shaped path about the central axis. The outer gear-shaped path includes a first outer diameter and a first inner diameter. The first inner diameter has a ratio to the first outer diameter that is greater than 75%. The first outer diameter of the outer gear-shaped path is less than the top edge diameter. The strengthening wall couples to a bottom wall formed from the bottom edge of the strengthening wall. The bottom wall has a depression centered about the central axis. An inner gear-shaped path defines the depression. The inner gear-shaped path extends about the central axis and defines the depression centered about the central axis. The inner gear-shaped path includes a second outer diameter and a second inner diameter. The second outer diameter is less than the first outer diameter and the second inner diameter is less than the first inner diameter. Inside the depression, a base is formed. The base extends from the inner gear-shaped path centered about the central axis. The base, the inner gear-shaped depression, the bottom wall, the outer gear-shaped strengthening wall, and the tapered sidewall are molded from plastic to form a single continuous fluid-tight vessel.

In another embodiment of the disclosure, a pierceable plastic container is described. The container includes a circular top flange that extends between an outside edge and a circular inside edge centered on a longitudinal, central axis. The circular inside edge has an edge diameter. The flange couples to a tapered sidewall that extends from the circular inside edge to an edge diameter defining a transition area. The edge diameter of the transition area defines a strengthening wall that extending from the edge diameter to a bottom edge. The strengthening wall includes a generally gear-shaped path centered about the central axis. The gear-shaped path includes an outer diameter and an inner diameter. The inner diameter's ratio to the outer diameter is greater than 75%. The outer diameter of the path is less than the top edge diameter. The strengthening wall couples to a bottom wall formed from the bottom edge of the strengthening wall. The bottom wall may include a depression centered about the central axis. The depression may define a circular diameter that is less than the inner diameter of the gear-shaped path. Inside the depression, a base is formed and centered about the central axis. The base, the depression, the bottom wall, the strengthening wall, and the tapered sidewall are molded together from plastic to form a fluid-tight vessel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view from below of an embodiment of the container.

FIG. 2 is a front view of the container of FIG. 1, the rear view, the left side view, and the right side view being the same as the front view.

FIG. 3 is a top view of the container of FIG. 1.

FIG. 4 is a bottom view of the container of FIG. 1.

FIG. 5A is a detailed view of the bottom of the container of FIG. 1, according to an exemplary embodiment.

FIG. 5B illustrates the cut-out along the curve C of FIG. 5A and illustrates some exemplary geometry, according to one embodiment.

FIG. 6 is a perspective cross-sectional view, taken along line 6-6 of FIG. 3, of the container of FIG. 1.

FIG. 7 is a cross-sectional view, taken along line 6-6 of FIG. 3, of the container of FIG. 1.

FIG. 8 is a perspective view from below of an embodiment of the container.

FIG. 9 is a front view of the container of FIG. 8, the rear view, the left side view, and the right side view being the same as the front view.

FIG. 10 is a top view of the container of FIG. 8.

FIG. 11 is a bottom view of the container of FIG. 8.

FIG. 12A is a detailed view of the bottom of the container of FIG. 8, according to an exemplary embodiment.

FIG. 12B illustrates the cut-out along curve C in FIG. 12A and illustrates some exemplary geometry, according to one embodiment.

FIG. 13 is a perspective cross-sectional view, taken along line 12-12 of FIG. 10, of the container of FIG. 8.

FIG. 14 is a cross-sectional view, taken along line 12-12 of FIG. 9, of the container of FIG. 7.

FIG. 15 is a perspective view from below of an embodiment of the container.

FIG. 16 is a front view of the container of FIG. 15, the rear view, the left side view, and the right side view being the same as the front view.

FIG. 17 is a top view of the container of FIG. 15.

FIG. 18 is a bottom view of the container of FIG. 15.

FIG. 19A is a detailed view of the bottom of the container of FIG. 15, according to an exemplary embodiment.

FIG. 19B illustrates the cut-out along curve C in FIG. 19A and illustrates some exemplary geometry, according to one embodiment.

FIG. 20 is a perspective cross-sectional view, taken along line 18-18 of FIG. 17, of the container of FIG. 15.

FIG. 21 is a cross-sectional view, taken along line 18-18 of FIG. 17, of the container of FIG. 15.

FIG. 22 is a perspective view from below of an embodiment of the container.

FIG. 23 is a front view of the container of FIG. 22, the rear view, the left side view, and the right side view being the same as the front view.

FIG. 24 is a top view of the container of FIG. 22.

FIG. 25 is a bottom view of the container of FIG. 22.

FIG. 26A is a detailed view of the bottom of the container of FIG. 22, according to an exemplary embodiment.

FIG. 26B illustrates the cut-out along curve C in FIG. 26A and illustrates some exemplary geometry, according to one embodiment.

FIG. 27 is a perspective cross-sectional view, taken along line 24-24 of FIG. 24, of the container of FIG. 22.

FIG. 28 is a cross-sectional view, taken along line 24-24 of FIG. 24, of the container of FIG. 22.

FIG. 29A illustrates some generic dimensions of a container, according to a preferred embodiment.

FIG. 29B illustrates additional dimensions of a container, according to a preferred embodiment.

FIG. 29C illustrates a detailed view of FIG. 29B along the curve B, according to an exemplary embodiment.

DETAILED DESCRIPTION

Referring generally to the figures, various embodiments of a pierceable plastic container are shown. The single-serve containers include a filter that holds a powder, e.g., a beverage mix such as coffee grounds. When the container is pierced and water funnels through the filter and container an instant cup of coffee is poured into a mug below. The container is pierced at the top to allow hot water to funnel into the container and mix with the powder. The container is also pierced at the bottom to allow the water to drain through the filter and out to the cup. This allows for the coffee powder to mix with the hot water and make an instant cup of coffee. Similarly, tea and hot chocolate can be mixed and similarly filtered with hot or cold water, or other liquids. The pierceable plastic cup enhances the instant coffee brewing experience for a single serve beverage.

Despite the growing popularity of these plastic pierceable containers, one problem or drawback occurs when the process of puncturing the cup deforms the base of the container. Such a collapse or deformation may cause the coffee, tea, or cocoa to spill out. For example, coffee grinds may not filter and spill into the beverage or the hot water may drain out from a tear along the base of the cup. In addition, the perforations through the base of the container may result in a torn filter that allows water, coffee grounds, tea leaves, or other beverage materials to spill into the surrounding environment or into the mixed beverage. When the needle or stylus punctures the base of the container, a reliable and repeatable fracture of the base is sought to drain the mixed contents of the container into the cup without spillage. Applicant has developed a gear-shaped pattern along a strengthening wall to reliably pierce the base of the container and prevent excess spillage of the contents of the container by changing the form of the container base.

As described in detail below, the use of a sprocket gear-shaped strengthening wall along the base of the container enhances the load distribution of the dynamic force generated at the point the needle punctures the base. Smooth contour lines along the base and strengthening wall ensure repeatable clean punctures into the base of the container. The various embodiments described herein demonstrate different gear-shaped embodiments that protect the central piercing location of the container base. Applicant has found that the use of a sprocket gear-shaped perimeter enhances the repeatability and reliability of the opening ensuring that filtered materials are not dispensed into the beverage or spilled.

FIGS. 1-7 and 29 illustrate a cup or container 100 for a single-serve beverage, according to an exemplary embodiment. When complete, container 100 includes a filter material (not shown) supported by the upper flange 102 of the container 100. The filter material contains a beverage material such as coffee grinds, tea leaves, hot chocolate mix, or other beverage material. A membrane extends across the upper flange 102 to seal the beverage material. Membrane material such as foil or plastic closes the top opening of the container 100 defined by the upper flange 102. The container 100 may have a circular top flange 102 extending between an outside edge 104 and a circular inside edge 106. The flange centers on a longitudinal, central axis 550. The circular inside edge 106 has an edge diameter. In a preferred embodiment, the outside edge 104 has a diameter of 2.00″ and the inner edge 106 has an edge diameter of 1.799″, as illustrated in FIGS. 29A-B.

FIG. 29C illustrates exemplary dimensions of an embodiment along the transition from the upper flange 102 to the tapered sidewall 108. The thickness of the upper flange 102 is shown as 0.025″ with a 1.5° taper along the inside edge 106 of the top flange 102. The inside edge 106 contains a tapered radius of 0.033″ to adjoin the tapered sidewall 108. The transition radius of the tapered sidewall 108 is 0.01°.

Container 100 is a single integrated component with several different features. For example, the container 100 includes an upper flange 102 with an outer and inner edge 104, 106. The upper flange 102 connects through a tapered sidewall 108 to a base 110 of the container. An edge diameter 124 defines a transition area 122 between the tapered sidewall 108 and the strengthening wall 112 with a generally gear-shaped pattern 114. The gear-shaped pattern 114 includes an outer diameter 116 and an inner diameter 118 of gear teeth 120 along the strengthening wall 112 and encircling the base 110.

A quasi-vertical wall or tapered sidewall 108 extends from the circular inside edge 106 of the upper flange 102 to an edge diameter 124 along the top of a strengthening wall 112. The tapered sidewall 108 may support the upper flange 102, the outside edge 104, the inside edge 106, and/or the filter material (e.g., sealed along the upper flange 102). For example, tapered sidewall 108 may be parallel or angled to the central axis 550. The tapered sidewall 108 may be angled at 0°, 5°, 10°, 15°, 20°, 25°, 30°, 35°, or 40°, of the longitudinal axis. Generally, the tapered sidewall 108 is made of the same material as the rest of container 100, but may seal a different material to the remainder of container 100. In some embodiments, container 100 and tapered sidewall 108 are plastic. The plastic material may include a polypropylene. In some embodiments, the plastic material is not polystyrene. The tapered sidewall 108 may connect the upper flange 102 to a strengthening wall 112 at the base 110 of container 100.

The basic design of the strengthening wall 112, beginning at an edge diameter 124 of the transition area 122 and extending to the base 110 includes equally and evenly spaced, inwardly and outwardly directed rounded spoke tips or gear teeth formed in a gear-shaped pattern 114. This configuration enhances the load distribution when the base 110 is punctured, reducing splits and tears (and spills) along the base 110. The design height of the strengthening wall 112 along the central axis 550 of container 100 may be selected to be less than twice of the length of brewing machine puncturing stylist or the stacking overlap at the top of cup whichever one is shorter.

The strengthening wall 112 defines an edge diameter 124 at the top of the strengthening wall 112 and a bottom edge 126 at the bottom. In between the edge diameter 124 and the bottom edge 126, the strengthening wall defines a path, or gear-shaped pattern 114. As with gear design, the gear-shaped pattern 114 has an outer diameter 116 defining the furthest reach of each gear tooth 120 or spoke, a pitch diameter 128 defining the load transfer location on the gear tooth 120 of an adjacent meshing gear, and an inner diameter 118, defining the lowest recess of the gear tooth 120 or spoke. The central axis 550 defines a center point of the outer diameter 116, pitch diameter 128, and inner diameter 118 of the strengthening wall 112 (illustrated in FIGS. 29A-B). The outside diameter 106 of the gear-shaped pattern 114 is less than edge diameter 124 of the transition area 122, such that the tapered sidewall 108 connects the upper flange 102 to the edge diameter 124 of the transition area 122.

The base 110 of container 100 is illustrated in FIGS. 5A-B, with a detailed cutout along curve C of the gear-shaped pattern 114 characterizing the strengthening wall 112. The gear-shaped pattern 114 defines an outer diameter 116, defined by the maximum diameter tangential to the gear teeth 120 and an inner diameter 118 defined by the minimum diameter tangential to the gear teeth 120. A pitch diameter 128 defines the location of force transfer between meshing adjacent gears and can be calculated based on the gear geometry and the outer and inner diameters 106, 108. The extended gear teeth 120 distribute dynamic loads introduced at base 110 evenly across the gear teeth 120 to the outer and inner diameters 106, 108 of the gear-shaped pattern 114. The gear-shaped pattern 114 thus enhances the probability that a stylus, probe, or needle inserted into base 110 will not tear.

FIGS. 5A and 5B illustrate a bottom view of container 100. FIG. 5B is a detailed cut-out of FIG. 5A along the curve C. The details of a preferred embodiment of the gear-shaped pattern are visible from this bottom view perspective. In some embodiments, the radii of the inward and outward gear spokes are generally equal to each other and between 2 to 8 times the nominal wall thickness of the sidewall and base section. The spoke radii might differ depending upon the material type and particular application for the container. For example, the inward radius at the inner diameter 118 has a radius of 0.63″ toward the pitch diameter 128. The outward radius at the outer diameter has a radius of 0.060″ extending toward the pitch diameter 128. The angular distance from the outer diameter 116 of a gear tooth 120 to the inner diameter of a gear tooth 120 is measured from the central axis 550 of the base 110. As illustrated, the angular distance from the top of a gear tooth 120 (outer diameter 116) to the bottom of the gear tooth 120 (e.g., inner diameter 118), is 10°. From this, the gear teeth 120 repeat every twenty degrees (e.g., from the top of one tooth the top of an adjacent tooth). Therefore, the gear-shaped pattern 114 includes 18 teeth (e.g., 360°/20° per tooth=18 teeth). This can be verified by counting the 18 gear teeth 120 on FIG. 5A. As illustrated, 30° is the sum of these two measurements, indicating the angular distance from one maximum to a minimum plus the distance to an adjacent maximum.

Referring to FIGS. 29A-C, some specific dimensions for a preferred embodiment of the strengthening wall 112 are provided. These scale drawings show the dimensions labeled in the illustrated embodiment. For purposes of this application, applicant intends for length, volume and angle dimensions and relative length, volume and angle dimensions to be taken directly from these drawings. In a preferred embodiment, the strengthening wall 112 is 0.100″ thick as measured from the tapered sidewall 108 to the base 110 of the container 100. The length of the upper flange 102 and tapered sidewall 108 may be 1.633″ compared to the total height or thickness of the strengthening wall 112. Thus, the total height of container 100 may be the height of the upper flange and tapered sidewall (e.g., 1.633″) plus the height of the strengthening wall (e.g., 0.100″) for a total height of 1.733″.

As illustrated in the preferred embodiment of FIGS. 29A-B, the inner diameter 118 of the gear-shaped pattern 114 design is equal to the base 110 diameter (e.g., 1.055″). The outer diameter of the gear-shaped pattern 114 is 1.40″. Thus, the inner diameter 118 (e.g., 1.055″) ratio to the outer diameter 116 (e.g., 1.40″) is 1.055″ divided by 1.40″ or 75.35%. In some embodiments, the ratio of the inner diameter 118 to the outer diameter 116 (e.g., inner diameter 118 divided by outer diameter 116) is greater than 60%. The ratio of the inner and outer diameters 118,116 may be greater than 65%, 70%, 75%, 80%, 85% or 90%. For example, the inner diameter 118 can be 1.050″, 1.055″, 1.060″, 1.065″, 1.070″, 1.075″, 1.080″, 1.085″, 1.090″, 1.100″, 1.150″, 1.200″, 1.250″, 1.300″, 1.350″, or 1.400″. Similarly, the outer diameter 116 can be 1.25″, 1.30″, 1.35″, 1.40″, 1.45″, 1.50″, 1.55″, 1.60″, 1.65″, 1.70″, 1.75″, or 1.80″. The ratio of these alternative combinations may define the absolute dimensions described above.

The edge diameter 124 defines a diameter about the bottom of the tapered sidewall 108 and the top of the transition area 122 of strengthening wall 112. The edge diameter 124 defines the top of the strengthening wall 112 and provides a smooth transition from the tapered sidewall 108 to the transition area 112 of strengthening wall 112. In some embodiments, the edge diameter 124 is approximately 1.40″ and has a radial transition between the tapered sidewall 108 and the transition area 122 of radius 0.03″ (e.g., as illustrated in FIG. 29A). The edge diameter 124 transition radius (e.g., radial connection) between the tapered sidewall 108 and the transition area 122 may have a transition radius of 0.01″, 0.02″, 0.03″, 0.033″, or 0.04″.

One feature of container 100 improves the transition area 122 between the tapered sidewall 108 and base 110. Without any transition, puncturing the base 110 may result in tears due to non-uniform stress distributions across base 110. The design is configured to maintain the compatibility and improve the load distribution along base 110. Container 100 and transition area 122 are compatible with existing customer production lines.

The strengthening wall 112 with the gear-shaped pattern 114 couples the transition area 122 to a bottom edge 126 that defines a base 110 of the container 100. The transition area 122 extends between the edge diameter 124 along the bottom of the tapered sidewall 108 and radially inward to the gear-shaped pattern 114. The transition area 122 seals the tapered sidewall 108 to the strengthening wall 112 along the edge diameter 124 (e.g., the top edge diameter of strengthening wall 112). The strengthening wall 112 is designed to distribute the stress of a needle puncturing a base 110 of the container 100, and therefore the transition area 122 is a low-stress region that seals and supports the strengthening wall 112.

The junction or transition area 122 at gear tips can be rounded (e.g., include transition radii) to facilitate the formation of a cup. The radii can be between 1 to 6 times of nominal wall thickness. Also, the perimeter arch length ratios between the straight wall design to the radial gear with rounded spoke tips design can be 0.95″ to 0.7″.

The bottom edge 126 follows the gear-shaped pattern 114 along the base or bottom of the pattern. The bottom edge 126 provides a smooth transition radius from the strengthening wall 112 to the bottom of the container 100. In some embodiments, the bottom edge 126 has a transition radius of 0.03″ (e.g., as illustrated in FIG. 29A). The bottom edge 126 may have a transition radius of 0.01″, 0.02″, 0.03″, 0.033″, or 0.04″.

A base 110 may form the bottom edge 126 of the strengthening wall 112. In some embodiments, a plastic mold forms the strengthening wall 112, tapered wall 105, and base 110 into an integrated plastic container 100 that forms a fluid-tight vessel. The base 110 may have a domed center to distribute load to the gear-shaped pattern 114 and permit the container 100 to rest in a vertical position on a horizontal plane (e.g., stacked upright on a counter-top). In one embodiment, the base 110 of the container 100 can be slightly concaved upward in a dome shape. The concave design allows the cup to rest evenly on a flat surface.

Similar outer gear spoke design principles can apply to a raised center platform with the same height criteria but with fewer spokes and smaller radii. Base 110 may include a generally flat ring that connects the strengthening wall to the domed center. Some embodiments include recesses, depressions, and additional gear-shaped patterns along a bottom wall encircling the base (e.g., bottom wall 234 encircling base 210 illustrated in FIG. 8). For example, a depression in the bottom wall can have a depth equal to or similar to the height or thickness of the strengthening wall. The inner wall created by the depression or recess can define a cylinder, a second gear-shaped pattern, or other pattern encircled within the outer gear-shaped pattern and centered about the central axis 550.

FIGS. 8-14 illustrate a second embodiment of a cup or container 200, according to an exemplary embodiment. Container 200 is substantially the same as or similar to container 100, with the differences indicated below. Unless noted otherwise, the dimensions and description in reference to FIGS. 1-7 and 29A-C above, applies to the exemplary embodiment of FIGS. 8-14. Like components in FIGS. 8-14 are identified with a similar reference number beginning with the container 200 series. For example, container 100 has a gear-shaped pattern 114 substantially similar to the gear-shaped pattern 214 of container 200.

Like container 100, container 200 is a single integrated component with several features briefly identified below. Container 200 includes an upper flange 202 with an outside and inside edge 204, 206. A tapered sidewall 208 joins the upper flange 202 to a strengthening wall 212 and base 210 of the container 200. The transition area 222 between the tapered sidewall 208 and the base 210 includes an outer gear-shaped pattern 230 with a generally gear-shaped pattern 230 defining a first outer diameter 216 and a first inner diameter 218 of gear teeth 120 along the strengthening wall 212 and encircling the base 210. Container 200 includes an inner depression or recess in the strengthening wall 212 following a general inner gear-shaped pattern 232. Similar to the outer gear-shaped pattern 230, the inner gear-shaped pattern 232 can create a depression in a raised central platform or bottom wall 234 with the same height criteria but with fewer spokes, smaller inner and outer diameters, and/or radii, as described below.

Container 200 includes an inner gear-shaped pattern 232 or path within the outer gear-shaped pattern 230. The inner gear-shaped pattern 232 is centrally located about the central axis 550 and has a second outer diameter 236 and a second inner diameter 238. An inner pitch diameter (not shown) can define the inner gear-shaped pattern 232. The second outer diameter 236 of the inner gear-shaped pattern 232 is less than the first outer diameter 216 (e.g., of the outer gear-shaped pattern 230). The second inner diameter 238 is less than the first inner diameter 218. The dimensions of the first outer diameter 216 and first inner diameter 218 may be the same as or similar to the dimensions described above in reference to container 100 (e.g., outer diameter 116 and inner diameter 118). A fraction of the first outer and inner diameters 216, 218 define the dimensions of the second inner diameter 238 and second outer diameter 236. For example, the second outer and inner diameters 236, 238 can be 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, or 70% of the first outer and inner diameters 216, 218 respectively. In a preferred embodiment, the ratio or size relative to the outer and inner diameters is the same, creating equal sized gears on concentrically located diameters. In this configuration, the gear teeth 220 on the inner gear pattern 219 align with the gear teeth 220 on the outer gear pattern 209. In some embodiments, the ratio of the second outer diameter 236 to the first outer diameter 216 are not equal to the ratio of the second inner diameter 238 to the first inner diameter 218 and/or the gear teeth 220 do not align.

The inner gear-shaped pattern 219 may include a depression in a bottom wall 234 defining and encircling base 210. In some embodiments, the height of the depression or recess is equal, or nearly equal (e.g., within 30%), to the height of the strengthening wall 212. In some embodiments, the depth of the depression or recess is greater than or less than the height of the strengthening wall 212. A preferred embodiment includes a strengthening wall 212 with the outer gear-shaped path 209 with a height of 0.100″ along the central axis 550 and measured from the bottom wall 234 of container 200 to the transition area 222. The inner gear-shaped pattern 232 includes a similar 0.100″ depression centered about central axis 550 and measured from the bottom wall 234 of container 200 to base 210.

Base 210 and/or bottom wall 234 may have a domed center. For example, the height of the inner gear-shaped path 219 may be less than the height of the outer gear-shaped path 209 to accommodate the dome shape of the bottom wall 234. The dome shape may distribute load to the gear-shaped patterns 209, 219. This configuration may permit the container 200 to rest evenly on a flat surface. In such an embodiment, the depression can be less than the height of the strengthening wall. For example, the depression can be 0.070″, 0.080″, 0.085″, 0.090″, or 0.095″.

FIGS. 15-21 illustrate a third exemplary embodiment of a container 300. Container 300 is the same as or similar to containers 100 and 200, with the differences described below. Unless noted otherwise, all the dimensions and description in reference to FIGS. 1-7 and 29A-C above, apply to the exemplary embodiment shown in FIGS. 15-21. Like components of container 300 illustrated in FIGS. 15-21 are identified with similar reference numbers to containers 100 and 200 beginning with the 300 series.

In some embodiments, the perimeter of the raised center platform or depression 330 in the bottom wall 334 is a straight cylindrical section without any additional radial design. The transition section between the inner diameter 418 of gear teeth 320 and the depression 330 may be a flat circular washer shape 332 as illustrated in FIGS. 15-21.

Depression 330 in bottom wall 334 supports a base 310 that evenly distributes the force generated by a puncturing stylus or needle. The dynamic force is evenly distributed through the depression 330, and radially through the flat circular washer shape to the gear teeth 320 of the gear-shaped pattern 309 on the strengthening wall 312.

In some embodiments, the flat circular washer shape 332 may have a domed shape. For example, the height of the depression 330 may be less than (30% or less) the height of the gear-shaped pattern 314 along the strengthening wall 312 to allow a dome shape. For example, the depression 330 in a 0.100″ tall strengthening wall can be 0.070″, 0.080″, 0.085″, 0.090″, or 0.095″. This domed configuration ensures that container 300 can rest in a vertical position on a horizontal surface and distributes the load evenly through the depression 330. In some embodiments, base 310 can have a dome shape.

FIGS. 22-28 illustrate a fourth exemplary embodiment of a container 400. Container 400 is the same as or similar to containers 100, 200, and 300 with the differences described below. Unless noted otherwise, all the dimensions and description in reference to FIGS. 1-7, 15-21, and 29A-C above, apply to the exemplary embodiment shown in FIGS. 22-28. Like components of container 400 in FIGS. 22-28 are identified with similar reference numbers beginning with the container 400 series.

Container 400 is most similar to container 300 illustrated in FIGS. 15-21. In both embodiments, the perimeter of the depression 330,430 (or the raised center platform) is a straight cylindrical section without any additional radial design. Whereas the transition section for container 300 is a flat circular washer shape 332, the transition section for container 400 is a concave pressure-washer shape 432. The concave pressure-washer shape 432 extends between a diameter less than the inner diameter 418 of the gear-shaped pattern 109 to the diameter of the depression 430. In this embodiment, the bottom 434 between gear teeth 420 and the depression 430 may be offset by the concave pressure-washer shape 432, as illustrated in FIGS. 22-28.

The depression 430 may support a base 410 that evenly distributes the force generated by a puncturing stylus or needle. For example, the diameter of the depression 430 ensures an even distribution of a puncturing force in the base 410 through the depression 430 and to the concave pressure-washer shape 432 encircled in a gear-shaped pattern 414. The puncture force is evenly distributed to the gear teeth 420 of the gear-shaped pattern 414, enhancing punctures without breaks or tears. This, in turn, reduces the probability of the container 400 spilling contents when filled with a fluid.

In some embodiments, the concave pressure-washer shape 432 may have a domed shape. For example, the height of the depression 430 may be less than the height of the gear-shaped pattern 409 along the strengthening wall 412 to allow the dome shape along the concave pressure-washer shape 432. For example, the depression 330 in a 0.100″ tall strengthening wall can be 0.070″, 0.080″, 0.085″, 0.090″, or 0.095″. This configuration ensures that container 400 can rest in a vertical position on a horizontal surface. The domed shape evenly distributes the load from the depression 430 to the gear-shaped pattern 414 of the strengthening wall 412. In some embodiments base 410 can have a dome shape.

It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above.

In various exemplary embodiments, the relative dimensions, including angles, lengths, and radii, as shown in the Figures are to scale. Actual measurements of the Figures will disclose relative dimensions, angles, and proportions of the various exemplary embodiments. Various exemplary embodiments extend to various ranges around the absolute and relative dimensions, angles and proportions that may be determined from the Figures. Various exemplary embodiments include any combination of one or more relative dimensions or angles that may be determined from the Figures. Further, actual dimensions not expressly set out in this description can be determined by using the ratios of dimensions measured in the Figures in combination with the dimensions set out in this description.

Containers discussed herein may include containers of any style, shape, size, etc. For example, the containers discussed herein may be shaped such that cross-sections taken perpendicular to the longitudinal axis of the container are generally circular. However, in other embodiments, the sidewall of the containers discussed herein may be shaped in a variety of ways (e.g., having other non-polygonal cross-sections, as a rectangular prism, a polygonal prism, any number of irregular shapes, etc.) as may be desirable for different applications or aesthetic reasons. In various embodiments, the sidewall of can 10 may include one or more axially extending sidewall sections that are curved radially inwardly or outwardly such that the diameter of the container is different at different places along the axial length of the container, and such curved sections may be smooth continuous curved sections. In one embodiment, container 10 may be hourglass shaped. Container 10 may be of various sizes as desired for a particular application.

Further, a container may include a container end (e.g., a closure, lid, cap, cover, top, end, can end, sanitary end, “pop-top”, “pull top”, convenience end, convenience lid, pull-off end, easy open end, “EZO” end, etc.). The container end may be any element that allows the container to be sealed such that the container is capable of maintaining a hermetic seal.

In various embodiments, the upper container may include a closure or lid attached to the body sidewall mechanically (e.g., snap on/off closures, twist on/off closures, tamper-proof closures, snap on/twist off closures, etc.). In another embodiment, the upper container end may be coupled to the container body via the pressure differential. The container end may be made of metals, such as steel or aluminum, metal foil, plastics, composites, paper, or combinations of these materials. In various embodiments, the container ends, double seams, and the sidewall of the container are adapted to maintain a hermetic seal after the container is filled and sealed.

The containers discussed herein may be used to hold the powder in a filter (e.g., food supplements, drink mixes, powder shakes, coffee grinds, tea leaves, cocoa, etc.). It should be understood that the phrase “powder” is used to describe various embodiments of this disclosure and may refer to dry drink mixes, food supplements, drink mixes, powder shakes, powder, coffee grinds, tea leaves, tea powder, or any other drinkable or edible material, regardless of nutritional value. In other embodiments, the containers discussed herein may be used to hold non-perishable materials or non-food materials.

According to various exemplary embodiments, the inner surfaces of the upper and lower container ends and the sidewall may include a liner (e.g., a filter, an insert, coating, lining, a protective coating, sealant, etc.). The protective coating acts to protect the material of the container from degradation that may be caused by the contents of the container. In an exemplary embodiment, the protective coating may be a coating that may be applied via spraying or any other suitable method. Different coatings may be provided for different food applications. For example, the liner or coating may be selected to protect the material of the container from acidic contents, such as carbonated beverages, tomatoes, tomato pastes/sauces, etc. The coating material may be a vinyl, polyester, epoxy, EVOH and/or other suitable lining material or spray. The interior surfaces of the container ends may also be coated with a protective coating as described above.

Claims

1. A pierceable plastic container comprising: a circular top flange extending between an outside edge and a circular inside edge centered on a longitudinal, central axis, the circular inside edge having an edge diameter;a tapered sidewall extends from the circular inside edge to an edge diameter defining a transition area;a strengthening wall extending from the edge diameter of the transition area to a bottom edge and defining a gear-shaped path about the central axis, the gear-shaped path including an outer diameter and an inner diameter, the inner diameter ratio of the outer diameter is greater than 75%, the outer diameter of the gear-shaped path is less than the top edge diameter of the circular top flange; anda bottom wall formed with the bottom edge of the strengthening wall, the bottom wall, the strengthening wall, and the tapered sidewall being molded from plastic to form a fluid-tight vessel.

2. The container of claim 1, wherein the plastic is polypropylene.

3. The container of claim 1, wherein the plastic is not polystyrene.

4. The container of claim 3, wherein the bottom wall includes a depression having a depth similar to the height of the strengthening wall, and a depression wall defining a gear-shaped path about the central axis.

5. The container of claim 1, including a filter material supported by the flange to form a bag within the container wherein the bottom of the bag is spaced from the bottom wall, and the bag contains a powder.

6. The container of claim 5, wherein the powder is coffee, tea or cocoa.

7. The container of claim 5, further comprising a fluid-tight seal sealed to the top flange to close the opening defined by the circular inside edge.

8. The container of claim 6, wherein the seal is formed from aluminum foil, steel foil, a plastic membrane or a paper membrane, and the seal is sealed to the top flange with thermoplastic material or an adhesive.

9. The container of claim 8, wherein the strengthening wall restricts the inward deflection of the bottom wall when the bottom wall is pierced by the piercing needle of a single serve coffee maker such as a Keurig coffee maker.

10. The container of claim 9, wherein the bottom wall has a domed center.

11. The container of claim 10, wherein the bottom wall includes a flat ring which connects the strengthening wall to the domed center.

12. A pierceable plastic container comprising: a circular top flange extending between an outside edge and a circular inside edge centered on a longitudinal, central axis, the circular inside edge having an edge diameter;a tapered sidewall extending from the circular inside to an edge diameter defining a transition area;a strengthening wall extending from the edge diameter of the transition area to a bottom edge and defining an outer gear-shaped path about the central axis, wherein the outer gear-shaped path has a first outer diameter and a first inner diameter, and the first inner diameter ratio to the first outer diameter is greater than 75%, the first outer diameter of the outer gear-shaped path is less than the top edge diameter;a bottom wall formed from the bottom edge of the strengthening wall and having a depression centered about the central axis;an inner gear-shaped path about the central axis defining the depression centered about the central axis, the inner gear-shaped path comprising a second outer diameter and a second inner diameter, wherein the second outer diameter is less than the first outer diameter and the second inner diameter is less than the first inner diameter; anda base formed inside the depression of the inner gear-shaped path and centered about the central axis, the base, the inner gear-shaped depression, the bottom wall, the outer gear-shaped strengthening wall, and the tapered sidewall being molded from plastic to form a continuous fluid-tight vessel.

13. The container of claim 12, wherein the inner gear-shaped path is aligned with the outer gear-shaped path.

14. The container of claim 12, further comprising a filter material supported by the flange to form a bag within the container wherein the bottom of the bag is spaced from the bottom wall, and the bag contains a powder, wherein the powder is coffee, tea, or cocoa.

15. The container of claim 12, wherein the strengthening wall with the gear-shaped path is 0.100″ thick as measured from the bottom wall to the transition area and the inner gear-shaped path defines a depression in the bottom wall that is 0.100″ deep along the bottom wall.

16. A pierceable plastic container comprising: a circular top flange extending between an outside edge and a circular inside edge centered on a longitudinal, central axis, the circular inside edge having an edge diameter;a tapered sidewall extending from the circular inside edge to an edge diameter defining a transition area;a strengthening wall extending from the edge diameter of the transition area to a bottom edge, the strengthening wall defining a gear-shaped path about the central axis, the gear-shaped path comprising an outer diameter and an inner diameter, the inner diameter ratio to the outer diameter being greater than 75%, the outer diameter of the path is less than the top edge diameter;a bottom wall formed from the bottom edge of the strengthening wall, the bottom wall comprising a depression centered about the central axis;a circular diameter defining the depression, the circular diameter being less than the inner diameter of the gear-shaped path; anda base formed inside the depression and centered about the central axis, the base, the depression, the bottom wall, the strengthening wall, and the tapered sidewall being molded from plastic to form a fluid-tight vessel.

17. The container of claim 16, wherein the recess provides stress relief to restrict the inward deflection of the bottom wall when the piercing needle of a single-serve coffee maker pierces the bottom wall.

18. The container of claim 16, further comprising a filter material supported by the flange to form a bag within the container wherein the bottom of the bag is spaced from the bottom wall, and the bag contains a powder, wherein the powder is coffee, tea, or cocoa.

19. The container of claim 16, wherein the strengthening wall with the gear-shaped path is 0.100″ thick as measured from the bottom wall and the circular diameter centered on the central axis creates a depression that is equal to 0.100″ deep along the bottom wall.

20. The container of claim 16, wherein the circular top flange edge diameter is 2.00″, wherein a height of the container is 1.733″ measured along the central axis, and the outer diameter of the gear-shaped path is 1.40″.