WO2009075686A1 - Appareil de conteneur et procédés liés - Google Patents

Appareil de conteneur et procédés liés Download PDF

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Publication number
WO2009075686A1
WO2009075686A1 PCT/US2007/087321 US2007087321W WO2009075686A1 WO 2009075686 A1 WO2009075686 A1 WO 2009075686A1 US 2007087321 W US2007087321 W US 2007087321W WO 2009075686 A1 WO2009075686 A1 WO 2009075686A1
Authority
WO
WIPO (PCT)
Prior art keywords
container
corner
sidewall
web
containers
Prior art date
Application number
PCT/US2007/087321
Other languages
English (en)
Inventor
Frano Luburic
Joshua Dana Urban
Ralph G. Perkins
Original Assignee
Ropak Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Ropak Corporation filed Critical Ropak Corporation
Priority to PCT/US2007/087321 priority Critical patent/WO2009075686A1/fr
Priority to US12/222,912 priority patent/US8256640B2/en
Priority to CA2713640A priority patent/CA2713640C/fr
Publication of WO2009075686A1 publication Critical patent/WO2009075686A1/fr
Priority to US13/557,824 priority patent/US20130020336A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/40—Details of walls
    • B65D1/42—Reinforcing or strengthening parts or members
    • B65D1/44—Corrugations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/0046—Details relating to the filling pattern or flow paths or flow characteristics of moulding material in the mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/37—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings
    • B29C45/372—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings provided with means for marking or patterning, e.g. numbering articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/22—Boxes or like containers with side walls of substantial depth for enclosing contents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D21/00—Nestable, stackable or joinable containers; Containers of variable capacity
    • B65D21/02—Containers specially shaped, or provided with fittings or attachments, to facilitate nesting, stacking, or joining together
    • B65D21/0233—Nestable containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/42—Moulds or cores; Details thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
    • B29C2033/422—Moulding surfaces provided with a shape to promote flow of material in the mould cavity

Definitions

  • the present invention relates generally to containers, and more specifically to methods and apparatus for designing, manufacturing, and using containers that have improved strength-to-material and/or strength-to-weight ratios, thereby reducing the raw materials and other costs needed to fulfill a given application or serve a given purpose.
  • a related CAD method can be used for more complicated geometries of the container or similar things.
  • Containers are useful and necessary in human society. In modern commerce and applications, they are used in a vast array of applications, some more demanding than others.
  • containers (like other manufactured items) need to use a minimum amount of material. Not only does this reduce the waste that results at the end of the container's useful life, it also reduces the costs of materials to manufacture the container, reduces the transportation costs that can be involved in using the container, and provides other benefits. For containers made from plastic or similar materials, the rising costs of materials and the need for ecological responsibility can be substantial. [0004] On the other hand, many or even most containers require some degree of reliable structural integrity. Among other things, they may be stacked three or four (or more) high on pallets for storage and/or transportation, and possibly have other pallets or objects stacked on top of those stacks.
  • Square, rectangular, or other cornered containers can more efficiently use a given volume of space on a pallet and/or in a warehouse or retail store (as compared to conventional round plastic buckets). They can benefit from the foregoing reduction in material usage, and can provide interesting design and performance challenges as compared to non-cornered containers.
  • Design and performance characteristics for a container or other product also may be important with respect to material selection. For example, in certain applications, one material may be preferred or even required instead of another (e.g., polypropylene instead of polyethylene) in order to meet the performance criteria (such as withstanding anticipated vertical compression loads or other forces).
  • one material may be preferred or even required instead of another (e.g., polypropylene instead of polyethylene) in order to meet the performance criteria (such as withstanding anticipated vertical compression loads or other forces).
  • reducing the non-material costs of manufacture also improves the economics and ecological considerations of making and using a given container. For example, to the extent that the energy requirements for making a given container can be reduced, the economic and environmental characteristics of the container and fabrication process are also improved. For applications and processes such as injection molding of plastic containers or other products, a lower injection pressure (to inject the plastic into a mold) can mean that less energy is needed to manufacture that product.
  • the invention provides containers having an integral structural support network, skeleton, or web formed within the container sidewalls.
  • the network can strengthen and improve the container's resistance to buckling and other forces, such as those that may occur when the container is loaded with product or is in a stack of heavy objects (such as similar containers).
  • the container of the invention preferably includes various combinations of some or all of the following: (1) a bottom and a sidewall portion extending upwardly therefrom; (2) at least one corner in horizontal cross section of the sidewall; (3) at least one "flow leader" pathway leading from a sprue injection point to other areas of thickened "webbing", to reduce the injection pressure or force required to injection- mold plastic in forming the container; (4) the corner including a generally constant radius along its height, to provide improved nesting characteristics; (5) the sidewall including an outwardly arced or curved shape in horizontal cross-section, to further reduce the likelihood of sidewall buckling under load, or other structural failures; and (6) at least one generally horizontal reinforcing rib extending substantially about the sidewall portion of the container to further improve stacking and/or nesting of a plurality of similar containers and provide other benefits.
  • FIG. 1 is an elevated perspective view illustrating a preferred embodiment of a container assembly of the invention, for a container having a generally rectangular cross-section or footprint;
  • FIG. 2 is similar to FIG. 1, but shows the container from a lower viewpoint (including showing the bottom of the container);
  • FIG. 3 is a section view of the upper surface of the bottom of the container of Fig. 1, sectioned along plane 3-3 of Fig. 1;
  • FIG. 4 is similar to Fig. 3, but is taken along a higher plane 4-4 of Fig. l;
  • FIG. 5 is an enlarged partial view taken along line 5-5 of Fig. 4;
  • FIG. 6 is similar to Fig. 5, but is taken along line 6-6 of Fig. 5, and is still further enlarged to better illustrate the details of the varying thicknesses of the sidewall at the web 30 (at locations a and c, for example) as compared to adjacent non-web portions (such as at locations b and d);
  • FIG. 7 shows a cross-section of the corners of two nested containers of the invention (Container X nested inside Container Y), both having a generally constant (non- tapering) radius of curvature in their respective corner sections;
  • FIG. 8 shows a cross-section of the corners of two nested containers (Container W nested inside Container Z), both having a generally tapered radius of curvature (e.g., a radius that is smaller near the bottom of the container as compared to the top);
  • FIGS. 9 A and 9B are similar to FIGS. 7 and 8, but show a more complete elevational cross-section of two nested containers, with 9B taken along the line 9B- 9B of Fig. 9A;
  • FIGS. 1OA and 1OB are similar to FIGS. 9A and 9B, but show two nested containers having a tapered corner radius;
  • FIGS. 1 IA and 1 IB are similar to FIGS. 9A and 9B, but show two nested containers having a generally non-tapered (constant) corner radius and a diamond pattern web formed on the sidewall and corner;
  • FIGS. 12A and 12B are similar to FIGS. 9A and 9B, but show two nested containers having a tapered corner radius and a diamond pattern web formed on the sidewall and corner;
  • FIG. 13 is an elevation view of one of the many embodiments of the web and/or flow leaders of the present invention, illustrating a section of a product surface having a generally diamond-shaped flow leader pattern;
  • FIG. 14 is similar to FIG. 13, but illustrates yet another of the many alternative embodiments of the present invention, a section of the container sidewall with circular web patterns;
  • FIG. 15 is similar to FIGS. 13 and 14, but illustrates yet another of the many alternative embodiments of the present invention, a section of the container sidewall with a combination of diamonds and vertical bars as a web or flow leader pattern;
  • FIG. 16 is similar to FIGS. 13 , 14 and 15, but illustrates yet another of the many alternative embodiments of the present invention, a section of the container sidewall with triangular flow leader patterns (with the triangles being equilateral and effectively forming hexagons as well);
  • FIG. 17 is similar to FIGS. 13, 14, 15, and 16, but illustrates yet another of the many alternative embodiments of the present invention, a section of the container sidewall with rectangular web/flow leader patterns;
  • FIGS. 18-21 illustrate various ways in which patterns such as those in Figs. 13-17 may be incorporated within various container sidewalls or similar products;
  • FIG. 22 shows one of the many alternative bottoms or base flow leader patterns in which the invention can be practiced
  • FIG. 23 is an enlarged view taken along line 23-23 of Fig. 3;
  • FIG. 24 is an elevational sectional view taken along line 26-26 of Fig. 1
  • FIG. 25 is an elevational sectional view taken along line 29-29 of Fig. l;
  • FIG. 26 is an isometric sectional view taken along line 26-26 of Fig. 1;
  • FIG. 27 is an enlarged view of the lower portion of Fig. 25, taken along line 27-27;
  • FIG 28 is an enlarged view of the portion of Fig. 26 taken along line 28-28;
  • FIG. 29 is an isometric sectional view taken along line 29-29 of Fig. 1;
  • FIG. 30 is an enlarged partial view taken along line 30-30 of Fig. 29;
  • FIG. 31 shows an isometric upper view of yet another of the many alternative embodiments of the invention, including a round bucket or container having a bottom portion having a criss-cross "web" pattern rather than "just" flow leaders;
  • FIG. 32 is an sectional view of the bucket of Fig. 31;
  • FIG. 33 is an enlarged partially sectional view of the lower right corner of Fig. 32; [00043] FIGS. 34 A-D show four of the many corner cross-sections with which the invention may be used;
  • FIG. 35 is an isometric view of another embodiment of the invention, in the form of a container having a generally square footprint;
  • FIG. 36 is a section view of the container of Fig. 35;
  • FIG. 37 is an isometric view of yet another embodiment of the invention, showing a rectangular container with a covering lid;
  • FIG. 38 is sectional view of the container and lid of Fig. 37; and [00048]
  • FIG. 39 is an isometric bottom view of a lid such as shown in Fig. 37 and 38.
  • the invention preferably is used to fabricate containers or similar things from any suitably strong, lightweight material.
  • the general and specific shape and dimensions of the container, including its base and sidewall portions, can be configured across a wide useful range, depending on the materials used, the applications for which the container is intended, and other factors.
  • the present disclosure focuses in large part on containers having a generally rectangular cross-section and tapered sides, many aspects of the invention can be incorporated into a wide variety of containers having other cross- sections, non-tapering sides, and other design variations.
  • the invention preferably includes a container 10 having a sidewall 12/14 attached to or integrally formed with a base 16.
  • the sidewall 12/14 preferably includes a web or pattern 30 of one or more series of "bars", or “columns" of relatively increased wall thickness.
  • the pattern can be any that provides the benefits of the invention, including (without limitation) a hexagon or similar honeycomb pattern, triangles or diamonds of a wide range of sizes and shapes, a series of repeating arches or circles, or others.
  • the pattern 30 can include a "mix" of various patterns, or can even be somewhat random.
  • these web patterns can be conveniently formed by providing corresponding shapes within the molds used to form the containers.
  • one embodiment of the invention can include a sprue injection site 17 within the container bottom 16.
  • One or more flow channels or "flow leaders" 18 preferably are provided within the base or bottom 16, to facilitate flow of the molten plastic or other material from the injection site 17 to the relatively wider channels of the web 30, so that the material is injected more efficiently (into the "thicker" webbing areas in greater volume than to the thinner "non-web” areas).
  • flow channels 18 can enable the web 30 to fill more easily (and with less pressure) than by using a generally uniform bottom thickness within the mold (which would not focus the injected material into the thicker web channels before spreading out into the thinner portions of the container sidewall 12/14 in the interstices of the web pattern 30).
  • the flow channels 18 can even themselves form a "web" pattern of their own (see, for example, Figs. 31-33), and/or a given container bottom (or sidewall or lid, or some other portion of another product) can be some combination of flow leaders and/or web patterns. [00057] As further discussed herein, some of the enlarged views in the attached
  • Figures further illustrate a preferred "curved" exterior surface for the channels forming the web 30.
  • Those enlarged views also illustrate how the intersection of two such curves (which can be viewed as intersecting crescent or half-moon flow channels) results in various horizontal and/vertical "lines" occurring at the intersections, in an elevation view of the web 30.
  • the materials flowing into the mold preferably are not "blocked" by those intersection lines - the lines instead are simply the visible exterior surface result of two curved geometries intersecting each other (for embodiments in which those top surfaces are flat and not curved, those "intersection" lines do not exist).
  • the web and flow leader elements discussed herein can be in any of a wide variety of cross-sectional shapes, such half-moon shapes provide a number of benefits. Among other things, they can make it easier to remove the molded part from the mold, reduce the amount of material required to form a suitable part, make it easier for the plastic to be dispensed through the mold during the molding process, ensure easier and/or more complete emptying or dispensing of the container's contents during use of the container, assist in spreading certain stress/loads (such as by eliminating sharp edges that might otherwise "harden” the molded product in those "sharp” areas and reduce desired flexibility characteristics of the product at that "sharp” location), etc.
  • the outer edges of the web 30 preferably gradually taper to a maximum thickness near the center of the web/flow channel's cross-section.
  • the embodiment illustrated in the drawings has an arc-like or crescent/half-moon cross-sectional shape that provides the desired "thicker" portion of the web element 30 in the center of that cross section.
  • this tapering also can improve the molding process and the performance of the container, require less plastic, and allow the containers to release faster from a nested state.
  • the sidewall 12/14 preferably is bowed at least slightly outwardly, away from the interior of the container 10. As shown in Fig. 4, such bowed or outwardly arced portions can be conveniently located between corners 20/22/24/26, such as locations A, B, C, and D. This outward arching helps ensure that compressive loads imposed upon the container sidewall force the sidewall outwardly and thereby take advantage of the hoop strength of the container sidewall.
  • a conventional CAD software system can be used to create a straight- walled container having a desired web pattern formed therein.
  • a user can then manipulate that design by hand, within the CAD program, to pull the sidewall into a different, non-dashed straight alignment such as a bow.
  • Each of the various elements of the strengthening pattern in the sidewall must be repositioned by hand into the new "plane" of the sidewall (or other part of the product being fabricated), but once the task is accomplished and saved, the electronic design can be used for purposes of mold creation or other manufacturing steps and processes, just as with any other electronic design.
  • the pattern of the flow leaders and reinforcing elements in the sidewall and corner portions of the container are virtually unlimited, and certainly are not limited to the diamond pattern shown in many of the attached drawings.
  • the pattern formed by the flow leaders and/or the reinforcing web may incorporate and/or constitute a combination of one or more of the following: a circular or round pattern, a hexagon or "honeycomb" pattern, and/or a triangular-shaped pattern. Examples of some of these many alternative designs in the flow leader patterns are shown in Figs. 13-21. Other embodiments can include oval, other sizes and shapes of diamonds, mixed sizes of the same or different shapes, spaced irregularities within an otherwise "regular" web pattern, and others.
  • Figs. 18-21 show elevations of web patterns formed in the "center" of a sidewall, surrounded by "flat" (non-web) portions of sidewall.
  • the flow leaders and sidewall-reinforcing web pattern can help strengthen the bottom and sidewall portions of the container, respectively, and thereby strengthen the entire container assembly generally, to permit performance characteristics that otherwise could only be achieved by non-webbed containers using more total material and having more total weight.
  • the design and location of the flow leaders and/or sidewall-reinforcing web patterns can be especially helpful and important in improving performance characteristics against forces in a downwardly projecting direction.
  • incorporating a sidewall-reinforcing web pattern within a corner element of the container can provide many of the same benefits as it does within the "non-cornered" portions of the sidewall (reduced weight and material for a given strength capacity, etc.).
  • the location and pattern of the web reinforcement within any corner can be any of a wide variety.
  • One such embodiment is illustrated in the figures, and is generally a continuation of the diamond pattern present on the other portions of the sidewall, with the pattern generally "balanced" or centered along the vertical centerline of the corner. In the embodiment of Fig.
  • the diamond pattern covers substantially all of the container sidewall 12/14 (including from lowermost to near the uppermost engaging lip 40 of the container), although other embodiments can include interruptions in the web pattern, complete coverage of the sidewall, etc.
  • the engaging lip 40, Fig. 4 preferably is configured to matingly engage with a corresponding lid element (not shown), which itself can incorporate various aspects of the integrated web reinforcement of the invention.
  • the flow leaders 18 similarly can be shaped and located and sized in a wide variety of ways, and still provide various benefits of the invention. They are illustrated, for example, in Fig. 3 as a series of thickened areas in the bottom portion 16, directing flow from a center sprue injection site 17 to the lowermost portions of the sidewall web pattern 30 (see Fig.
  • sprue/injection sites 17 can be utilized, including on the sidewall itself.
  • These flow leaders 18 preferably extend also to the web 30 where it intersects the bottom 16 in any corner portions of the container.
  • the flow leaders 18 can be oriented and dimensioned at any suitable angle and size, and can be spaced a selected distance apart from each other, depending on the materials used, the applications for which the container is intended, and other factors. Another of the many embodiments of such flow leaders is shown in Fig. 22, as four large flow leaders, each directed respectively from a central injection site on the container bottom toward each of four sides. Multiple series of flow leaders can be introduced within a single container or object, to provide variations in injection flow. The paths of the flow leaders 18 can even overlap each other in certain embodiments (not shown).
  • the "thickness" of a given flow leader and/or reinforcing web element preferably is greater than the thickness of the surrounding sidewall, bottom, lid surface, or other portion of the product.
  • Such "thickening" of the sidewall or other element to form the desired network or web pattern 30 can be of any suitable dimension or scale.
  • a container having wall thickness of 0.050" in non-webbed areas of the container may have a web/flow leader thickness of 0.075"; in such an embodiment, the portion comprising the web or flow leader can be viewed as adding an extra 0.025" added to the adjacent or underlying 0.050" wall.
  • the other polypropylene container that was tested included both (1) the same flow leaders as Container B (formed in its bottom to facilitate the flow of plastic from the sprue injection site to the sidewalls) and (2) a strengthening web pattern in the sidewalls (which permitted the overall plastic material requirements to be further reduced as compared to Container B).
  • Container C the same exterior mold was used in each case (resulting in an identical outer shape for each of Containers A, B, and C), and the interior portion of the injection-molding mold was changed to achieve the differences discussed herein. Similar results (as discussed herein) should be achieved in other embodiments (such as where the flow leaders/web patterns are formed on the exterior of the container, or on both the interior and exterior).
  • a container without a web and flow leader pattern (Container A) used approximately 50% more plastic (700 gms compared to 470 gms). It required a higher tonnage to inject, and actually had a lower compression strength (it was not as strong under compression/vertical loading - 1260 lbs. compared to 1330 lbs.). Accordingly, and among its many benefits, in this example the invention allowed the use the same equipment (except for changing the inside mold) and the same injection machines, but required less material and provided better product performance.
  • the flow leaders and web pattern also can enable the use of other materials than those used in prior art designs. For example, (depending on the location within the world, and pricing/subsidies/markets at any given time in those locations) because of the improved injection performance provided by the flow leaders and/or web pattern of the invention, similar containers can be made from less expensive and/or more easily recycled materials (e.g., polypropylene - which typically has better top load-bearing performance characteristic - rather than conventional polyethylene).
  • the flow leader and pattern within the sidewall can be generally uniform about the circumference of the container.
  • the wall thickness in the corners normally needs to be thicker than the rest of the sidewall, because most of the compressive load (in stacked pallets of filled containers, etc.) is supported on the corners.
  • Conventional tapering of the sidewalls also can impact the design of these corners and the ability of any given design to reduce the material used and maintain desired strength and sufficient spacing between nested containers to facilitate easy removal of a nested container from within another container.
  • the invention preferably is practiced with a non-tapering corner radius. That is, the radius of curvature around the corner remains generally constant throughout the height of the sidewall, rather than reducing to a "tighter" radius near the bottom 16.
  • the spacing between the nested containers is increased, permitting the "extra" wall thickness of the web pattern to be included in the corner without creating undesired frictional engagement between the nested containers' corners.
  • filling line speed can increase (because the containers can be delivered to the filling lines at a faster rate) and overall efficiency of use can be improved.
  • One or more separating ribs 60, Fig. 4 can be provided to help keep the containers spaced from each other when nested, to further ensure desired easy de-nesting.
  • FIGS. 7 and 8 Another aspect of the invention is illustrated in FIGS. 7 and 8, comparing the nesting relationship of containers that have a constant radius corner section with those of a tapered radius corner section.
  • the corner radius generally “constant” (or untapering) as you travel along the height of the corner (FIG. 7)
  • the total corner wall thickness can be greater than compared to a tapered corner radius (see FIG. 8).
  • this facilitates the incorporation of "thicker" web areas formed through and around the corner areas of a given container, and generally allows for a stronger corner. Because corners typically are a load-bearing location in cornered structures, providing stronger corners can improve the performance of the container and/or allow a given container to exceed the performance limitations faced by conventional constructions.
  • non-tapered corner embodiments of the invention also have a greater space or gap between the containers when they are nested with each other. This ensures a relatively easier release of the containers from each other when they are denested (which can be important not only for manual denesting, but especially so when denesting is accomplished via machine and/or as part of an assembly line filling operation).
  • FIGS. 9, 10 , 11, and 12 provide a further comparison between various nested containers.
  • FIG. 9 shows containers having a constant corner radius section without integral diamond web patterns
  • FIG. 10 shows tapered corner radius sections without diamond web patterns
  • FIG. 11 shows constant corner radius sections with diamond web patterns
  • FIG. 12 shows tapered corner radius sections with diamond web patterns.
  • the corner gap of the nested containers with constant corner radius sections without diamond web patterns is greater than the gap of the nested containers with tapered corner radius sections without diamond web patterns.
  • the corner wall thickness of the containers with constant corner radius sections is greater than the corner wall thickness of the containers with tapered corner radius sections (0.055" compared to 0.035").
  • the corner gap is greatest in the nested containers with constant corner radius and diamond web pattern (0.0144"), compared to the other containers (containers with constant tapered corner radius sections without diamond web pattern (0.0291”) and containers with tapered corner radius sections with diamond web pattern (0.0141”)).
  • the outer surface of the sidewalls can be relatively smooth (with no physical disruption at the positions of the web).
  • Alternative embodiments can instead provide a similarly smooth interior (with the web "protrusion” visible and tactilely perceptible on the outside of the sidewall 12/14), or anywhere between those extremes (some of the web showing on both inside and outside of the sidewall).
  • one or more generally horizontal rib structures 50 can provide additional structural integrity to the container.
  • Such ribs 50 preferably surround the periphery of the container's exterior near the upper lip 40 to provide, among other things, additional hoop strength against internal loads and vertical compressive forces.
  • the ribs span across the flow leaders and are affixed to the sidewalls near the top of the container, although they can be positioned in any desired location and pattern, including being interrupted, on non-uniform width around the container, etc.
  • the location, angle, frequency, thickness, and other characteristics of any such reinforcing ribs can be customized depending on a variety of factors.
  • One or more handles 52 and/or attachment points 54 can be formed on the sidewall portion, and may be connected to or integrally formed with a horizontal rib such as rib 50.
  • the molten plastic, or other material is preferably introduced into the mold at the sprue injection site or gate 17 at the center of the bottom 16 of the container.
  • flow leaders extend from the gate 17 area to the sidewalls 12/14, where they intersect the overlapping web pattern 30. The plastic then flows up the sidewalls 12/14 to the top of the container, until the mold is completely filled.
  • the flow leaders preferably extend out uniformly around the circumference/to all sides of the container.
  • the invention preferably includes container sidewalls 12/14 that have a slight outward arc to them, such that the sidewalls 12/14 bow slightly outwardly, even when unfilled.
  • the sidewalls can be tapered from the top of the container to the bottom of the container such that the arced or curved sidewall shape is generally continuous in cross- section for at least substantially the entire height of the sidewalls, but the radius of the arcs at the bottom of the container sidewalls is smaller than the radius of the arcs at the top of the container sidewalls.
  • the width of the container (from one sidewall to its opposite sidewall) at the top is wider than the width of the container at the bottom.
  • the curved or arc-shaped sidewalls provide structural integrity to the container such that container is able to hold its shape after molding.
  • Containers with straight sidewalls i.e., the center of the container is the same width as the corner width
  • the preferred embodiment of the present invention provides methods and apparatus for strengthening containers by forming tapered sidewalls, with flow leader patterns, so that the cross-section of the sidewall includes "concave out” arced or curved sidewalls.
  • the invention includes forming one or more cross-sectional shapes or patterns into a container sidewall.
  • the shape or pattern of the strengthening web 30 incorporated into the container sidewall 12/14 can be relatively consistent, can include spaced irregularities, can have sharp or smooth patterns or elements, etc.
  • the "depth" of the pattern (how far in or out the element is positioned off of the general trend line of the wall's cross-section) and the particular cross-sectional shape itself can be selected in order to provide varying degrees of "strength" for a given wall thickness and/or for a specific location on the sidewall.
  • the wall thickness itself can be varied at locations around the container and can even include a single corrugation or multiple corrugations, to provide more or less strength and weight, etc.
  • the patterns or elements formed in the sidewalls extend generally the full height of the sidewall, and can "terminate" at or near the top and bottom in any suitable manner.
  • the patterns or elements can extend for only a part of the height of the wall, can be formed in sections spaced vertically from each other in a single container sidewall, or can be in any of a wide variety of other configurations and combinations.
  • Figures 34 A-D show four of the many corner cross-sections with which the invention may be used.
  • Fig. 34A is similar to many of the cornered embodiments of the other
  • Fig. 34B shows a "double -concave” corner
  • Fig. 34C shows a single-concave corner shape
  • Fig. 34D shows an "angled" corner (four bend lines with generally straight sections between them, to traverse an approximately 90 degree corner).
  • Figures 35 and 36 show yet another embodiment of the invention, in the form of a container having a generally square footprint.
  • Figures 37-39 likewise show a further of the many alternative embodiments of the invention, as a generally rectangular container with an associated lid.
  • Methods of the invention include, by way of example and not by way of limitation, forming containers of the type described herein, nesting and stacking same, handling materials using such containers, and other methods.
  • forming containers of the type described herein nesting and stacking same, handling materials using such containers, and other methods.
  • persons of ordinary skill in the art will understand that the flow leaders make it less likely that heavy loads (such as caused by the contents of the containers and/or by the stacking of similar containers, or other things) will buckle the sidewall of the container.
  • the invention can be practiced in a wide variety of embodiments.
  • the invention can be practiced with other corner shapes (convex, wavy, centered vertical channel with one or more grooves on each side, one or more "sharp" angles combined to wrap around a corner, etc.).
  • corner shapes convex, wavy, centered vertical channel with one or more grooves on each side, one or more "sharp" angles combined to wrap around a corner, etc.
  • the invention can further allow designers to improve and refine and customize the performance of various products.
  • the web 30 itself can even function as a "spring” to allow slight deformation of the container (without a complete failure of the container) and even a "spring back" into the product's original desired shape.
  • Benefits of the invention include, again by way of example and not by way of limitation, thinner walls being able to carry greater loads, less material being required to provide a container of a given "strength", etc.
  • the invention may be used on containers for transporting materials and things. In such applications, the container itself is simply added weight that must be transported (the thing inside the container typically being the item sought by the end user). Accordingly, by providing sufficient container wall strength with less material, the costs of shipping are reduced because each "thing" in its package weighs less. Furthermore, shipping costs are reduced because the containers nest within each other, providing a means for stacking the containers such that they occupy less space and thus more containers can be shipped at one time. Therefore, persons of ordinary skill in the art will understand that the invention is economically and environmentally beneficial.

Abstract

L'appareil et les procédés permettant de concevoir, de fabriquer et d'utiliser des conteneurs selon la présente invention fournissent de meilleurs rapports résistance-matériau et/ou résistance-poids, ce qui permet ainsi de réduire les coûts liés à la matière première et les autres coûts nécessaires pour répondre à une application donnée ou servir un objectif donné. Un motif en réseau 30 est formé d'un seul tenant à l'intérieur d'une paroi latérale de conteneur 12/14. En ce qui concerne les modes de réalisation avec coins, le réseau de renforcement est intégré au moyen d'au moins un coin 20. En ce qui concerne les processus de fabrication tels que le moulage par injection, des voies d'alimentation (ou des voies d'orientation d'écoulement) 18 facilitent l'injection tout en réduisant les besoins en énergie. Les procédés de conception assistée par ordinateur permettent d'obtenir des formes de conteneurs et d'autres produits qui ne peuvent normalement pas être réalisés à l'aide d'un logiciel classique et d'outils de conception liés.
PCT/US2007/087321 2007-12-13 2007-12-13 Appareil de conteneur et procédés liés WO2009075686A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
PCT/US2007/087321 WO2009075686A1 (fr) 2007-12-13 2007-12-13 Appareil de conteneur et procédés liés
US12/222,912 US8256640B2 (en) 2007-12-13 2008-08-19 Container apparatus and related methods
CA2713640A CA2713640C (fr) 2007-12-13 2008-12-11 Receptacle et procedes associes
US13/557,824 US20130020336A1 (en) 2007-12-13 2012-07-25 Container apparatus and related methods

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2007/087321 WO2009075686A1 (fr) 2007-12-13 2007-12-13 Appareil de conteneur et procédés liés

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US12/222,912 Continuation US8256640B2 (en) 2007-12-13 2008-08-19 Container apparatus and related methods

Publications (1)

Publication Number Publication Date
WO2009075686A1 true WO2009075686A1 (fr) 2009-06-18

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WO (1) WO2009075686A1 (fr)

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US8925755B2 (en) 2010-04-13 2015-01-06 Ipl, Inc. Tamper evident system and method
NL2011948C2 (nl) * 2013-12-12 2015-06-15 Tom Franklin Fikkert Gespuitgiet kunststof krat en werkwijze daarvoor.
EP3385188A1 (fr) * 2017-04-05 2018-10-10 Ipl Inc. Récipient et son procédé de fabrication

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US3362576A (en) * 1964-01-06 1968-01-09 Dow Chemical Co Plastic tote case and method of making same
US4375265A (en) * 1978-07-21 1983-03-01 Wetering Gerrit Van De One piece molded pallet-container
US6701200B1 (en) * 2001-12-27 2004-03-02 The Protomold Company, Inc. Automated custom mold manufacture
US20050189360A1 (en) * 2003-02-05 2005-09-01 Rubbermaid Incorporated Laundry basket with hip hugging feature

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Publication number Priority date Publication date Assignee Title
US3362576A (en) * 1964-01-06 1968-01-09 Dow Chemical Co Plastic tote case and method of making same
US4375265A (en) * 1978-07-21 1983-03-01 Wetering Gerrit Van De One piece molded pallet-container
US6701200B1 (en) * 2001-12-27 2004-03-02 The Protomold Company, Inc. Automated custom mold manufacture
US20050189360A1 (en) * 2003-02-05 2005-09-01 Rubbermaid Incorporated Laundry basket with hip hugging feature

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US8925755B2 (en) 2010-04-13 2015-01-06 Ipl, Inc. Tamper evident system and method
NL2011948C2 (nl) * 2013-12-12 2015-06-15 Tom Franklin Fikkert Gespuitgiet kunststof krat en werkwijze daarvoor.
WO2015088330A1 (fr) * 2013-12-12 2015-06-18 Tom Franklin Fikkert Caisse en plastique moulée par injection et son procédé de fabrication
EP3385188A1 (fr) * 2017-04-05 2018-10-10 Ipl Inc. Récipient et son procédé de fabrication

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