Note: Descriptions are shown in the official language in which they were submitted.
2043958
COMPOSITE CONTAINER AND ASSOCIAl~ CARRIER
EIELD OF THE INVENTION
This invention generally relates to containers
for holding various materials, particularly liquid
foodstuffs, for example milk, water, juice, dish and
laundry detergent, as well as petroleum products
such as motor oil and the like. More specifically,
the present invention relates to a collapsible,
disposable container and a relatively rigid reusable
container carrier which is adapted to receive the
collapsible container in a nested relationship, and
w~lich enables the consumer to use and then dispose
of the empty container. Identical refill containers
may be purchased for use alone or with the
relatively permanent and reusable carrier.
BACKGROUND AND SUMMARY OF THE INVENTION
In my earlier issued U.S. Patent No. 4,805,799,
novel containers are disclosed which include a
substantially rigid upper container segment, a
flexible bladder integral with, and depending from,
the upper container segment, and a lower
substantially rigid container segment attached to
the upper container segment so that the flexible
bladder is housed therewithin. While the containers
disclosed in that patent are usable in many end-use
applications, certain specialized end-use
applications demand equally specialized containers.
2 20~3~58
The containers of the present invention
represent improvements over the container disclosed
in my earlier filed parent and related applications,
and are particularly well suited for use in
additional special end-use applications as described
further herein.
There is great concern in government and in the
food packaging industry for potential environmental
hazards associated with disposable plastic
containers used in the packaging and sale of
beverages such as milk, water, juice, etc. and other
liquids or semi-liquids (viscous liquids) such as
motor oil, detergents, ketchup, etc. It has been
estimated that in the dairy industry alone, as much
as 500 million pounds of plastic are required each
year for consumer oriented container applications,
virtually all of which eventually finding its way to
landfills and/or'other waste sites. Significant
amounts of waste plastic are also produced by the
manufacture of such large amounts of plastic,
thereby also contributing to the waste problem. The
container assemblies of the present invention
alleviate this problem to the extent of reducing the
plastic required to form, for example a one-gallon
container, by about fifty percent.
Moreover, and quite surprisingly, applicant has
discovered that even with only approximately half
the plastic content, containers made in accordance
with this invention nevertheless pass the standard
beverage container "drop test", by utilizing a low
density polymer plastic, preferably polyethylene, in
the container construction as disclosed herein.
D
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3 20~39~8
As a result of this discovery, raw material
costs for producing one gallon plastic containers
are also reduced by about fifty percent. Given the
sheer volume of such containers currently produced
in the U.S., it is readily apparent that substantial
savings, estimated at about 50% per unit for raw
material costs, can be realized by constructing
containers in accordance with this invention.
Similar relative savings can be expected in smaller
(for example, one pint and quart) and larger (for
example, five gallon) containers. In addition to
reduced cost, the amount of plastic disposed of by
the consumer will also be reduced by as much as
about 50%, and the reduced raw material requirements
will also result in reduced waste disposal at the
plastics manufacturing plant.
In one exemplary embodiment of the invention, a
collapsible container and carrier assembly is
provided which includes an open-top, relatively
rigid carrier and a relatively thin, flexible and
collapsible container having an integral dispensing
portion adapted to receive a conventional closure,
e.g., a screw on cap. The container, which is
preferably normally self-supporting (filled or
empty), may be nested within the carrier.
In accordance with a preferred use of the
invention, packagers in the dairy industry would
fill one ga~lon plastic containers in accordance
with this invention, ship the containers to
retailers, divided proportionately (as determined by
market demand) between containers nested in
carriers, and stand alone containers. Additional
carriers would also be supplied for separate sale,
4 20939S8
again as determined by consumer demand. Consumers
would then purchase one or more of the relatively
rigid reusable carriers and filled containers, and
will thereafter purchase "refill" or "insert"
plastic containers for nesting within the carriers
or for use alone, as will be described further
herein. The containers themselves would be
collapsed and disposed of upon depletion of the
liquid contents, and the collapsibility feature will
result in significantly reduced volumes of waste.
It will be appreciated that the relatively
rigid carriers provide protection, strength and
rigidity to the overall assembly, which is
particularly advantageous when the inner container
is less than full, and thus more easily collapsed
merely by handling. Specifically, the carrier and
container shape are preferably complimentary so that
good support is afforded to substantial portions of
the container side and bottom walls.
It is a further advantageous feature of the
invention that the container is releasably held
within the carrier, so that pouring of the liquid
contents is easily accomplished via use of a handle
provided on the carrier, without danger of the
container sliding out of the carrier.
It should be appreciated that while using the
container with an associated carrier has certain
benefits and advantages as described herein, the
container may be used alone if desired. In other
words, in the preferred embodiment, the container is
normally self-supporting, but collapsible. This
means that the container will stand alone both
filled and empty, and the li~uid contents may be
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poured from the container in a controlled fashion,
particularly if the bottom of the container is held
with the other hand to prevent the body of the
container from collapsing during pouring.
Thus, in accordance with one aspect of the
present invention, there is provided a container
comprising a relatively thin, flexible stand-alone
but collapsible polymer container body having a
peripheral side wall, a bottom wall and a top wall,
the top wall having a unitary, upstanding dispensing
portion formed therein; the peripheral side wall of
said container body having a thickness of between 2
and about 12 mil, the dispensing portion of said top
wall having a thickness of at least about 15 mil,
and wherein the container body is self-supporting
both filled and empty and sufficiently strong for
stand-alone use.
In accordance with another aspect of the
invention, a collapsible container and carrier
assembly comprises a relatively rigid plastic
carrier having a substantially open upper end, a
first peripheral side wall and a first bottom wall
defining a first shape; a relatively thin, flexible
stand-alone but collapsible polymer container body
having a second peripheral side wall and a second
bottom wall defining a second shape substantially
complementary to the first shape; the container body
also provided with a top wall, the top wall having a
unitary, relatively rigid upstanding dispensing
portion formed therein, the second peripheral side
wall of said container body having a thickness of
between 2 and about 12 mil, the dispensing portion
of said top wall having a thickness of at least
6 20~3sss
about 15 mil, wherein said container body is
self-supporting both filled and empty and
sufficiently strong for stand-alone use, and wherein
the container body is nestable within the outer
carrier so that substantially all of the first
peripheral side wall and first bottom wall are in
engagement with and provide support for the second
peripheral side wall and second bottom wall, the
carrier being provided with a handle on an exterior
side thereof to facilitate pouring of contents from
the container body.
In accordance with another aspect of the
invention, a method of packaging and distributing
liquid filled containers comprising:
a) providing a plurality of relatively rigid
and reusable carriers each having a first peripheral
side wall including a handle, a first bottom wall,
and an open upper end;
b) providing a plurality of of replaceable,
flexible, normally self-supporting and collapsible
containers each having a second peripheral side
wall, a second bottom wall and top wall, formed with
a dispensing portion therein, the second peripheral
side wall having a thickness of between 2 and about
6 mil;
c) filling the containers with a liquid and
applying removable closures to the dispensing
portions; and
d) shipping at least some of the filled
containers to retailers in a stand-alone mode
without external support such that end users may
utilize the containers in either a stand-alone mode
or in nested relationship with the carriers, the
20~3958
carriers being reusable with other of the
replaceable containers.
Thuæ, in accordance with the present invention,
the cost of such beverage and other liquid
containers can be significantly reduced, while at
the same time alleviating environmental concerns by
reason of a significant reduction in the amount of
plastic required to manufacture such containers, and
a concurrent reduction in amount and volume of
plastic container waste at the consumer and
manufacturing levels.
Additional objects and advantages of the
variously described exemplary embodiments of the
invention will become apparent after careful
consideration of the detailed description which
follows.
BRIEE DESCRIPTION OF TUE DRAWINGS
FIGURE 1 is a perspective, exploded view of a
container and associated carrier in accordance with
the present invention; and
FIGURE 2 is a side cross sectional view of the
container and carrier shown in Figure 1, but in
nested relationship.
FIGURE 3 is an enlarged detail of a portion of
Figure 2, but illustrating a wall thickness
variation;
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FIGURES 4 and 5 are peræpective views of a
container in accordance with another embodiment of
the invention;
FIGURES 6 and 7 are perspective views of a
container in accordance with another embodiment of
the invention;
FI~JURE 8 is a side elevation of a container in
accordance with still another embodiment of the
invention; and
FI~URE 9 is a side view, partially in section,
showing the container of Figure 8 in combination
w-th an assoc~ated carrier, in a pouring orientation.
DETAILED D~SCRIPTION OF T~E DRAWINGS
Referring to Figures 1 and 2, a carrier 10 is
provided in the form of a pitcher, and is
preferably, but not necessarily, constructed of
relatively rigid plastic material. The carrier is
formed with a periphera~ side wall 12, a bottom wall
14, and an upper open end 16. The upper open end
may be provided with an integrally formed peripheral
reinforcing ring or rib 18.
The peripheral side wall 12 has a substantially
square configuration, with four substantially
identical sides, but it will be understood that
other shapes sucn as round, rectangular, or
polygonal could also be used.
%
20~3958
A handle 20 is provided on the carrier, with an
upper portion 24 joined to the reinforcing ring 18
and a lower portion 22 joined to a lower portion of
the side wall 12. While the handle is shown to have
a somewhat modified C-shape, any handle
configuration conducive to a pouring motion can be
employed.
Opposed tabs 26, 28 are formed on the interior
surface of the reinforcing ring and serve to hold
the container within the carrier as described in
more detail below.
The collapsible container 30 is unitarily
formed by any suitable plastic forming process, and
is preferably a low density polymer, preferably
polyethylene, and includes a peripheral side all 32,
a bottom wall 34 and a top wall 36. The peripheral
side wall 32 is formed with a peripheral reinforcing
ring or rib 38 extending about the upper end of the
side wall at the juncture with the top wall 36. The
top wall 36 incudes an inwardly and upwardly tapered
shoulder 40 which merges with a gently tapered top
wall portion 42. An upstanding dispensing portion
44 is integrally formed with the top wall and
extends upwardly from a generally axially centered
location of the top wall. The dispensing portion 44
includes a generally cylindrical spout 46 provided
with a flanged portion 48 and an exteriorly threaded
portion 50 which is adapted to receive a
conventional closure, such as a screw cap 52. Other
closures may be utilized as well, such as
conventional valve type spouts, and the like.
A textured pattern 54 may be provided over
portions of the top wall 36, if desired, including
.g
20~3~8
the shoulder portion 40 and spout 46 for decorative
purposes, as is conventional in the art.
In one exemplary embodiment of the invention, a
one gallon capacity container has a peripheral side
wall 32 with a thickness of between about 2 and
about 12 mil and preferably about 6 mil. This is
contrasted with a conventional wall thickness of
about 20 mil. The bottom wall 34 preferably has a
thickness substantially identical to the side wall,
but it may be greater if desired, as shown at 34' in
Figure 3. The top wall 36 preferably has a wall
thickness similar to side wall 32, but the
dispensing portion 44 must be thicker to provide the
necessary degree of rigidity to support the
container during filling, handling, and repeated
application and removal of the screw cap S2. Thus,
the dispensing portion in accordance with this
invention remains of a thickness similar to
conventional containers, i.e., at least about 15 to
about 20 mil if the depending portion is blow
molded. If the dispensing portion is compression
molded, thicknesses in particular areas of the
dispensing portion may be as great as 90 mil.
Containers of the above described configuration
and thicknesses will be collapsible but normally
self-supporting, i.e., they will normally stand
alone, empty or filled. It will be understood that
the thickness dimensions provided above are
applicable generally to one gallon and one-half
gallon containers. Thickness dimensions may be
increased for larger containers, for example,
fifty-five gallon drums, but with substantially the
20~3958
same percent reduction in plastic required as
compared to conventional containers of similar size.
Collapsible containers produced in accordance
with this invention, in a conventional one gallon
configuration, weigh about 30 grams, and depending
on the precise wall thicknesses, slightly above (up
to about 60 grams) or below. Conventional one
gallon containers used in the dairy industry
typically weigh between about 57 and 70 grams, the
container in accordance with this invention weighing
up to about 50% less than conventional containers.
Similar percent reductions in weight will accrue
with larger containers as well.
In use, it will be appreciated that the
container 30 will nest within the carrier 10 such
that the peripheral side and bottom walls 12, 14,
respectively, of the carrier will provide
substantially full surface support for the
peripheral side and bottom walls 32, 34 of the
container. In addition, and as best shown in Figure
2, tabs 26, 28 will engage the reinforcing ring 38
just above the latter's upper edge to thereby hold
the container 30 within the carrier 10 during
pouring.
In an alternative use of the container 30, it
is possible to handle and pour the contents from the
container without the carrier 10. In other words,
while the carrier has beneficial features which
enhance the user's ability to pour the liquid
contents from the container, the carrier is not
necessarily required for the container 30 to
function. Thus, user or consumer may pour the
contents from container 30, although two hands may
2043958
be required to provide support, i.e., one hand at
the neck 44, and the other near the lower end of the
side wall 32 and/or bottom wall 34. To facilitate
use of the container alone, an integral, flexible
gripping tab (not shown) may be integrally ~ormed
near the bottom wall 34. The flexibility of the tab
would permit the latter to fold against the side
wall 32 upon insertion into the carrier 10 so as not
to interfere with the nested relationship of the
carrier and container.
In another and preferred aspect of the
invention, a method of packaging and distributing
liquids includes the steps of:
a) providing a relatively rigid and reusable
carrier 10 having a first peripheral side wall 12
including a handle 20, a first bottom wall 14, and
an open upper end 16;
b) providing a flexible, normally
self-supporting and collapsible container 30 having
a second peripheral side wall 32, a second bottom
wall 34 and top wall 36 formed with a dispensing
portion 44 thereon;
c) filling the container 30 with a liquid and
applying a removable closure 52 to the dispensing
portion 44; and
d) shipping at least some of the filled
containers to retailers in a stand-alone mode
without external support such that end users may
utilize the containers in either a stand-alone mode
or in nested relationship with the carriers, the
carriers being reusable with other of the
replaceable containers.
r
13
20~39~
Referring now to Figures 4 and 5, a second
exemplary embodiment of the invention is illustrated
which includes a thin walled, flexible and
collapsible but stand-alone container adapted
particularly for use with petroleum products such as
motor oil. The container includes a peripheral side
wall 62, a substantially flat bottom wall 64, a
tapered shoulder portion 66 extending from the upper
end of the peripheral side wall 62, and a dispensing
portion 68. The dispensing portion 68 includes an
expandable/contractible bellows portion 70 (which
may be of the pop-out/pop-in type), a radially
outwardly extending flange 72, and a threaded upper
end enclosed by a removable screw cap 74.
A recess 76 is provided in the tapered shoulder
section 66 as well as in the upper end of the
peripheral side wall 62. This recess includes a
substantially vertical wall 78, a portion of which
has a radius of curvature at its inwardmost portion
which corresponds substantially to the curvature of
the dispensing portion 68. The recess 76 also
includes a substantially flat bottom wall 80 as well
as a groove 82 extending about the vertical wall
78. At the entrance to the recess, there are
provided a pair of substantially vertical ribs 84.
For shipment and inventory purposes, the
dispensing portion 68 may be bent over through an
angle of substantially 180 and secured within the
recess 76 as shown in Figure 4. In doing so, it
will be appreciated that the groove 82 in the
vertical wall 78 will receive the radial flange 72
of the dispensing portion 68 while the removable
14 2 0~ 3g~ 8
screw cap 74 is snapped in place behind the vertical
ribs 84.
The container as described above is
particularly advantageous not only in that the
profile the container can be reduced for shipment
and/or storage, but also in that the dispensing
portion 68 can be expanded vertically to the extent
permitted by the bellows portion 70, thereby
facilitating pouring of the oil from the container
into, for example, a filler hole of a vehicle engine
which is sometimes difficult to access with
conventional oil containers.
After emptying the container of its contents,
the dispensing portion 68 may again be tucked into
the recess 76 and the remainder of the container
easily collapsed in a random fashion to
substantially reduce post consumer waste volumes.
It will be appreciated that the above described
container has substantially the same differentiated
wall thicknesses as described above in connection
with the embodiment illustrated in Figures 1 and 2.
In this instance, the thicker wall portion will
commence in the tapered shoulder 66 and extend
through the dispensing portion 68. It will also be
appreciated that the container as described is also
unitarily formed by any suitable plastic forming
process (such as blow molding) and is preferably a
low density polymer such as polyethylene.
A variation of the embodiment illustrated in
Figures 4 and 5 is shown in Figures 6 and 7. For
convenience, similar reference numerals as used in
Figures 4 and 5 are used in Figures 6 and 7 to
designate common components, but with the prefix 1
2043958
added. Thus, the container 160 includes a
peripheral side wall 162, a substantially flat
bottom wall 164, a tapered shoulder section 166 and
an upstanding dispensing portion 168. The
dispensing portion 168 includes an
expandable/contractible bellows portion 170, a
radially outwardly extending flange 172 and an upper
threaded end closed by a removable screw cap 174.
A recess 176 is provided in the container in an
area which overlaps the tapered shoulder section 166
and the upper end of the peripheral side wall 162.
Unlike the recess 76 in the embodiment illustrated
in Figures 4 and 5, recess 176 has a fairly shallow
configuration, defined by a wall 178 which has a
radius of curvature at its innermost end
substantially similar to the curvature of the
upstanding dispensing portion 168. The entrance to
the recess 176 (substantially at the interface of
tapered shoulder section 166 and peripheral side
wall 162) is provided with a pair of outstanding
lugs or ribs 182. For shipment/storage (as well as
disposal) purposes, the dispensing portion 168 may
be folded over and snapped into the recess 176
behind the lugs 182. The manner of use and the
disposal procedures are otherwise similar to the
embodiment illustrated in Figures 4 and S.
It will be appreciated that variations of the
above described containers are possible which
nevertheless remain within the scope of this
invention. For example, the manner in which the
dispensing portions 68 or 168 are held within
recesses 76 or 176 may merely include a friction fit
or the use of cooperating ribs, detents, etc. In
16 20439~8
addition, the degree of expansion/contraction of the
bellows portion of the dispensing portion 68 or 168
may also be varied to suit particular applications.
It will further be appreciated that the size and
shape of the containers may also be varied so long
as the features of the invention, i.e., the
reduction in plastic required to form the container,
its flexibility, collapsibility, and capability for
stand-alone use, are retained.
The containers illustrated in Figures 4 through
9 are fully capable of stand-alone use, i.e., no
external rigid supporting carrier is required. It
will be appreciated, however, that the container may
be used with a relatively rigid outer carrier or
funnel if so desired, particularly to facilitate
pouring.
Turning now to Figures 8 and 9, another
variation of the subject invention is disclosed,
also particularly suitable for use with petroLeum
products such as motor oil. In this embodiment
(reference numerals similar to those used in Figures
4, 5, 6 and 7 are utilized to designate common
components, but with the prefix 2 added), the
container 260 includes a peripheral side wall 262 a
substantially flat bottom wall 264, a tapered
shoulder portion 266 extending from the upper end of
the peripheral side wall 262, and a dispensing
portion 268. The dispensing portion 268 is provided
with a radially outwardly extending flange 272 and a
threaded upper end 273 enclosed by a removable screw
cap (not shown). As will be appreciated from Figure
8, this embodiment is generally similar to the
embodiments illustrated in Figures 4 through 7 but
' ~~ 17 20~3958
does not include an expandable/contractible bellows
portion in the upstanding dispensing portion, and
does not include a recess for receiving the
upstanding dispensing portion for shipment and/or
storage. Otherwise, the container is similar in
terms of both wall thickness dimensions, material,
etc.
In order to facilitate pouring of the liquid
contents of the container, for example motor oil,
into the filler tube of a vehicle engine, a
relatively rigid container carrier or funnel 300 is
provided as shown in Figure 9. The funnel comprises
a container supporting device, open at either end
and adapted to support a container in a pouring
orientation. The funnel includes a relatively
smaller diameter discharge portion 302 and a
relatively larger container supporting portion 304.
The discharge portion 302 is small enough to be
received within a filler tube 306 of a vehicle
engine (not shown). The container supporting
portion 304 supports the container along its entire
length and about a substantial portion of the
periphery of the container. In the embodiment
illustrated in Figure 9, the container supporting
portion 304 surrounds the container through more
than 180 of the container periphery, although it
should be understood that the extent of peripheral
support may vary. The remaining peripheral portion
of the funnel is substantially open to allow easy
insertion and removal of the container from the
funnel.
In order to provide additional support for the
container, an interior shoulder 308 is provided
18 2043958
within the funnel in a transitional area between the
discharge portion 302 and the container supporting
portion 304. The shoulder 308 is provided with a
circular opening 310 sized to permit insertion of
the threaded portion 273 of the container but to
engage the annular flange 272, thus serving not only
to limit the extent of insertion of the container
within the funnel, but also to provide stability and
support for the dispensing portion 268 of the
container. This arrangement prevents wedging of the
dispensing portion 268 within the discharge portion
302 of the funnel which might otherwise interfere
with the free flow of liquid from the container.
Additional support for the container is
provided for at least a part of the tapered shoulder
portion 266 of the container by the a supporting
"shelf" 312 integrally formed in the funnel between
container supporting portion 304 and discharge
portion 302. The supporting portion 304 and shelf
312 are configured to substantially match the
angular relationship between the side wall 262 and
tapered shoulder 266 of the container to provide
maximum support without othewrwise disturbing the
shape of the thin walled container.
It will be appreciated that the carrier or
funnel 300 eliminates any difficulty which might
otherwise be encountered in attempting to pour the
contents of the container into a relatively small
filler tube without undesirable spillage.
While the invention has been described in
connection with what is presently considered to be
the most practical and preferred embodiments, it is
to be understood that the invention is not to be
19
204~958
limited thereto, but on the contrary, is intended to
cover various modifications and equivalent
arrangements for dispensing other products which are
included within the spirit and scope of the appended
claims.
