Stackable re-useable container

Abstract

A reusable container, made of a thermoplastic material, with at least one filler and drain opening (18) in the top panel (20) and with a circumferential upper and lower stacking ring (12, 16). To permit reuse, direct stackability, good residual drainability as well as good manipulability of the container, this invention provides for the upper stacking ring (12) to have a slightly larger diameter than the lower stacking ring (16) and to feature on the inside of its upper rim a recess matching the diameter of the lower stacking ring (16) and on the outside a vertically protruding circular flange, so that, when stacked one container atop the other, the lower stacking ring of the upper container fits into the recess in the upper stacking ring of the barrel underneath and is snugly centered therein by the vertically protruding circular flange. This allows for the direct, multiple, secure stacking of the containers that are the object of this invention.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. application Ser. No. 09/555,011, filed Sep. 13, 2000, now U.S. Pat. No. _______, which is the U.S. National Stage designation of PCT/EP98/07554, filed Nov. 23, 1998.

BACKGROUND OF THE INVENTION

[0002] This invention relates to a reusable container made of a thermoplastic material, with at least one filler and drain opening in the top panel or container lid, and with an upper and a lower circumferential stacking ring. A similar thermoplastic container has been described for instance in DE-A 26 29 630. That earlier container, featuring thin extruded side walls, offers relatively poor stackability, its residual drainability is inadequate and it is not suitable for reuse.

SUMMARY OF THE INVENTION

[0003] It is the objective of this invention to eliminate such shortcomings by introducing a reusable container which is sturdy in design, permits direct multi-tiered stacking, offers good residual drainability and, in particular, allows for multiple use and facilitated manipulation.

[0004] According to the invention, this is accomplished by means of the characteristic features specified in patent claim 1. By giving the upper stacking ring a slightly larger diameter than the lower stacking ring, providing a recess inside the top rim of the upper stacking ring which recess matches the diameter of the lower stacking ring, and incorporating on the outside a vertically protruding circular flange whereby, when stacked one container atop the other, the lower stacking ring of the upper container fits into the recess in the upper stacking ring of the container underneath and is snugly centered by the vertically protruding circular flange, it is possible for containers per this invention to be securely stacked in multiple tiers without requiring intermediate stacking pallets. Moreover, the larger diameter of the upper stacking ring facilitates the handling and manipulation of filled containers of this type. Various enhanced, advantageous design variations of this invention are specified in the subclaims.

[0005] The structural design of the container and the advantages it offers also make the container per this invention quite suitable for relatively hazardous liquids such as herbicides or pesticides, allowing multiple reuse. This novel reusable container may incorporate any of the following features and enhancements:

[0006] The upper rim at the top end of the collar of the upper stacking ring has a solid square cross section from the outside of which the circular flange protrudes vertically in the axial direction;

[0007] The collar of the upper stacking ring is slightly flared toward the outside;

[0008] The center section of the container body is fully cylindrical over a certain axial length while its upper and lower sections respectively connecting to the upper and lower stacking ring are slightly rounded and tapered;

[0009] The height (=axial length) of the rounded, tapered wall sections respectively connecting to the upper and lower stacking ring, i.e. to the respective collar to where the fully cylindrical section of the container wall begins, is approximately 110 mm (4.33″);

[0010] The maximum diameter of a manually manipulable i.e. portable container with a limited capacity of not more than 70 liters (18.5 gallons) is approximately 380 mm (15″) in the area of the fully cylindrical container wall or the outer edge of the upper stacking ring;

[0011] The top panel is essentially flat or slightly convex and is provided in the area of its flat perimeter with two mutually opposite, protruding bungs with gas-tight sealable bungholes;

[0012] The essentially flat or slightly convex (domed) top panel connects via a flared or rounded circular section at the junction of the upper stacking ring to the tapered section of the lower container wall;

[0013] The bottom panel is slightly sloped toward one side in such fashion that a depression (=trough) constituting a sump is formed underneath a drain bung;

[0014] In the area of the sump, the bottom panel is provided with at least three protrusions, slightly pointing inwards, serving to center the bottom end of a pump tube (e.g. a Micromatic filler and drain suction tube);

[0015] The center of the bottom panel is slightly convex or domed to facilitate residual drainage;

[0016] The center of the top panel is slightly concave to facilitate residual draining of an inverted container;

[0017] The container wall is a multilayered structure consisting of at least two or more different types of thermoplastic material (co-extrusion);

[0018] The container has a limited capacity of about 70 liters (18.5 gallons) and is provided with at least two handles in the upper stacking ring, so that the container is still manually manipulable i.e. portable;

[0019] A single, interchangeable-cavity blow mold according to this invention is capable, by inserting circular sections of different heights in the fully cylindrical part of the container wall, of producing containers of varying heights (same diameter, top and bottom panels) with a capacity for instance of 25 L, 30 L, 50 L, 60 L or 70 L (6.6, 7.9, 13.2, 15.9 or 18.5 gallons);

[0020] The collar of the lower stabilizing ring above the angled circular foot is provided with perforations (e.g. drilled holes) allowing the circular foot of a stacked container to be fastened to the upper stacking ring of a container underneath it, in that suitable fastening aids (such as wire clips or plastic cable ties) can be inserted through a perforation and a handle opening;

[0021] For fastening at least two side-by-side containers to one another, they are so positioned that their handle openings line up, permitting a length of a fastening aid (such as a clamping strap, a wooden lath or board) to be inserted through the handle openings for locking the containers together;

[0022] For more secure stacking during storage or transport, several containers stacked on a pallet can be fastened to one another or to the pallet itself by means of fastening aids inserted through the handle openings in the upper stacking ring and/or through the perforations in the circular foot;

[0023] As a particularly salient feature of the new blow mold for producing a reusable container per this invention, the two blow-mold parts are each provided with an attachment serving to punch out the handle openings in the upper stacking ring. The blow mold is designed as an interchangeable-cavity mold in which the mold parts for the fully cylindrical center section of the container are separated along a horizontal mold-parting plane permitting the production of different container sizes, having the same diameter but varying heights, by the simple process of exchanging and inserting the desired circular section. By inserting the desired circular center section it is thus possible to produce in one single blow mold different container sizes with capacities from 25 to 70 liters.

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The following explains and describes this invention in more detail with the aid of the design examples illustrated in the drawings in which:

[0025] FIG. 1 is a perspective view of a 50-liter bung-type container according to this invention;

[0026] FIG. 2 is a partly sectional side view of the reusable container per FIG. 1, with a Micromatic pump tube inserted;

[0027] FIG. 3 is a bottom view of the reusable container per FIG. 1;

[0028] FIG. 4 is a perspective view of the container according to this invention with a screw-on lid;

[0029] FIG. 5 is a partly sectional side view of a 60 liter screw-lid-type container;

[0030] FIG. 6 is a side view of a reusable 25 liter container;

[0031] FIG. 7 is a top view of the screw-lid-type container per FIG. 4;

[0032] FIG. 8 is a top view of a rectangular-base reusable container;

[0033] FIG. 9 is a partial, sectional side view of the top and bottom ends of two reusable containers stacked one atop the other;

[0034] FIG. 10 shows part of the upper stacking ring with a handle opening;

[0035] FIG. 11 is a partial, sectional side view of the top and bottom ends of two reusable containers stacked one atop the other and secured to one another;

[0036] FIG. 12 is a partial, sectional side view of the top and bottom ends of two reusable containers stacked one atop the other and secured in a different manner;

[0037] FIG. 13 is a top view of a pallet holding nine reusable containers;

[0038] FIG. 14 is a side view of palletized reusable containers;

[0039] FIG. 15 is a top view of a container with a square base;

[0040] FIG. 16 is a top view of a container with a hexagonal base;

[0041] FIG. 17 is a side view of a 70 liter screw-cap-type container; and

[0042] FIG. 18 is a partial, sectional view of the top end of a lidded container.

DETAILED DESCRIPTION OF THE INVENTION

[0043] FIG. 1 shows a preferred design example of a reusable thermoplastic container 10 according to this invention, in this case with a capacity of 50 liters (13.2 gallons) and with a height/diameter ratio H/D of 1.60. The upper rim of the drum incorporates as an integral part a circumferential stacking ring 12 (handling and transport ring) with two diametrically opposite handle openings 14. The bottom rim of the container body is equipped with a corresponding support ring 16. Built into the top panel 20 are two mutually opposite, internally threaded 2-inch bung fittings sealed with bungs 18.

[0044] FIG. 2 is a partly sectional side view showing an inserted pump tube 62 (Micromatic tube) which extends all the way to the sump 66 on the bottom panel 64 underneath the bung. As can be seen in the illustration of the bottom panel 64 in FIG. 3, the sump area 66 is provided with four inward-protruding centering lugs 68 which center the lower end of the pump tube 62, holding it positioned in the sump.

[0045] FIG. 4 shows a desirable design variant of the reusable container in the form of a small screw-lid-type barrel 22 with a capacity of 50 liters (H/D=1.60), in which case the top panel 20 is provided with only one large, central filler and drain opening which is closed with a threaded cap 24. The threaded protruding fitting may be a 2-inch or 3-inch bung fitting with an internal thread and a matching bung with a corresponding external thread, or the fitting has a male thread and is closed with an internal-thread screw-on cap. The diameter may be about 80 mm (3.15″) (for a K 80 screw cap) up to 400 mm (15.75″) for large screw lids. Particular preference is given to the popular sizes with a diameter of 150 mm (5.9″), 220 mm (8.65″) or 250 mm (9.85″).

[0046] FIG. 5 illustrates a 60 liter screw-lid-type container (approx. diameter 380 mm (15″), approx. height 685 mm (27″), H/D ratio 1.75) with an interpositioned circular adapter section 70. The reusable container may be produced from a transparent thermoplastic material (without the addition of any coloring) or, if opaque, with a transparent viewing strip 72, ideally with a fill-level scale molded into the outer container wall. Where necessary, two outward-protruding, circumferential rolling profiles may be provided in the transitional part between the cylindrical wall and the rounded, tapered wall sections.

[0047] FIG. 6 depicts a small 25 liter reusable container with an H/D ratio of 0.97.

[0048] FIG. 7 is a top view of a screw-lid barrel 22 with one central filler and drain opening for the large screw lid 24, while the upper stacking ring 12 is perforated in the area of the right-hand handle opening, as shown in the partial sectional illustration.

[0049] FIG. 8 is a similar top view of a special design variant of the reusable container per this invention in the form of a canister 26 with an L-shaped upper stacking ring 12. The basic shape of this canister version 26 (L-ring jerrican) is essentially rectangular and the handle openings 14 are located opposite each other in the upper stacking ring 12 on the two long side walls while the filler and drain opening, closed off with the screw cap 28, is positioned at the outer perimeter of the top panel 20 next to one of the two short side walls in between. In this case, in contrast to the lower stacking ring, the upper stacking ring 12 is not completely continuous but is interrupted by a cutout 30 in front of the filler and drain opening to permit unimpeded pouring of the liquid content. Where a large filler and drain opening is located in the center, the upper stacking ring as well will be circumferentially continuous.

[0050] FIG. 9 is a partial, sectional view of the corner areas of two containers one stacked atop the other. In this case, the upper container, with the horizontal contact surface 50 of the support ring 16 of the circular foot 48, facing downward, rests on the horizontal, upward-pointing contact surface 36 of the angled rim 32 of the upper stacking ring of the lower container. The circular flange 38 (centering ring) protruding vertically from the outside of the angled rim 32 centers the circular foot 48 of the stacked barrel, preventing any lateral slippage of the barrels or drums for instance due to vibration during transport. When the containers are stacked directly one atop the other, there is no axial load on the vertically protruding flange 38 (no leverage).

[0051] Below the junction 42 of the collar 44 of the upper stacking ring, and again above the junction of the collar 46 of the lower support ring 16, the container wall 40 recedes at a slightly oblique angle or is rounded over a height from about 100 mm (4″) to the cylindrical section of the drum body. The largest angle of inclination in this case is about 15 to 20. At the same time, the collar 44 of the upper stacking ring 12 (angle of inclination about 5 to 8) and the collar 46 of the lower stabilizing ring 16 are slightly sloped toward the outside. For increased radial rigidity, the upper edge, i.e. the angled rim 32 of the upper stacking ring is relatively thick and solid. The bottom surface of the angled rim 32 of the upper stacking ring 12 constitutes a wide, essentially horizontal or perhaps slightly sloped contact surface 34 for the lower claw of a barrel loader. The upper claw of the barrel loader engages on the inside of the angled rim 32 which, being an extension of the collar 44, serves as a counter-support.

[0052] The partial view in FIG. 10 shows a handle opening 14 in the stacking ring 12. According to the invention, the containers are preferably produced in one piece by a single-operation blow-molding process employing two header dies for shaping the two circumferential stacking rings while at the same time, still in the blow mold, two rotary punch dies punch out the handle openings in the upper stacking ring.

[0053] FIG. 11 illustrates one possible way to secure the containers per this invention for transport purposes. The collar of the lower stabilizing ring, above the circular foot 48, is provided with several evenly spaced perforations 52. These may be for instance simple drill holes but may also be horizontal slots already molded in when the circular foot 48 is formed by heading during the blow-molding process. It is thus possible to run for instance a retaining wire or, as shown here, cable ties 54 through the perforations 52 and the handle opening 14, securely tying the two vertically stacked containers together. The containers are released by simply cutting the cable ties.

[0054] FIG. 12 shows another possible way to secure the containers per this invention for transport purposes, whereby the handle openings are lined up and a wooden lath 56 is inserted to lock the containers together.

[0055] FIG. 13 is a top view illustrating this fastening method applied to containers placed side by side on a base pallet 58.

[0056] FIG. 14 depicts triple-tier direct stacking (i.e. without intermediate pallets) of 3×3×3=27 containers 10 stacked on a base pallet 58, in which case the containers are secured especially against vibration during transport for instance by clamping straps 60 run vertically through the handle openings in the upper stacking ring down to below the deck of the pallet and, respectively, wrapped horizontally around the containers and attached to the pallet 58 proper.

[0057] When loading 60 liter containers per this invention (approx. diameter 380 mm [25″], approx. height 665 mm [26.18″]) into a 20-foot ISO container (DIN 668) accommodating 10 side-by-side ISO pallets (1140×1140 mm [45″×45″]), it is possible to load 9 containers in one plane of each ISO pallet which equals 27 containers when triple-stacked or 270 containers on 10 pallets, with a combined capacity of 16,200 liters (4,280 gallons).

[0058] Reusable containers according to this invention may have a container body with circular stacking and support rings yet with an essentially rectangular, square or hexagonal base.

[0059] FIG. 15 and FIG. 16 respectively show a square-base container 74 and a hexagonal-base container 76. The rounded comers may also have a larger radius or curvature.

[0060] An extra-high container 78 with a capacity of about 70 liters (18.5 gallons) is depicted in FIG. 17. On one side of its top panel, this tall container 78 is provided with a filler and drain bung fitting 80 (diameter 80 mm [3.15″]) with an external thread for a K 80 screw cap. It is equally possible to position the fitting 80 in the center of the top panel.

[0061] FIG. 18 shows a section of a special design version of a lidded container 82 according to this invention. In this case the detachable lid 84 is provided with a stacking ring 12 (and handle opening 14) and at least one lateral bung fitting 86. Underneath the stacking ring 12 the lid 84 has an inverted-U-shaped peripheral lid flange 88 with an inlaid gasket or foamed-in circular seal 90. The lid flange 88 rests on the lip of a wall flange 92 on the rim of the upper perimeter of the drum body. When closed, the lid flange 88 and the wall flange 92 are locked together in gas-tight and impermeable fashion by a clamping ring 94. This lidded drum 82 is particularly suitable for multiple reuse for holding viscous or granular substances.

[0062] For multiple reuse, appropriately sturdy containers can be produced in larger sizes as required, for instance with a capacity of 100, 120, 150, 200 or 220 liters (26.4, 31.7, 39.6, 52.8 or 58.1 gallons). However, when filled, these containers can no longer be handled manually but must be manipulated preferably with the aid of mobile elevating platforms or forklifts with the necessary drum-loading equipment (‘parrot beak’). The features described may be easily substituted for one another and/or used in any combination.

[0063] List of Reference Numbers

[0064] 10 Reusable container 70 Circular adapter section

[0065] 12 Stacking ring 72 Level-viewing strip

[0066] 14 Handle opening 74 Rectangular-base container

[0067] 16 Support ring 76 Hexagonal-base container

[0068] 18 Bung 78 Tall container

[0069] 20 Top panel 80 Filler/drain fitting

[0070] 22 Screw-lid-type small drum 82 Lidded barrel

[0071] 24 Screw-on lid 84 Barrel/drum lid

[0072] 26 L-ring canister 86 Bung fitting

[0073] 28 Screw cap 88 Lid flange

[0074] 30 Cutout (12) 90 Seal/gasket

[0075] 32 Angled rim (12) 92 Wall flange

[0076] 34 Lower contact surface for barrel loader 94 Clamping ring

[0077] 36 Horizontal contact surface (32)

[0078] 38 Centering ring (32)

[0079] 40 Container wall (10/22/26)

[0080] 42 Junction (12/40)

[0081] 44 Collar (12)

[0082] 46 Collar (16)

[0083] 48 Circular foot (46)

[0084] 50 Contact surface (48)

[0085] 52 Perforation (bore)

[0086] 54 Fastening aid/cable tie

[0087] 56 Fastening aid (board, lath)

[0088] 58 Pallet

[0089] 60 Clamping straps

[0090] 62 Pump tube

[0091] 64 Bottom panel

[0092] 66 Sump

[0093] 68 Centering lugs

Claims

1. A barrel, comprising:

a lower stacking ring disposed on a lower side of the barrel;

a top panel that defines at least one filler/drain opening; and

an upper stacking ring disposed about the top panel and comprising a flange extending upwardly, the upper stacking ring defining an upward facing recess inside and adjacent the flange and configured to receive, center, and support a lower stacking ring of another similar barrel in a predetermined position stacked on the upper stacking ring.

2. The barrel of

claim 1, wherein the flange, recess, and lower stacking ring are configured to receive the lower stacking ring of the other barrel snugly in the recess in the predetermined position.

3. The barrel of

claim 2, wherein the recess substantially matches a shape of the lower stacking ring to receive the lower stacking ring of the other barrel snugly.

4. The barrel of

claim 1, wherein the lower and upper stacking rings are substantially circular.

5. The barrel of

claim 1, wherein:

the flange has an inner flange dimension at the recess and an outer flange dimension; and

the lower stacking ring has an outer lower-ring dimension that is smaller than the outer flange dimension and sufficiently close to the inner flange dimension to be snugly received therein.

6. The barrel of

claim 1, further comprising a collar having an upper end defining an upper rim which has a solid, squared cross-section and from which the flange protrudes vertically.

7. The barrel of

claim 6, wherein the collar extends upwardly and is flared outwardly.

8. The barrel of

claim 6, wherein:

the collar extends upwardly and defines handle openings disposed opposite each other;

the lower stacking ring defines perforations disposed opposite each other; and

the handle openings and the perforations are disposed such that the handle openings are substantially alignable with the perforations of the another stacked barrel such that a fastening aid can be inserted through the aligned handle openings and perforations for securing the stacked barrels to one another.

9. The barrel of

claim 1, further comprising a sidewall that has a substantially nontapered portion and a curved tapered portion disposed between the nontapered portion and one of the stacking rings, wherein the curved tapered portion tapers toward the one of the stacking rings.

10. The barrel of

claim 1, wherein the top panel comprises a threaded bung fitting about the filler/drain opening configured for sealing with a screw cap to provide a gas-tight and impermeable seal.

11. The barrel of

claim 1, wherein the top panel comprises a substantially flat portion and a tapered lower portion that is disposed between the flat portion and the upper stacking ring.

12. The barrel of

claim 1, wherein the barrel comprises a bottom panel disposed within the lower stacking ring and forming an internal sump.

13. The barrel of

claim 1, wherein the top panel defines a second filler/drain opening, wherein the top panel comprises a portion that is concave between the filler/drain openings configured for facilitating residual drainage of the barrel when inverted.

14. The barrel of

claim 1, wherein the barrel comprises a multi-layered wall structure of different thermoplastic materials.

15. The barrel of

claim 1, wherein the barrel has a capacity of more than about 25 liters.

16. The barrel of

claim 1, further comprising a transparent viewing area and a scale for viewing a level to which the barrel is filled.

17. A blow mold with a cavity for blow-molding thermoplastic material to form a barrel, the cavity comprising:

a lower portion configured for blow-molding the material to form a lower stacking ring disposed on a lower side of the barrel;

a top portion configured for blow-molding the material to form a top panel that defines at least one filler/drain opening;

an upper ring portion configured for blow-molding the material to form an upper stacking ring disposed adjacent the top panel and comprising a flange extending upwardly, the upper stacking ring defining an upward facing recess inside and adjacent the flange and configured to receive, center, and support in a predetermined position on the upper stacking ring a lower stacking ring of another similar barrel stacked thereon.

18. The blow mold of

claim 17, further comprising a punch configured for punching handle openings in the upper stacking ring.

19. The blow mold of

claim 17, further comprising a first sidewall portion configured for blow molding a sidewall of a first height between the upper and lower portions, wherein the sidewall portion is replaceable in the blow mold with a second sidewall portion of a different height to configure the blow mold for blow molding a barrel with a sidewall of a second height.

20. A barrel, comprising:

a top panel that defines at least one fill/drain opening;

an upper stacking ring disposed about the top panel and comprising a flange having an inner perimeter defining a recess inside and adjacent the flange; and

a lower stacking ring disposed on a lower side of the barrel and having an outer perimeter, wherein the outer perimeter substantially matches the inner perimeter.

21. The barrel of

claim 20, wherein the upper stacking ring has a continuous perimeter.

22. The barrel of

claim 20, wherein the upper stacking ring is interrupted by at least one cutout.

23. The barrel of

claim 20, wherein the upper stacking ring is substantially circular.

24. The barrel of

claim 20, wherein the upper stacking ring is substantially rectangular.

25. The barrel of

claim 20, wherein:

the inner perimeter defines a first radial dimension from a center point of the inner perimeter to a first point on the inner perimeter;

the outer perimeter defines a second radial dimension from a center point of the outer perimeter to a second point on the outer perimeter; and

the first radial dimension is slightly greater than the second radial dimension.

26. The barrel of

claim 20, wherein:

the inner perimeter defines a first radial dimension from a center point of the inner perimeter to a first point on the inner perimeter;

the outer perimeter defines a second radial dimension from a center point of the outer perimeter to a second point on the outer perimeter; and

the first radial dimension is substantially equal to the second radial dimension.

27. The barrel of

claim 20, wherein the flange extends substantially vertically from the upper stacking ring.

28. The barrel of

claim 27, wherein the flange includes an inner wall defined by the inner perimeter, and the recess includes a substantially upward facing contact surface that is oriented substantially transversely to the inner wall.

29. The barrel of

claim 20, wherein the upper stacking ring further comprises a collar extending upwardly and flared radially outwardly from the top panel, the collar having an upper end from which the flange protrudes substantially vertically.

30. The barrel of

claim 29, wherein:

the collar defines first and second handle openings that are angularly displaced from one another by a first angle;

the lower stacking ring defines first and second perforations that are angularly displaced from one another by a second angle that is substantially equal to the first angle.

31. The barrel of

claim 20, wherein the top panel and upper stacking ring are formed integrally as a lid, the lid moveable between a first position in which the lid seals the barrel, and a second position in which the lid is separated from the barrel.

32. The barrel of

claim 20, wherein the barrel has a capacity of greater than about 25 liters.