FOLDING CONTAINER

Abstract

A folding container comprising a body portion defining a receptacle chamber within the container into which product can be filled and at least one rib extending along at least a portion of the body portion. The at least one rib being collapsible to permit the body portion to collapse to a generally flattened position in the absence of the product contained therein.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/484,396, filed on May 10, 2011. The entire disclosure of the above application is incorporated herein by reference.

FIELD

This disclosure generally relates to containers for retaining a commodity, such as a solid or liquid commodity. More specifically, this disclosure relates to a foldable container and/or a container that is ultra flexible for squeezing.

BACKGROUND

This section provides background information related to the present disclosure which is not necessarily prior art.

As a result of environmental and other concerns, plastic containers, more specifically polyester and even more specifically polyethylene terephthalate (PET) containers are now being used more than ever to package numerous commodities previously supplied in glass containers. Manufacturers and fillers, as well as consumers, have recognized that PET containers are lightweight, inexpensive, recyclable and manufacturable in large quantities.

Blow-molded plastic containers have become commonplace in packaging numerous commodities. PET is a crystallizable polymer, meaning that it is available in an amorphous form or a semi-crystalline form. The ability of a PET container to maintain its material integrity relates to the percentage of the PET container in crystalline form, also known as the “crystallinity” of the PET container. The following equation defines the percentage of crystallinity as a volume fraction:

$\%\mathrm{Crystallinity}=\left(\frac{\rho -{\rho }_a}{{\rho }_c-{\rho }_a}\right)\times 100$

where ρ is the density of the PET material; ρ_a is the density of pure amorphous PET material (1.333 g/cc); and ρ_c is the density of pure crystalline material (1.455 g/cc).

Container manufacturers use mechanical processing and thermal processing to increase the PET polymer crystallinity of a container. Mechanical processing involves orienting the amorphous material to achieve strain hardening. This processing commonly involves stretching an injection molded PET preform along a longitudinal axis and expanding the PET preform along a transverse or radial axis to form a PET container. The combination promotes what manufacturers define as biaxial orientation of the molecular structure in the container. Manufacturers of PET containers currently use mechanical processing to produce PET containers having approximately 20% crystallinity in the container's sidewall.

Thermal processing involves heating the material (either amorphous or semi-crystalline) to promote crystal growth. On amorphous material, thermal processing of PET material results in a spherulitic morphology that interferes with the transmission of light. In other words, the resulting crystalline material is opaque, and thus, generally undesirable. Used after mechanical processing, however, thermal processing results in higher crystallinity and excellent clarity for those portions of the container having biaxial molecular orientation. The thermal processing of an oriented PET container, which is known as heat setting, typically includes blow molding a PET preform against a mold heated to a temperature of approximately 250° F.-350° F. (approximately 121° C.-177° C.), and holding the blown container against the heated mold for approximately two (2) to five (5) seconds. Manufacturers of PET juice bottles, which must be hot-filled at approximately 185° F. (85° C.), currently use heat setting to produce PET bottles having an overall crystallinity in the range of approximately 25%-35%.

SUMMARY

This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features.

According to the principles of the present teachings, a folding container is provided comprising a body portion defining a receptacle chamber within the container into which product can be filled and at least one rib extending along at least a portion of the body portion. The at least one rib being articulatable to permit the body portion to collapse to a generally flattened position in the absence of the product contained therein.

Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.

FIG. 1A is a front view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 1B is a side view of the plastic container of FIG. 1A;

FIG. 1C is a top view of the plastic container of FIG. 1A;

FIG. 1D is a bottom view of the plastic container of FIG. 1A;

FIG. 2A is a front view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 2B is a side view of the plastic container of FIG. 2A;

FIG. 2C is a top view of the plastic container of FIG. 2A;

FIG. 2D is a bottom view of the plastic container of FIG. 2A;

FIG. 3A is a front view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 3B is a side view of the plastic container of FIG. 3A;

FIG. 3C is a top view of the plastic container of FIG. 3A;

FIG. 3D is a bottom view of the plastic container of FIG. 3A;

FIG. 4A is a front perspective view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 4B is a front view of the plastic container of FIG. 4A;

FIG. 4C is a side view of the plastic container of FIG. 4A;

FIG. 5A is a front view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 5B is a side view of the plastic container of FIG. 5A;

FIG. 5C is a side view of the plastic container of FIG. 5A in an opened configuration;

FIG. 5D is a bottom view of the plastic container of FIG. 5A;

FIG. 6A is a front perspective view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 6B is a side view of the plastic container of FIG. 6A;

FIG. 6C is a side view of the plastic container of FIG. 6A without a body sleeve portion;

FIG. 6D is a top perspective view of the body sleeve portion of FIG. 6C;

FIG. 7A is a front view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 7B is a side view of the plastic container of FIG. 7A;

FIG. 7C is another side view of the plastic container of FIG. 7A;

FIG. 8A is a front view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 8B is a side view of the plastic container of FIG. 8A;

FIG. 8C is a top view of the plastic container of FIG. 8A;

FIG. 8D is a bottom view of the plastic container of FIG. 8A;

FIG. 9A is a front view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 9B is a side view of the plastic container of FIG. 9A;

FIG. 9C is a top view of the plastic container of FIG. 9A;

FIG. 9D is a bottom view of the plastic container of FIG. 9A;

FIG. 10A is a front view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 10B is a side view of the plastic container of FIG. 10A;

FIG. 11A is a front view illustrating a plastic container according to some embodiments of the present teachings;

FIG. 11B is a side view of the plastic container of FIG. 11A;

FIG. 11C is a top view of the plastic container of FIG. 11A; and

FIG. 11D is a bottom view of the plastic container of FIG. 11A.

Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

This disclosure provides for a container that is sufficiently flexible or collapsible to permit flattening after molding for reduced shipping volume prior to filling. That is, in some embodiments of the present teachings, a container is provided that can be flattened after molding to facilitate simplified shipping to a filling location. In some embodiments, this flexible or collapsible function can further assist in the dispensing and/or evacuation of product from the container by a user. Still further, in some embodiments, this flexible or collapsible function can further aid in recycling and/or disposal of the container by reducing the container volume. Finally, in addition to other benefits, the container of the present teachings provides for lighter weight containers, thereby reducing material and shipping costs.

It should be appreciated that the size and the number of panels, creases, and/or columns are dependent on the size of the container and the required collapsibility. Therefore, it should be recognized that variations can exist in the present embodiments.

As illustrated in FIGS. 1-11, the present teachings provide a one-piece plastic, e.g. polyethylene terephthalate (PET), container generally indicated at 10. The container 10 is substantially elongated when viewed from a side. Those of ordinary skill in the art would appreciate that the following teachings of the present disclosure are applicable to other containers, such as rectangular, triangular, pentagonal, hexagonal, octagonal, polygonal, or square shaped containers, which may have different dimensions and volume capacities. It is also contemplated that other modifications can be made depending on the specific application and environmental requirements.

As shown in FIGS. 1-11, the one-piece plastic container 10 according to the present teachings defines, in some embodiments, a body 12, and includes an upper portion 14 having a sidewall forming a finish 20. Integrally formed with the finish 20 and extending downward therefrom is a shoulder portion 22. The shoulder portion 22 merges into and provides a transition between the finish 20 and a sidewall portion 24. The sidewall portion 24 extends downward from the shoulder portion 22 to a base portion 28 having a base 30. In some embodiments, sidewall portion 24 can extend down and nearly abut base 30, thereby minimizing the overall area of base portion 28 such that there is not a discernable base portion 28 when container 10 is uprightly-placed on a surface.

The exemplary container 10 may also have a neck 23. The neck 23 may have an extremely short height, that is, becoming a short extension from the finish 20, or an elongated height, extending between the finish 20 and the shoulder portion 22. The upper portion 14 can define an opening for filling and dispensing of a commodity stored therein. Although the container is shown as a commodity container, it should be appreciated that containers having different shapes, such as sidewalls and openings, can be made according to the principles of the present teachings.

Although not shown, the finish 20 of the plastic container 10 may include a threaded region having threads, a lower sealing ridge, and a support ring. The threaded region provides a means for attachment of a similarly threaded closure or cap. Alternatives may include other suitable devices that engage the finish 20 of the plastic container 10, such as a press-fit or snap-fit cap for example. Accordingly, the closure or cap engages the finish 20 to preferably provide a hermetical seal of the plastic container 10. The closure or cap is preferably of a plastic or metal material conventional to the closure industry and suitable for subsequent thermal processing.

Referring now to FIGS. 1-11, shoulder portion 22, sidewall portion 24, and base portion 28 of the present teachings will now be described in greater detail. As discussed herein, shoulder portion 22, sidewall portion 24, and/or base portion 28 can each separately, collectively, or in various combinations comprise internal and/or external folding features 100 extending at least a length thereof that effectively permits flexing and/or collapsing of the container in a direction conducive to reduce packaging size requirements. That is, in some embodiments, this flexing and/or collapsing of the container can be in a non-longitudinal direction (e.g. flattening and the like). Shoulder portion 22, sidewall portion 24, and base portion 28 can be arranged such that folding features 100 are equidistantly arranged about at least a portion of container 10. Such symmetrical arrangement provides aesthetic qualities and improves collapsing and/or grip performance.

With continued reference to FIGS. 1-11, in some embodiments folding features 100 of shoulder portion 22, sidewall portion 24, and/or base portion 28 can each comprise an inwardly and/or outwardly directed rib 102. Ribs 102 can define a smooth surface and/or edge that in some embodiments can extend uninterrupted from and including shoulder portion 22 to and including base portion 28. In some embodiments, ribs 102 can each define a smooth surface that extends uninterrupted and/or continuously along sidewall portion 24. In some embodiments, ribs 102 can serve to encourage and/or facilitate flattening, collapsing, or otherwise compressing of sidewall portion 24, base portion, and/or other portions of container 10. In some embodiments, ribs 102 can act as a hinge member to promote such collapsing and subsequent expanding of container 10.

Although ribs 102 can be considered as being inwardly directed or outwardly direction and, thus, define similar construction, such features will be described in greater detail. In some embodiments, as illustrated in FIGS. 1A-1D, rib 102 can be described as having an outwardly directed central peak portion 104 having one or more inwardly directed valley portions 106 (also referred to as inwardly directed rib 102 above). Valley portions 106 can descend generally in mirrored orientation from a central peak portion 104 along a transition surface 105 or can descend from only one side of central peak portion 104, such is the case for central peak portions 104 disposed adjacent to a face or side portion 108 of container 10. In some embodiments, transition surface 105 can be arcuately shaped and in some embodiments can be convex (FIG. 2), planar (FIG. 3), and the like. In some embodiments, an upstanding spine section 110 can extend above a surface of central peak portion 104. Upstanding spine section 110 can extend from finish 20 to base portion 28. Similarly, ribs 102 (and central peak portion 104 and valley portions 106) can extend generally from finish 20 or shoulder portion 22 to base portion 28.

In some embodiments, as illustrated in FIGS. 2A-2D, upstanding spine section 110 can be used in conjunction with a single rib 102, such that a rib 102 is configured to descend from a central peak portion 104 directly to side portions 108 of container 10. In some embodiments, as illustrated in FIGS. 3A-3D, rib 102 can comprise central peak portion 104 descending along a pair of transition surfaces 105 directly to side portions 108. In some embodiments, as illustrated in FIGS. 4A-5D, spine section 110 can be used on connection with a squeeze dispense container and can, in some embodiments, further comprised a serrated portion 112 therealong having a plurality of notches. A cap section 114 can be used to seal an end and/or add a resilient compression system.

In some embodiments, as illustrated in FIGS. 6A-6D, container 10 can comprise a removable sleeve member 120 that can extend about a sidewall portion 24. During shipping, sleeve member 120 can be removed from container 10 to permit container 10 to be collapsed.

In some embodiments, as illustrated in FIGS. 7A-7C and FIGS. 10A-10B, container 10 can comprises a rib 102 having an arcuate and/or flowing shape such that it defines a generally wave pattern. This wave pattern can result in generally wave panels 130 disposed about container 10. However, wave panels 130 can still be arranged such that they permit the collapse of container 10 for storage and/or transportation along a side seam that results in a generally flat orientation of container 10.

Still further, in some embodiments as illustrated in FIGS. 11A-11D, rib 102 can comprise a plurality of ribs 102 that can extend from shoulder portion 22 (or finish 20) along a first side of sidewall portion 24, along base portion 28 and then, in some embodiments, extend along an opposing side of sidewall portion 24 and return to shoulder portion 22 (or finish 20). In some embodiments, ribs 102 can be continuous along such paths.

The plastic container 10 has been designed to retain a commodity. The commodity may be in any form such as a solid or semi-solid product. In one example, a commodity may be introduced into the container during a thermal process, typically a hot-fill process. For hot-fill bottling applications, bottlers generally fill the container 10 with a product at an elevated temperature between approximately 155° F. to 205° F. (approximately 68° C. to 96° C.) and seal the container 10 with a closure (not illustrated) before cooling. In addition, the plastic container 10 may be suitable for other high-temperature pasteurization or retort filling processes or other thermal processes as well. In another example, the commodity may be introduced into the container under ambient temperatures.

The plastic container 10 of the present disclosure is a blow molded, biaxially oriented container with a unitary construction from a single or multi-layer material. A well-known stretch-molding, heat-setting process for making the one-piece plastic container 10 generally involves the manufacture of a preform (not shown) of a polyester material, such as polyethylene terephthalate (PET), having a shape well known to those skilled in the art similar to a test-tube with a generally cylindrical cross section. An exemplary method of manufacturing the plastic container 10 will be described in greater detail later.

An exemplary method of forming the container 10 will be described. A preform version of container 10 includes a support ring, which may be used to carry or orient the preform through and at various stages of manufacture. For example, the preform may be carried by the support ring, the support ring may be used to aid in positioning the preform in a mold cavity, or the support ring may be used to carry an intermediate container once molded. At the outset, the preform may be placed into the mold cavity such that the support ring is captured at an upper end of the mold cavity. In general, the mold cavity has an interior surface corresponding to a desired outer profile of the blown container. More specifically, the mold cavity according to the present teachings defines a body forming region, an optional moil forming region and an optional opening forming region. Once the resultant structure, hereinafter referred to as an intermediate container, has been formed, any moil created by the moil forming region may be severed and discarded. It should be appreciated that the use of a moil forming region and/or opening forming region are not necessarily in all forming methods.

In one example, a machine (not illustrated) places the preform heated to a temperature between approximately 190° F. to 250° F. (approximately 88° C. to 121° C.) into the mold cavity. The mold cavity may be heated to a temperature between approximately 250° F. to 350° F. (approximately 121° C. to 177° C.). A stretch rod apparatus (not illustrated) stretches or extends the heated preform within the mold cavity to a length approximately that of the intermediate container thereby molecularly orienting the polyester material in an axial direction generally corresponding with the central longitudinal axis of the container 10. While the stretch rod extends the preform, air having a pressure between 300 PSI to 600 PSI (2.07 MPa to 4.14 MPa) assists in extending the preform in the axial direction and in expanding the preform in a circumferential or hoop direction thereby substantially conforming the polyester material to the shape of the mold cavity and further molecularly orienting the polyester material in a direction generally perpendicular to the axial direction, thus establishing the biaxial molecular orientation of the polyester material in most of the intermediate container. The pressurized air holds the mostly biaxial molecularly oriented polyester material against the mold cavity for a period of approximately two (2) to five (5) seconds before removal of the intermediate container from the mold cavity. This process is known as heat setting and results in a heat-resistant container suitable for filling with a product at high temperatures.

Alternatively, other manufacturing methods, such as for example, extrusion blow molding, one step injection stretch blow molding and injection blow molding, using other conventional materials including, for example, high density polyethylene, polypropylene, polyethylene naphthalate (PEN), a PET/PEN blend or copolymer, and various multilayer structures may be suitable for the manufacture of plastic container 10. Those having ordinary skill in the art will readily know and understand plastic container manufacturing method alternatives.

The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.

Claims

1. A folding container comprising:

a body portion defining a receptacle chamber within said container into which product can be filled; and

at least one rib extending along at least a portion of said body portion, said at least one rib being collapsible to permit said body portion to collapse to a generally flattened position in the absence of the product contained therein.

2. The folding container according to claim 1 wherein said at least one rib comprises a central peak portion, at least one inwardly extending valley portion, and a transition surface extending therebetween, at least one of said central peak portion and said at least one inwardly extending valley portion being collapsible.

3. The folding container according to claim 2 wherein said transition surface is generally convex.

4. The folding container according to claim 2 wherein said transition surface is generally planar.

5. The folding container according to claim 1, further comprising:

a finish;

a shoulder portion extending between said finish and said body portion, said shoulder portion defining a transition between said finish and said shoulder portion.

6. The folding container according to claim 5 wherein said at least one rib extends along at least a portion of said shoulder portion.

7. The folding container according to claim 8 wherein said at least one rib is serrated.

8. The folding container according to claim 1, further comprising:

a base portion extending along a bottom of said body portion, said base portion enclosing said receptacle chamber.

9. The folding container according to claim 8 wherein said at least one rib extends along at least a portion of said base portion.

10. The folding container according to claim 8 wherein said base portion is generally flat.

11. The folding container according to claim 8 wherein said base portion comprises a collapsible opening.

12. The folding container according to claim 1 wherein said body portion comprises at least one side panel portion and said at least one rib comprises a central peak portion, said central peak portion transitioning directly into said at least one side panel portion.

13. The folding container according to claim 1 wherein said at least one rib comprises a central spine section extending along at least a central portion of said at least one rib.

14. The folding container according to claim 1 wherein said at least one rib comprises a plurality of ribs, each of said plurality of ribs being continuous and extending from said body portion to a base portion and again to said body portion.

15. The folding container according to claim 1, further comprising:

a finish;

a shoulder portion extending between said finish and said body portion, said shoulder portion defining a transition between said finish and said shoulder portion; and

a base portion extending along a bottom of said body portion, said base portion enclosing said receptacle chamber,

wherein said at least one rib extends continuously from at least said shoulder portion along said body portion to said base portion.

16. The folding container according to claim 1, further comprising:

a finish;

a shoulder portion extending between said finish and said body portion, said shoulder portion defining a transition between said finish and said shoulder portion; and

a base portion extending along a bottom of said body portion, said base portion enclosing said receptacle chamber,

wherein said at least one rib extends continuously from at least said shoulder portion along a first side of said body portion to said base portion and again along a second side of said body portion to said shoulder portion.

17. A folding container comprising:

a finish;

a body portion defining a receptacle chamber within said container into which product can be filled;

a shoulder portion extending between said finish and said body portion, said shoulder portion defining a transition between said finish and said shoulder portion; and

a base portion extending along a bottom of said body portion, said base portion enclosing said receptacle chamber,

said body portion being positionable in a first position where said body portion is collapsed to define a first overall thickness and a second position where said body portion is expanded to define a second overall thickness to receive the product within said receptacle, said second overall thickness being greater than the first overall thickness.

18. The folding container according to claim 17, further comprising:

at least one rib extending along at least a portion of said body portion, said at least one rib being collapsible to permit said body portion to collapse to said first overall thickness and be expanded to said second overall thickness, said at least one rib acting as a hinge member during such movement.

19. The folding container according to claim 18 wherein said at least one rib comprises a central peak portion, at least one inwardly extending valley portion, and a transition surface extending therebetween.

20. The folding container according to claim 18 wherein said body portion comprises at least one side panel portion and said at least one rib comprises a central peak portion, said central peak portion transitioning directly into said at least one side panel portion.