Container

This application claims priority under 35 U.S.C. § 119 (e) to U.S. Provisional Patent Application No. 63/572,602, filed Apr. 1, 2024, which is expressly incorporated by reference herein in its entirety.

The present disclosure relates to a container, and particularly to a container configured to hold contents. More particularly, the present disclosure relates to a container with features that facilitate removal of high-viscosity contents from the container.

According to the present disclosure, a container includes a floor and a sidewall coupled to the floor and arranged to extend about a central axis. The sidewall includes an exterior surface facing away from the central axis and an inner surface facing toward the central axis. The exterior surface and interior surface may each have a constant sidewall radius of curvature with a center at the central axis at all horizontal planes perpendicular to the central axis along a height of the sidewall.

In illustrative embodiments, the container further includes a plurality of scalloped segments coupled to the inner surface of the sidewall and facing toward the central axis. The plurality of scalloped segments provide the container with an undulating or wave-like inner surface to increase a rigidity of the container.

In illustrative embodiments, the plurality of scalloped segments includes a plurality of vertically-extending ridges and a plurality of vertically-extending valleys. The plurality of vertically-extending ridges are located on a reference circle having a first radius of curvature about the central axis. Each vertically-extending valley included in the plurality of vertically-extending valleys is offset radially from the reference circle and has a second radius of curvature between adjacent ridges included in the plurality of ridges. The second radius of curvature is less than the first radius of curvature.

Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.

A containerin accordance with the present disclosure, includes a brim, a sidewall, and a flooras shown in. The brimand the sidewallextend annularly around a central axis. The central axispasses through a center of the floor. The containeris formed to include a storage regionconfigured to hold products, such as liquids, mortar, joint compound, spackling, etc. The sidewalland the floormay cooperate to form the storage region, which may be suitable for storing, containing, and/or holding contents for subsequent removal. The brimmay be configured to provide a structure for coupling a lid to container, for example, by extending radially outwardly to provide one or more mounting surfaces for the lid. The brimmay be, for example, suitable for connecting a lid via a snap fit engagement and/or a lid with tamper evident features.

The flooris coupled to a lower end of the sidewall. The sidewallincludes an inner surfacefacing toward the central axisand an exterior surfacefacing away from the central axis. The inner and exterior surfaces,of the sidewallboth have constant radii of curvature with a center at the central axis. The sidewallalso has a substantially constant thicknessbetween the inner and exterior surfaces,, e.g. such that the thickness of the sidewall does not vary by more than 5% around the central axis.

In the illustrative embodiment, the container further includes a plurality of scalloped segmentscoupled to the inner surfaceof the sidewalland facing toward the central axis. Each of the scalloped segmentsmay be coupled to adjacent segmentsor spaced apart from one another about the central axis. The plurality of scalloped segmentsare configured to reinforce the sidewallof the containerso that the amount of material forming the container can be reduced or minimized.

The plurality of scalloped segmentsinclude a plurality of vertically-extending ridgesand a plurality of vertically-extending valleysas shown in. The plurality of vertically-extending ridgesare located on a reference circlehaving a first radius of curvatureabout the central axis. Each vertically-extending valleyincluded in the plurality of vertically-extending valleysis partially offset radially outward from the reference circleand has a second radius of curvaturebetween adjacent ridgesincluded in the plurality of ridges. The second radius of curvatureis less than the first radius of curvature. In other words, the containerthicker at each ridgeand thinner between the plurality of ridgesin each valley.

Each of the vertically-extending ridgesmay form an innermost portion or apexof the plurality scalloped segmentsas shown in. The reference circleis established at a tangent point of each of the plurality of vertically-extending ridges. The reference circlehas a center Cat the central axis. In other words, a radially-innermost portion of each of the vertically-extending ridgesis spaced a common distance from the central axisat all horizontal planes perpendicular to the central axisalong a height of the sidewall.

Each of the vertically-extending valleyshas an inner surfacefacing toward the central axisand having the second radius of curvature. The inner surfaceof each vertically-extending valleyhas a center Clocated radially between the central axisand the sidewall. In the illustrative embodiment, the center Cof each inner surfaceis located radially between the center Cand the innermost apexof each vertically-extending ridge.

Each vertically-extending ridgeof the plurality of vertically-extending ridgeshas a ridge thicknessas shown in. Each vertically-extending valleyof the plurality of valleyshas a valley thicknessthat is less than the ridge thickness. In the illustrative embodiment, the valley thicknessis smallest at an arc centerlineof each of the valleys. The arc centerlineis spaced equal distances from each adjacent ridge. The valley thicknessmay be zero at the arc centerlinesuch that the inner surfaceof the sidewallis located at a tangent point of the second radius of curvaturealong the arc centerline. The valley thicknessmay constantly decrease from each ridgetoward the centerline. The constant decrease in thickness is gradual in the illustrative embodiment due to the inner surface of each valleyhaving the second radius of curvature. In some embodiment the constant decrease in thickness may be linear such that at least a portion of each valleyhas no radius of curvature and each valleyincludes a v-shape when viewed in cross section.

Each vertically-extending valleyincludes a first rampcoupled to a first ridgeA included in the plurality of ridgesand a second rampcoupled to the first rampand to a second ridgeB included in the plurality of ridgesand adjacent to the first ridgeA. The first rampand the second rampare joined at the centerlineof each valley.

Each of the ridges included in the plurality of ridgeshas a first heightand each of the valleys included in the plurality of valleyshas a second heightless than the first height. The first heightis defined between a filletincluded in the sidewallat a lower end thereof and an upper endof each ridge. The second heightis defined between the filletand an upper endof each valley.

Each of the plurality of scalloped segmentsfurther includes a gradient upper regioncoupled to the upper endof two vertically-extending ridgesincluded in the plurality of vertically-extending ridgesand to the upper endof a single valleyincluded in the plurality of valleysas shown in. Each gradient upper regionhas an upper region edgejoined with the upper ends,of the two ridgesand the single valley. Owing to the height differences between the ridgesand the valleys, the upper region edgevaries in height as it extends circumferentially between the two ridges. In the illustrative embodiment, each upper region edgehas an arcuate shape located a first distance from the brimat the two ridges and a second distance from the brim, greater than the first distance, at the centerline. The distance of the upper region edge to the brimincreases as the upper region edgeextends from each ridgeto the centerlineof each valley. The increase in distance is non-linear in the illustrative embodiment to provide each upper region edgewith the arcuate shape. In some embodiments, the upper region edgemay have a linear change in distance from the brimas the upper region edgeextends from each ridgetoward the centerlineto provide the upper region edgewith a v-shape.

Each gradient upper regionhas a gradient thicknessthat may vary as each gradient upper regionextends from the upper region edgetoward the brim. In the illustrative embodiment, the gradient thicknessincreases from the upper region edgetoward the brim. In some embodiments, the gradient thickness remains substantially constant from the upper region edgetoward to the brim.

Another embodiment of a containeris shown in. The containeris similar to containerand includes a brim, a sidewall, and a floor. The containerfurther includes a plurality of scalloped segmentshaving a plurality of ridges, a plurality of valleys, and a plurality of gradient upper regionslike container. The containerdiffers from containerin that each scalloped segmentfurther includes an upper bandcoupled to a top endof each gradient upper regionand to the brim. The upper bandextends annularly around a central axisof the container and has a substantially constant band thicknessgreater than or equal to a gradient thickness. An apexof each ridgeis also joined with a lower end of the upper band.

Some embodiments of a container, such as the exemplary embodiment shown in, may include a brimdefining a top opening into a storage region, a sidewall, and/or a floor. Sidewalland floormay cooperate to form storage region, which may be suitable for storing, containing, and/or holding contents for subsequent removal. Brimmay be configured to provide a structure for coupling a lid to container, for example, by extending radially outwardly, or for any other reason. Brimmay be, for example, suitable for connecting a lid via a snap fit engagement and/or a lid with tamper evident features. A beadmay be provided to protect an underside of a lid or for any other reason. A ringmay be provided axially below bead. Ringmay be provided for any of a variety of reasons, including but not limited to providing reinforcement for a handle attachment areaand/or protecting an underside of a lid when coupled to container.

Sidewallmay include one or more areas of reduced material or scallops or scallop segments, as shown for example in. Scallopsmay be formed on an inner surface of sidewallto give the inner surface of sidewallan undulating or wavelike form circumferentially. Scallopsmay include and/or be separated by one or more ridges, which may represent a local maximum thickness, or ridge thickness. Ridgesmay have a ridge thickness that represents a maximum thickness of sidewall. Ridgesmay extend longitudinally or axially transverse to a radial direction and/or a circumferential direction. Scallopsmay include troughs or valleysinterposed between adjacent ridges, which valleysmay include a valley thickness that represents a minimum thickness of sidewall. By providing valleysthat are thinner than ridges, containermay be made with less material and/or a lighter weight than conventional containers having a uniform sidewall thickness and no scallops, yet still maintain appropriate strength and rigidity for desired functions. For example, containermay be used to store and/or transport a relatively high volume and/or a relatively high weight of material.

Sidewallmay include one or more gradient upper regionsproximate brim, a shown for example in. Brimmay have a substantially uniform thickness circumferentially and/or gradient upper regionmay have a gradually changing, blended, and/or gradient thickness as it extends longitudinally or axially downwardly away from brimtoward floor. Brimand/or sidewallat or near brimmay have a thickness that is greater than minimum thickness and/or valleythickness such that the gradient thickness and/or blending of thickness takes the most distance from brimto an upper region edgeat a circumferential location of valley, for example, if the gradient or transition of thickness is linear in gradient upper region. Upper region edgemay represent a boundary where a thickness of upper gradient regionis approximately equal to a thickness of scallop. Less blending may be needed at ridgerelative to brim, and in some embodiments the thickness at ridgemay approximately equal the thickness at brimsuch that no blending is needed, resulting in an apexthat is axially at the highest point of upper region edgeand/or at brim.

Referring to, scallopsmay be arcuately shaped with a scallop radius of curvature having a center radially inward of sidewall. Sidewallmay have a sidewall radius of curvature that may be measured at ridges, which may represent a radius of curvature of a given diameter of containerhaving a uniform or constant sidewall thickness before incorporating scallops. By providing a minimum sidewall thickness at valleysand a maximum sidewall thickness at ridges, scallop radii of curvature may be less than the sidewall radius of curvature. It may be appreciated that a smaller scallop radius of curvature relative to the sidewall radius of curvature may result in scallopsand/or valleysthat are deeper radially, narrower circumferentially, and/or more pronounced than with scallop radii of curvature than greater and/or more nearly equal to the sidewall radius of curvature.

In some embodiments, containermay be configured to store and/or transport a scrapable material, such as gypsum, concrete, cement, mud, and/or other relatively high weight and/or high viscosity granular substances, amorphous solids, pastes, or liquids. In order to facilitate scraping material from container, or for any other reason or combination of reasons, sidewalland/or scallopsmay be configured to have a relatively gradual arc and/or relatively large radius of curvature, for example, to allow a scraper blade, shovel, or the like, to contact or nearly approach a high degree of surface area to maximize the material that may be removed or scraped from container. In some embodiments, the ridgesare spaced circumferentially from one another by a predetermined distance or arc length corresponding to a tool dimension, such as a width of a scrapper or putty knife. The predetermined distance or arc length may be 1 inch, 2 inches, 3 inches, 4 inches, 5 inches, 6 inches, or any other suitable distance corresponding to the width of a tool to facilitate scrapping material from the tool with the ridges.

Sidewalland/or scallopsmay be configured for scrapability while also optimizing container weight, rigidity, and other performance criteria, such as impact resistance and top load capacity. As used herein, “impact resistance” may mean the ability of containerto withstand sudden and/or prolonged external forces without failing, such as by cracking or breaking. As used herein, “top load capacity” may mean the ability of containerto withstand sudden and/or prolonged forces to the top (e.g., brim), such as may occur from stacking one or more fully loaded containersor other objects on top of it, which may occur for example during palletization and/or transport of containerswith contents therein. “Scrapability” may refer to the relative ability of a user to scrape out or otherwise remove material from containerstored in storage region, which material may be proximate and/or at least partially stuck to sidewallor scallop, whether doing so by hand or by use of a tool or implement such as a scraper, blade, shovel, or the like. It is understood that a scallop or flute that has too small of a radius of curvature and/or that is too deep and/or narrow could negatively impact and/or prevent effectively scraping out all material in container. Moreover, it is understood that an outer surface of sidewallmay be uniform and/or consistent, as shown for example in, for any of a variety of reasons, including but not limited to aesthetic appearance and/or facilitating decorating the outer surface.

In order to optimize scrapability, containerweight, structural rigidity, impact resistance, and/or top load capacity, scallopmay have a radius of curvature and/or a ratio of its radius of curvature to that of sidewallthat is optimized. For example, in one illustrative embodiment shown in, sidewallmay have a radius of curvatureof about 5.608″ measured at the inner surface of peaks or ridgesnear the top of sidewall(see), and/or scallopmay be arced with a radius of curvatureof about 5.320″ near the top of sidewall(See) and/or of about 4.847″ near the bottom of sidewall(see), with sidewall radius of curvatureand scallop radius of curvatureboth having a center point located radially inwardly of sidewall. In this illustrative embodiment, the difference in the radii at the top of sidewallis about 0.288″. This difference in radii with a uniform outer surface may result, in this illustrative embodiment having an outside radius at the top of about 5.698″ (see), in a difference in thickness of about 0.025″ between ridgeand valley, for example, with a thickness of about 0.090″ at ridge(see) and/or of about 0.065″ at valley(see), representing a reduction in material within scallop. As shown in, the illustrative embodiment of containermay have a sidewallhaving a taper angle A of about 2.3 degrees.

The scrapability of sidewallmay be expressed in terms of the radiiand, for example those listed above, and/or in terms of a first ratio/of the scallop radius to the sidewall radius at ridges. In the above example, the ratio at the top of sidewallis 5.320 to 5.608, or about 0.945. A radiusmay be provided for a circle tangent to valleysat centerline, which in the illustrative embodiment above may be about 5.633″ (see, e.g.,). In this embodiment, a second ratio at the top/may be about 5.320 to about 5.633 and/or about 0.944. Another first ratio/at the bottom may be about 4.847″ (see) to about 5.147″ (see) and/or about 0.942 and another second ratio/at the bottom may be about 4.847″ to about 5.174″ (see) and/or about 0.937. In some embodiments, the first ratio and/or the second ratio may be in the range of less than 1.000 to about 0.600. In some embodiments, the first ratio and the second ratio may be different. In other embodiments, the first ratio and the second ratio may be substantially the same.

As shown in, scallop arc radius of curvaturemay have a center point that is offset a distancefrom the central axis of container. For example, distancemay be about 0.313″ near the top of sidewalland/or about 0.327″ near the bottom of sidewall.

Containerand/or sidewallare shown inhaving eight scallops, eight ridges, and eight valleys. It is understood that more or less scallops, ridges, and/or valleysmay be provided in containerand/or sidewall. For example, there may be between about 2 and about 40 of each of scallops, ridges, and valleys, there may be between about 4 and about 24 of each, and/or there may be between about 4 and about 16 of each.

Containermay be configured to hold a predetermined volume of contents. For example, containermay hold approximately 1 gallon, approximately 2 gallons, approximately 3 gallons, approximately 4 gallons, approximately 5 gallons, or approximately 6 gallons when full or nearly full. Sidewalland/or containermay have an inside radius and/or an outside radius of about 5″ to about 6″, for example, when configured to hold about 5 gallons.

It is understood that containerand/or any component thereof may be made of any of a variety of materials, including, but not limited to, any of a variety of suitable plastics material, any other material, or any combination thereof. Suitable plastics material may include, but is not limited to, polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP), polystyrene (PS), high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), crystallized polyethylene terephthalate (CPET), polylactic acid (PLA), mixtures and combinations thereof, or any other plastics material or any mixtures and combinations thereof. Suitable plastics material may include fillers or filled resin such as mineral, acrylic, glass, and/or other fillers, which may for example be found in post-consumer recycled (PCR) or post-industrial recycled (PIR) materials. It is understood that multiple layers of material may be used for any of a variety of reasons, including to improve barrier properties, or to provide known functions related to multiple layer structures. The multiple layers, if included, may be of various materials, including but not limited to those recited herein.

It is further understood that containeror any component thereof may be substantially rigid, substantially flexible, a hybrid of rigid and flexible, or any combination of rigid, flexible, and/or hybrid, such as having some areas be flexible and some rigid. It is understood that these examples are merely illustrative, are not limiting, and are provided to illustrate the versatility of options available in various embodiments of container.

It is further understood that any of a variety of processes or combination thereof may be used to form container, any component thereof, or any layer or substrate used therein. In some embodiments, containerand/or any component thereof may be formed substantially of injection molded HDPE, although other materials and forming processes may be used instead of or in addition to HDPE and injection molding, respectively. Various materials and/or processes may be used to form containerand/or any component thereof as will be understood by one of ordinary skill in the art. In some embodiments, containermay be substantially a one-piece design and/or substantially formed as an integral or unitary structure.

Embodiments are described herein with reference to the accompanying drawings, in which some, but not all embodiments are shown. Indeed, embodiments may take many different forms and the present disclosure should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include plural referents unless the context clearly dictates otherwise.

The terms “substantial” or “substantially” may encompass the whole as specified, according to certain embodiments, or largely but not the whole specified according to other embodiments.

These and other modifications and variations may be practiced by those of ordinary skill in the art without departing from the spirit and scope, which is more particularly set forth in the appended claims. In addition, it should be understood that aspects of the various embodiments may be interchanged in whole or in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and it is not intended to limit the scope of that which is described in the claims. Therefore, the spirit and scope of the appended claims should not be limited to the exemplary description of the versions contained herein.