Container for a Package

This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/636,363, filed Apr. 19, 2024, which is expressly incorporated by reference herein in its entirety.

The present disclosure relates to a container, and particularly to a polymeric container. More particularly, the present disclosure relates to a polymeric container including a retainer configured to retain a closure to the container.

According to the present disclosure, a container is formed to include an interior product storage region and is configured to engage selectively with a closure to block access to the interior product storage region. The container includes a product-storage basin including a floor arranged generally perpendicular to a central axis of the container and an inner sidewall coupled to an outer perimeter of the floor and arranged to extend upwardly from the floor to define the interior product storage region above the floor and radially inward of the inner sidewall. The container further includes a child-resistant closure retainer coupled to the inner sidewall and configured to retain the closure to the container.

In illustrative embodiments, the child-resistant closure retainer includes a sidewall mount, a sidewall band, and a closure-lock tab. The sidewall mount is coupled to an outer surface of the inner sidewall and extends radially outward away from the inner sidewall. The sidewall band is coupled to a radially-outer end of the sidewall mount and is spaced radially from the inner sidewall to provide a clearance gap radially between the inner sidewall and the sidewall band. The closure-lock tab is coupled to the sidewall band and is moveable relative to the sidewall band between a closure-retention position and a closure-release position. In the closure-retention position, the closure-lock tab is spaced a first distance from the outer surface of the inner sidewall and is engaged with the closure to block removal of the closure from the container. In the closure-release position, the closure-lock tab is spaced a second distance from the outer surface of the inner sidewall, less than the first distance, to allow removal of the closure from the container.

In illustrative embodiments, the container further includes a gap filler coupled to the sidewall band for movement relative to the sidewall band from a molded configuration to a folded configuration. The container is formed with the gap filler initially in the molded configuration where the gap filler extends downwardly away from the sidewall band and is spaced radially outward from the inner sidewall. The gap filler is subsequently moved to the folded configuration after pivoting relative to the sidewall band toward the inner sidewall to cover the clearance gap between the inner sidewall and the sidewall band and block movement of at least a portion of the sidewall band radially inward as the closure-lock tab moves from the closure-retention position to the closure-release position so that the clearance gap is maintained between the sidewall band and the inner sidewall as the closure is removed from the container.

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 packageincludes a closureand a containeras shown in. The containeris formed to include an interior product storage regionconfigured to store one or more products therein. The closureis removable from the container and is configured to engage selectively with the container to block access to the interior product storage region.

The containerincludes a product-storage basinand a closure retainercoupled to the product-storage basinas shown in. The product-storage basinincludes a floorarranged generally perpendicular to a central axisof the container and an inner sidewallcoupled to an outer perimeter of the floorand arranged to extend upwardly from the floorto define the interior product storage regionabove the floorand radially inward of the inner sidewall. The closure retaineris coupled to the inner sidewalland is configured to retain the closureto the container.

The closure retaineris at least partially spaced radially from the inner sidewallof the product-storage basinto provide a clearance gapradially between the inner sidewalland a portion of the closure retainer. In the illustrative embodiment, the containerfurther includes a gap fillercoupled with one of the product-storage basinand the closure retainerand configured to cover the clearance gapfor improved aesthetics of the containerand to reinforce the closure retainerrelative to the product-storage basin.

In the illustrative embodiment, the gap filleris formed integrally with the closure retainerduring manufacturing of the container. The containeris made of a polymeric material, such as polypropylene, polyethylene, polyethylene terephthalate, or a combination of such materials, and is formed by injection molding the polymeric material to form the containerin a mold. The mold is structured to minimize overhangs so that the containercan release from the mold after the polymeric material solidifies in a direction generally along the central axis. The gap filleris initially molded in a first configuration, or molded configuration, relative to the product-storage basinwhere the gap filleris oriented so that release from the mold is possible as shown in. After releasing from the mold, the gap filleris configured to deform relative to the rest of the containerto a second configuration, or folded configuration, where the gap fillercovers the clearance gap. The gap filleris substantially perpendicular to the central axisin the second configuration and overlaps other parts of the containerwhich would typically make release from the mold more difficult due to the gap fillerproviding a large overhang in the second configuration.

The closure retaineris a child-resistant closure retainerand includes a sidewall mount, a sidewall band, and a pair of closure-lock tabs,as shown in. The sidewall mountis coupled to an outer surface of the inner sidewalland extends radially outward away from the inner sidewallto an inner surface of the sidewall band. The sidewall bandis coupled to a radially-outer end of the sidewall mountand is spaced radially from the inner sidewall to provide the clearance gapradially between the inner sidewalland the sidewall band. Slotsare formed in the sidewall bandto form the closure-lock tabs,.

The closure-lock tabs,are coupled to the sidewall bandand are moveable relative to the sidewall bandbetween a closure-retention position and a closure-release position as shown in. In the closure-retention position, the closure-lock tabs,are spaced a first distance from the outer surface of the inner sidewallto engage with the closureand block removal of the closurefrom the container. In the closure-release position, the closure-lock tabs,are spaced a second distance from the outer surface of the inner sidewallless than the first distance to allow removal of the closurefrom the container. The slotsallow the closure-lock tabs,to flex inwardly toward the central axisrelative to the sidewall band. The clearance gapprovides spacing for the closure-lock tabs,to move between the closure-retention position and the closure-release position.

The containerincludes gap-filler means by way of gap fillercoupled to the sidewall bandfor movement relative to the sidewall bandfrom the molded configuration to the folded configuration. In the molded configuration, the gap filler means extends downwardly away from the sidewall bandand is spaced radially-outward from the inner sidewall. In the folded configuration after pivoting relative to the sidewall band, the gap-filler means covers the clearance gapbetween the inner sidewalland the sidewall bandand blocks movement of at least a portion of the sidewall bandradially inward as the closure-lock tabmoves to the closure-release position so that the clearance gapis maintained between the sidewall bandand the inner sidewallas the closureis removed from the container.

The gap filleris coupled at or near a lower end of the sidewall bandof the closure retaineras shown in. The gap fillerincludes a plurality of tabsspaced circumferentially around the central axisand extending downwardly away from the sidewall band. Each tabis bendable relative to the sidewall bandfrom the first configuration, as shown in, to the second configuration, as shown in. After pivoting relative to the sidewall band, the tabscover the clearance gapbetween the inner sidewalland the sidewall band. The tabsalso reinforce the containerby blocking movement of at least a portion of the sidewall bandradially inward as the closure-lock tabs,move to the closure-release position. In this way, the tabscover the clearance gapand maintain the clearance gapbetween the sidewall bandand the inner sidewallas the closureis removed from the container.

Each of the tabsincludes a base wall or endcoupled to the sidewall band, a first circumferential wall or end, a second circumferential wall or end, and a distal wall or endas shown in. The base wallis formed integrally with the sidewall bandand provides a hinge or bend point for the tab. The base wallhas a reduced thickness relative to at least one of the sidewall band or the rest of the tab. The first and second circumferential walls,are angled to extend toward one another as the tabextends from the base wallto the distal wall. Each of the circumferential walls,extends along a plane through the central axisin the folded configuration so that they abut against a wall,of an adjacent tabin the folded configuration and minimize gaps therebetween. The distal wallinterconnects the first and second circumferential walls,and has a radius of curvature with a center coinciding with the central axisin the second configuration.

The circumferential walls,are angled and the distal wallis curved to accommodate lost space as the tabschange from the first configuration to the second configuration because the containeris circular. If the containerhas a different shape, such as a square or rectangular shape, some or all of the tabsmay have circumferential walls that are not angled and a distal wall that is not curved.

Each tabhas a length sufficient to span the clearance gapat or near a lower end of both the sidewall bandand the flooras shown in. The distal wallof each tab formed to include a first notched ledgeand the product-storage basinis formed to include a second notched ledgeas shown in. The first notched ledgeis curved with the distal endof each tab and is sized to fit within a space defined above the second notched ledgein the floorand/or inner sidewall. The second notched ledgeis an annular ring extending circumferentially about the central axisand projects outwardly toward each of the tabs. When each tab moves to the second configuration, the notched ledgeof the tabsinterlock with the notched ledge of the product-storage basinto retain each of the tabsin the second configuration. Each tabmay further include a recessthat a user can use (i.e. with a fingernail, for example) to return one or more tabsto the first configuration to access the clearance gapfor storage.

In the illustrative embodiment, the tabsare coupled to a lower end or regionof the sidewall bandas shown in. Each of the tabsis also coupled to a radially inner edgeof the lower endand/or an inner surfaceof the sidewall bandand may extend at an inward angle toward the central axisof the containerin the molded configuration. When the tabsare moved to the folded configuration, the inner edgemay be rounded for increased aesthetics and to reduce sharp edges on the container.

Each of the tabsmay vary in thickness as shown in. For example, the tabsmay be thinnest at the base endand thickest at or near the distal end. Thinning the tabsat the base endmay facilitate moving each tabfrom the molded configuration to the folded configuration while thickening the distal endmay reinforce the connection between the notched ledges,to further block separation of the distal endsfrom the product-storage basin. The closure retainermay further include a lower lipcoupled to the lower endof the sidewall bandand that projects downwardly from the lower endand past the floor. The lower lipmay block structures in the environment (i.e. surfaces the containermay rest on or contact when dropped) from contacting the base endof each of the tabswhere they are thinnest. The lower lipmay also act as a guide for a tool used to change each of the tabsfrom the molded configuration to the folded configuration during manufacture. In the folded configuration, each of the tabsmay be located entirely above a lowermost end of the lower lipsuch that the tabswill not contact any surface on which the containerrests.

A method of forming packageincludes forming closureand container. Closureand containermay be formed by injection molding, thermoforming, blow molding, or any other suitable forming method. The gap filleris molded in the first configuration so that the containercan be released from the mold. The method further includes bending each of the tabsinwardly toward the central axis. The tabsmay extend at a slight angle (i.e. less than 10 degrees) toward the central axisas they extend away from the sidewall bandin the first configuration. This pre-orients each tabfor movement to the second configuration to limit movement of the tabs in an opposite direction away from the central axis. A tool, such as a flat plate or ring can press each tabinto place into the second configuration at the same time.

Once the containeris formed and the gap filleris moved to the second configuration, the containercan be filled with product and closurecan be attached to the closure retainer. Labels can be applied over the gap fillerand the floorto further block view of the clearance gap. Other comparative containers are formed without an integral gap filler and, instead, include a separately formed component that is attached to the container after being formed as shown in. These comparative containers are more difficult to assemble and increase cost for the process as a whole.