Blow Molded Container for Storing and Transporting Fluids

The present invention relates to a container for use in storing and transporting fluid materials, such as liquids, slurries or other flowable materials. The body of the container is preferably made from a thermoplastic material and formed by a blow molding process.

Liquid, slurries or other flowable materials, including industrial chemicals, are often stored in large containers, such as a pail, drum, tote, or carboy. It is desired that bulk containers are efficiently shipped and otherwise transported from the manufacturer or distributor. The containers often need to be moved by the end user at their working destination. Body shape and volume often play a role in the selection of a container. Other considerations include cost and durability.

In embodiments, there is provided a container structure defined by a body having an interior volume for retaining flowable materials. The body is generally rectangular in form and includes a handle and an attached wheel-axle combination, permitting the container to be maneuverable during use.

In embodiments, a container structure is defined by a rectangular-shaped body having a top, bottom, and four walls. The four walls form a front wall, a rear wall and two sidewalls, with each wall connected to two adjacent walls, the top and bottom at a corner. The rectangular form positions the front and rear walls substantially parallel to one another, with the two side walls substantially parallel to one another and perpendicular to the front and rear walls. The top and bottom walls are also generally parallel to one another and substantially perpendicular to the front wall, rear wall and two side walls. The top, bottom and four walls create a unitary construction and define a closed interior volume.

In embodiments, the top wall includes a unitary handle and at least one bung opening for providing access into the interior volume. The rear wall preferably includes an engagement structure in the form of an inwardly formed engagement slot, extending transversely between two sidewalls. The rear wall may also include a recessed portion positioned between the engagement slot and the bottom. A pair of wheels are preferably provided on opposite ends of and rotatable about a transverse axle. The axle is preferably retained within the engagement slot and the wheels are positioned parallel to the two sidewalls.

In combination with the container, a separate extension handle may be provided. The extension handle preferably includes an engagement structure for releasably securing the extension handle to the body of the container. The engagement structure may be provided for engagement between the extension handle and a formed (or otherwise attached) handle on the top of the container. The extension handle is provided for assisting in the maneuverability of the container. A removable bung or cap is preferably provided within the opening provided in the container body. In further combination, a cap wrench may be formed as part of the extension handle. The wrench structure is formed to engage with the cap and assist in its removal from the opening.

In embodiments the container may include a handle structure that is separately formed from the container body and fixed thereto. The form of attachment may include an over molding process or a frictional engagement within contours formed in the container body. The attached handle may include pivoting structures and/or be extendable from the body during use. Other features of the handle and its attachment are also contemplated.

In the drawings, where like elements are identified by similar number designations, there is shown a generally rectangular and accompanying handle having various forms. In, the containeris shown as including a body portionhaving a generally hollow interior for retaining fluids, slurries, or other flowable materials. The bodyis formed by a top, four walls,,,and a bottom. The rectangular form positions the front and rear walls substantially parallel to one another, with the two side walls substantially parallel to one another and perpendicular to the front and rear walls. The top and bottom walls are also generally parallel to one another and substantially perpendicular to the front wall, rear wall and two side walls. Two wheel members,are provided adjacent the bottom end of sidewallsand. Two sealed openings,are provided on the top, along with a fixed handlethat projects from the top wall. The handleis integrally formed with the structure of the container body.

As shown in, the front wallof the body portionincludes a spacefor application of labels or other information, such as, identifying the contents, acceptable use, or other properties of the contents and/or the container. Preferably, the spaceis planer in form and is recessed in the front wall. These features promote ease of label mounting and may improve label life. In, the rear wallof the body portionis shown as including an engagement structure for securing a pair of wheels,to the container body. The engagement structure is in the form of a retention slotfor receiving an axle membertherein. The wheels,are secured on the ends of and rotatable about the axle. As shown, wheelis positioned within a well portionformed at the bottom of sidewall. Wheelis similarly positioned within a well portionformed in the opposing sidewall(not fully shown). Preferably, the outside surfaces of the two wheels,are aligned with the outside surfaces of the corresponding sidewalls,. The size of the wheels,is preferably in the range of 7 inches in diameter. Relatively large diameter wheels assist in the maneuverability of the containerover curbs, steps, and the like.

The walls,,,and the bottomare shown as including a corrugated configuration for the purpose of improving sidewall and overall body strength. The corrugated structure is preferably formed to minimize expansion or deformation of the wall structure due to internal pressures from the retained material. In, the bottomis shown as including a rib structure. The rib structurepreferably is in the form of a plurality of raised ribs projecting from the bottomof the container body. The rib structureis preferably integrally formed as part of the bodyand provides both stiffness and a raised skid surface for protection of the bottom. A recessed portionis provided at the lower portion of the rear wall, below the position of the retention slotfor the wheel axle. The recesspreferably extends across the rear wall, between the two sidewalls,, and creates a set-back. The recessgenerally makes it easier to tilt the container during use and transport.

shows a plurality of containerspositioned on a pallet. Preferably, the outer dimensions of the container bodyare defined to match the dimensions of the palletso as to maximize the available space during shipment. In the embodiment shown, the width and depth dimensions of the container bodyare defined to fit six containers on a typical 42-inch by 42-inch pallet. Hence, the preferred width of the containeris set at less than 21 inches and the preferred depth of the container is set at less than 14 inches. The overall height of the container is preferably in the range of 45 inches.

show the addition of a separate extension handleused to assist in transport of the container. Inthe extension handleis removably attached or secured to the container body. The extension handleincludes an engagement endinserted under the fixed handleon the top wall. After insertion, the extension handleis pivoted upwards (from the phantom position in) into an engagement position (shown is solid lines in). In the cross section of, the extension handleis shown with the engagement endcontacting the top wallof the container body. An engagement means is formed by a first bend portionpositioned adjacent the engagement endThe first bendcontacts the front of the fixed handle. Further, a second bendas provided adjacent the first bendand fits under the, preferably, integrally formed handle. The second bendfurther contacts the rear of the handle. The bends,preferably engage the handleon opposite sides with the engagement endin contact with the body. The engagement frictionally secures the extension handleto the handleand container body. A projecting portionof the extension handleis formed on an opposite end and is directed in an upward angle, away from the handleon the container body. As shown in, the engagement of the extension handleunder the fixed handlepermits a user to pivot () the containerfor rolling movement, using the wheels,. The extension handlemay be removed from its engagement by a downward pivot motion (into the phantom position of). The downward pivot disengages the bends,from the fixed handle. In a preferred embodiment, the extension handleprovides a tilt of the container to an angle in the range of 20 to 25 degrees.

As shown in more detail in, the engagement endof the extension handleincludes a wrench structurefor removing or attaching the bung or capfrom or to the bung openings,. In the cross section of, the capis shown inserted into the openingand sealed by means of screw threadsand a flange gasket. Interior slotsare formed on the top of the cap. Four slotsare shown on the cap. The wrench structureon the engagement endincludes a corresponding pattern of projecting tabs(see, e.g.,). Upon engagement of the tabsin the slots, the handlemay be rotated to unscrew the capfrom the opening. As shown in, securing the capinto the openingis created by an opposite rotation.

show the attachment structure for mounting the wheels,on the container body. The wheels,are preferably first mounted on the axle(). The combination is then inserted into the retention slotformed in the lower portion of the rear wall(). The retention slotis preferably formed to create a friction fit with the axle. The wheels,are positioned in the wheel wellson opposite sides of the body. The engagement of the axlein the slotis shown in cross section in. The recessed portionis also shown as being formed in the rear wall, between the slotand the bottom wall. Retention structures are preferably formed on the inside surfaces of the slotto both strengthen the walls and to firmly retain the axle.

The container bodyis preferably formed from a rigid plastic material and may be manufactured via a blow molding process. Certain portions of the container body may be formed separately and fused into an assembly. The handleis preferably hollow. The wall thickness of the bodyis preferably sufficient to retain the flowable material, without leaks or cracking, and to withstand common use, such as shipment, movement, pressure changes and storage of potentially corrosive chemicals. The internal storage volume is preferably around 20 gallons. This volume sizing is contemplated to be between many existing container volumes, thus making the containerapplicable to replace existing containers. The containeris intended to serve as a replacement for existing pail, carboy, tote or drum structures.

show various views of a container embodiment identified as, having a telescoping handlethat is retained within molded contours of the rear wallof the container body. The handleas shown has an inverted “U” shape, with a gripping portionpositioned transversely between two projecting leg members. The leg membersare inserted into two molded slotsformed the upper contoured portions of the rear wallof the body. Inthe handleis separated from the bodywith directional arrows indicating the direction of insertion into the slots. Inthe legsof the handleare inserted into the slots. As shown, a fixed handleis also provided on the top wallof the body. This fixed handleis an optional structure and may be integrally formed as part of the blow molding of the container body. In, the extension handleis retracted, such that the leg membersare almost fully retained within the slots. Inthe handleis shown in the extended position, created by sliding the legsupwardly within the formed slots. The axleand wheels,ofmay be included with the containerof. The axlemay be inserted into the slotformed in the lower end of the rear wall, adjacent the recess portion. The wheels,may be positioned within side well portions. A strengthening rib or corrugation structureis also shown within the recessed portion, with the ribs wrapping around to the bottom surface (not shown).

Inthere is shown multiple cross sectioned views of one of the handle legsretained within the corresponding slotwithin the rear wallof the container. The slotincludes an outer or main portionand an inner or control portion. The handle legis retained with in the main portionof the slotand can moved longitudinally (vertically as shown) within the length of the slot.shows the handle legin the extended position, such as that shown in. In, the legis in the downward position of. A stop memberis provided adjacent the end of the leg member. As shown, the stopis a bolt that is fixed within the handle leg. A projected endof the stopis positioned within the inner, control portionof the slot. The control portionincludes a top edge or shoulderand a bottom edge or bottom shoulder.

In the extended position of, the protected endof the stopcontacts the top edgeof the control portionof the slotto define a maximum extension for the handle. In the retracted position of, the projected endof the stopengages the bottom edgeof the inner portionof the slotto define a lower limit for the handle. As an alternative, the bottom endof the outer portionof the slotmay be contacted by the bottom edge of the leg memberto fix the lower retraced position. The stopmay be retracted or removed to permit the handle legslide out of the slot, to separate the handlefrom the body. In, a preferred contour of the outer slot portionis shown as wrapping partially around the handle legto retain the legwithin the slot. This retaining contour is preferably formed into the bodyduring the blow molding formation process.

show various views of a container embodimenthaving a fixed handledthat is secured to the top wallof the container bodyas part of an over-molding process. The top wallincludes retaining slotsformed in the surface. The handleincludes a crossing memberand two opposing leg members. A foot portionis formed at the lower end of the leg members. The rear view of the container inshows a retaining slotformed in the lower end of the rear wall, adjacent the recessed portion. The axleand wheels,ofmay be attached to the bodyby the axlebeing inserted into the slotThe wheels,may be positioned within the side well portions. A strengthening rib structureis also shown within the recessed portion, with the ribs wrapping around to the bottom surface (not shown).

As more particularly shown in the cross section of, the foot membersare positioned within the top slots. In the over-molding process, the formed handleis fixed in the mold for forming the blow molded bodyof the container. As the bodyis formed, the top wallsurrounds the foot membersof the handle. As the formed container body cools, the foot membersare fixed within the top wall.

show various views of a further container embodimenthaving a fixed handledthat is attached to the top wallof the container body. As shown by the exploded view ofand the partial cross section of, the handleis attached to a base memberby a rod. The baseincludes opposing projectionshaving openings therein to receive the rod member. The rodis inserted into the openings and into the lower portion of the handle member, with the handle positioned between the projections and the outer ends of the rod being fixed to the projections.

In the container embodiment, the base memberof the handle assembly is secured within the top wallof the container bodyby an over molding process, with the other portions assembled thereafter. As shown by, a well portionis formed in the top walland in final formation of the bodysurrounds the base member. As shown by, the handle bodymay include a structural lattice, formed by, for example, an injection molding process. The cross section ofis taken through one of the vertical members within the lattice.

The rear view of the containerinshows a retaining slotformed in the lower end of the rear wall, adjacent a recessed portion. The axleand wheels,ofmay be attached to the bodywith the axleinserted into the slotThe wheels,may be positioned within the side well portions. A strengthening rib structuremay be provided within the recessed portion, with ribs preferably wrapping around to the bottom surface (not shown).

show various views of a further container embodimenthaving a handledpositioned on the top wallof the container body. The handleis pivotable on a base memberthat is fixed to the top wall. The handleis pivoted to a raised position inand downwardly to stored position in. A recessis provided in the upper portion of the rear wall. The recessreceives the handlein its pivoted downward position. The base memberis preferably secured within the top wallof the container bodyby an over molding process, with the other portions assembled thereafter. A well portionis formed in the top walland in final formation the bodysurrounds the base member. As shown by, the handle bodymay include a structural lattice, formed in, for example, an injection molding process.

The rear views of the containerinshow a retaining slotformed in the lower end of the rear wall, adjacent a recessed portion. Similar to that discussed previously, the axleand wheels,ofmay be attached to the bodywith the axleinserted into the slotThe wheels,may be positioned within the side well portions. A strengthening rib, corrugation or other structuremay be provided within the recessed portion, and preferably wrapping around to the bottom surface.

As shown by the exploded view of, the handleis attached to the base memberby a rod. As in the container, the baseincludes opposing projectionshaving openings therein to receive the rod member. The rodis inserted into the openings and through a retaining structure on the handle member. The retaining structure is positioned between the projections and the outer ends of the rodare fixed. A stop membermay be provided on the axle formed by the rodto control rotation of the handle.

Inthere is show the handlein various positions that are defined by the stop member. In, the handleis shown from the rear. The stop memberis slid along the rodto the right as shown by the arrow. The bottom surface of the stop memberengages the top of the baseand is displaced from a recessformed in the surface of the base. The engagement of the stop memberwith the baselimits the downward rotation of the handletowards the base. Hence, the stop memberprevents the handle from moving into the downward position shown in.

In, the handle is shown from the front. The stop memberis moved to the right as shown by the arrow in this view and aligns with the recessin the top surface of the base.shows the alignment of the stop memberwith the recessfrom the rear of the handle. In this aligned position, the handleis permitted to rotate downwardly, as shown by the arrow in. In, there is shown a springon the rod. The springprovides resistance to movement of the stop memberon the rod. In addition, the spring provides a return force for moving the stop memberfrom the aligned position () back to the engaged position (). When the stop memberis in the aligned position, a downward movement of the handle () causes the stop memberto move within the recess, whose side wall prevents the springfrom returning the stop memberto the engaged position (). Other resilient return means may be provided for creating a normal position for the stop. Additional resilient means may be provided to normally set the handle in either the rotated up or rotated down positions.

show various views of a container embodimenthaving a fixed handlethat is inserted into and retained within the molded contoursof a the rear wallC of a container body. The handle baseis retained in the contoursof the container body, with a gripping portionformed on the upper end of the handle body. The handle gripping portionis projected above the top wallof the container body. The handle member is preferably injection molded, while the container body is formed by a blow molding process.

In, there is shown a set of wheels,similar in form to those shown in. An axle () may be inserted into the slotformed in the lower end of the rear wall, adjacent the recessed portion(see). The wheels,may be positioned within the side well portions. A strengthening rib, corrugation or similar structureis also shown within the recessed portion, with the ribs preferably wrapping around to the bottom surface (not shown) of the container body.

Inthere is shown the handlein cross section as positioned within the contoursof the rear wallof the container body. There is also shown ina forward portion of the handle basethat projects into contoured portions formed in the top wallof the container body. In addition, stop membersare positioned on a lower portion of the base. The stopsare preferably flexibly mounted on the base. In the fixed position for the handle, the stops engage a shoulder edgeformed in the lower portion of the body contours.

show various views of a container embodimenthaving a telescoping handlethat insertable into and retained by molded contourswithin the rear wallof the blow molded container body. Similar to, the handleis secured in the contoursof the body and may be raised and lowed as desired.

shows the handlein the raised position. The handleis preferably injection molded. There is also shown a set of wheels,similar in form to those shown in. An axle (in) may be inserted into the slotformed in the lower end of the rear wall, adjacent the recessed portion(see). The wheels,may be positioned within the side well portions. A strengthening rib structureis also shown within the recessed portion, with the ribs preferably wrapping around to the bottom surface (not shown) of the container body.

Inthere is show the handlein cross section as positioned within the contoursin the rear wallof the container body. Stop membersare positioned on a lower portion of the base. The stopsare preferably flexibly mounted to the base. In the raised position of the handle, the stopsengage a shoulder edgeformed in the upper portion of the body contours.

Inthere is shown a container embodimenthaving a pivotable handlethat is rotatably fixed to an axis rodthat is integrally formed as part of the container bodyin the blow molding process. The handleis preferably injection molded having multiple parts,. In, the handleis shown in a downward (assembled) position.shows an exploded view with the handle baseseparated from the retaining structure. The retaining structurehas a number of tabs that project from its main body portion. The tabs are inserted through openings formed between the axis rodand the top wallof the container body. The tabs are received by the handle base, with screw fasteners directed through the tabs and base to rotationally secure the retainerto the handle baseabout the axis rod.

Inthe handleis shown in the downward position, resting adjacent to the top wallof the container body. In, the handleis raised upwardly to an operational position. In this operational position, the gripping portionof the handleis exposed, along with the adjacent opening for hand insertion.

Inthere is shown a cross section of the handleattached to the axis rodand in the downward position. The crossing memberis positioned adjacent the intersection of the top walland the rear wall. A curve is provided in the handle structure to match the contour of the wall intersection. The retaining memberis secured around the axis rod. In the blow molding process, the retaining rodis formed integrally with the walls of the container bodyand is preferably positioned at the parting lineof the mold (as shown in the molded body). In the cross section of, the handleis shown in the raised/operative position. A projecting portionon the retaining structureis shown engages with the top wallof the container body. The projection portionforms a stop for the upward rotation of the handle.

show a set of wheels,similar in form to those shown in. An axleis inserted into the slotformed in the lower end of the rear wall, adjacent the recessed portion. The wheels,may be positioned within the side well portions. A strengthening rib structureis also shown within the recessed portion, with the ribs preferably wrapping around to the bottom surfaceof the container body.

In the various embodiments, there is provided a container structure defined by a blow molded body having an interior volume for retaining flowable materials, such as industrial chemicals. The four walls of the body form a front, a rear and two sidewalls, with each wall connected to adjacent walls at a corner. The top, bottom and four walls preferably include a unitary construction. The body is substantially rectangular in form, includes a top handle and includes one or more integrally formed bung openings. Rolling wheels may be attached to the body.

In embodiments, the rear wall of the container body incudes an inwardly formed engagement slot, extending transversely across A lower section of the wall. The rear wall may also include a recessed portion positioned between the engagement slot and the bottom wall. A pair of wheels are provided on opposite ends of and rotatable about a transverse axle. The axle may be frictionally retained within the engagement slot, with the outside surface of the wheels positioned parallel to and, preferably, planer with the outside of the two sidewalls.

In embodiments, a number of handle structures are shown and described. In one embodiment, a fixed handle is provided that is integrally formed with, and molded as part of, the top wall. In other embodiments, a base of the handle, either forming an integral part thereof or as a separately attached element, is fixed within the top wall by an over molding process, fixing a base of the handle by molding the wall around the base structures. In other embodiments, the handle may be slidably retained within retention grooves formed in the contours of the walls of the container body. In embodiments, the handle may by be slidable so as to extend from a retracted position to the extended position. In embodiments, the handle may receive a separate extension structure for releasably securing the extension to the handle.

The rectangular shape of the container body provides for easy storage and efficient shipping. Corrugations, ribs or similar structures may be formed as part of the top, bottom and side walls of the container body. These structures preferably minimize bloating or swelling of the container walls and further reduce the risk of cracking along parting/assembly lines formed in the blow molding process.

Although specific terms are employed herein, these terms are used in a generic and descriptive sense and, unless specifically designated, are not for purposes of limitation. The scope of the invention is set forth in the following claims.