CONTAINER

PRIORITY CLAIM

[0001]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.

BACKGROUND

[0002]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.

SUMMARY

[0003]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.

[0004]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.

[0005]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.

[0006]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.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]The detailed description particularly refers to the accompanying figures in which:

[0008]FIG. 1 is a perspective view of an exemplary embodiment of a container having a sidewall and a plurality of scallops or scalloped segments to provide the container with a scalloped inner surface;

[0009]FIG. 2 is a cross-sectional perspective view of the container of FIG. 1;

[0010]FIG. 3 is a cross section of a portion of the container showing an enlarged view of a portion of the container of FIG. 2;

[0011]FIG. 4 is a cross section of the container taken along line 4-4 in FIG. 1;

[0012]FIG. 5 is an enlarged view of a portion of FIG. 4;

[0013]FIG. 6 is a partial perspective view of a portion of the container showing an exemplary scallop arc radius dimension measured near the top of the sidewall;

[0014]FIG. 7 is a partial perspective view of a portion of the container showing an exemplary scallop arc radius dimension measured near the bottom of the sidewall;

[0015]FIG. 8 is a partial perspective view of a portion of the container showing an exemplary radius of a circle tangent to the peaks or ridges defining the sides of the scallops measured near the top of the sidewall;

[0016]FIG. 9 is a partial perspective view of a portion of the container showing an exemplary radius of a circle tangent to the valleys located in the center of the scallops measured near the top of the sidewall;

[0017]FIG. 10 is a partial perspective view of a portion of the container showing an exemplary radius of a circle tangent to the peaks or ridges defining the sides of the scallops measured near the bottom of the sidewall;

[0018]FIG. 11 is a partial perspective view of a portion of the container showing an exemplary radius of a circle tangent to the valleys located in the center of the scallops measured near the bottom of the sidewall;

[0019]FIG. 12 is a partial perspective view of a portion of the container showing an exemplary radius of the sidewall outer surface measured near the top of the sidewall;

[0020]FIG. 13 is a partial perspective view of a portion of the container showing an exemplary radius of the sidewall outer surface measured near the bottom of the sidewall;

[0021]FIG. 14 is a partial perspective view of a portion of the container showing an exemplary sidewall taper angle;

[0022]FIG. 15 is a perspective view of another embodiment of a container including a plurality of scalloped segments having an upper band; and

[0023]FIG. 16 is a cross section showing a portion of the container.

DETAILED DESCRIPTION

[0024]A container 10 in accordance with the present disclosure, includes a brim 11, a sidewall 14, and a floor 15 as shown in FIGS. 1-5. The brim 11 and the sidewall 14 extend annularly around a central axis 20. The central axis 20 passes through a center of the floor 15. The container 10 is formed to include a storage region 19 configured to hold products, such as liquids, mortar, joint compound, spackling, etc. The sidewall 14 and the floor 15 may cooperate to form the storage region 19, which may be suitable for storing, containing, and/or holding contents for subsequent removal. The brim 11 may be configured to provide a structure for coupling a lid to container 10, for example, by extending radially outwardly to provide one or more mounting surfaces for the lid. The brim 11 may be, for example, suitable for connecting a lid via a snap fit engagement and/or a lid with tamper evident features.

[0025]The floor 15 is coupled to a lower end of the sidewall 14. The sidewall 14 includes an inner surface 22 facing toward the central axis 20 and an exterior surface 24 facing away from the central axis 20. The inner and exterior surfaces 22, 24 of the sidewall 14 both have constant radii of curvature with a center at the central axis 20. The sidewall 14 also has a substantially constant thickness 21 between the inner and exterior surfaces 22, 24, e.g. such that the thickness of the sidewall does not vary by more than 5% around the central axis 20.

[0026]In the illustrative embodiment, the container further includes a plurality of scalloped segments 200 coupled to the inner surface 22 of the sidewall 14 and facing toward the central axis 20. Each of the scalloped segments 200 may be coupled to adjacent segments 200 or spaced apart from one another about the central axis 20. The plurality of scalloped segments 200 are configured to reinforce the sidewall 14 of the container 10 so that the amount of material forming the container can be reduced or minimized.

[0027]The plurality of scalloped segments 200 include a plurality of vertically-extending ridges 210 and a plurality of vertically-extending valleys 220 as shown in FIGS. 1-5. The plurality of vertically-extending ridges 210 are located on a reference circle 202 having a first radius of curvature 211 about the central axis 20. Each vertically-extending valley 220 included in the plurality of vertically-extending valleys 220 is partially offset radially outward from the reference circle 202 and has a second radius of curvature 221 between adjacent ridges 210 included in the plurality of ridges 210. The second radius of curvature 221 is less than the first radius of curvature 211. In other words, the container 10 thicker at each ridge 210 and thinner between the plurality of ridges 210 in each valley 220.

[0028]Each of the vertically-extending ridges 210 may form an innermost portion or apex 212 of the plurality scalloped segments 200 as shown in FIG. 3. The reference circle 202 is established at a tangent point of each of the plurality of vertically-extending ridges 210. The reference circle 202 has a center C1 at the central axis 20. In other words, a radially-innermost portion of each of the vertically-extending ridges 210 is spaced a common distance from the central axis 20 at all horizontal planes perpendicular to the central axis 20 along a height of the sidewall 14.

[0029]Each of the vertically-extending valleys 220 has an inner surface 222 facing toward the central axis 20 and having the second radius of curvature 221. The inner surface 222 of each vertically-extending valley 220 has a center C2 located radially between the central axis 20 and the sidewall 14. In the illustrative embodiment, the center C2 of each inner surface 222 is located radially between the center C1 and the innermost apex 212 of each vertically-extending ridge 210.

[0030]Each vertically-extending ridge 210 of the plurality of vertically-extending ridges 210 has a ridge thickness 214 as shown in FIG. 5. Each vertically-extending valley 220 of the plurality of valleys 220 has a valley thickness 224 that is less than the ridge thickness 214. In the illustrative embodiment, the valley thickness 224 is smallest at an arc centerline 225 of each of the valleys 220. The arc centerline 225 is spaced equal distances from each adjacent ridge 210. The valley thickness 224 may be zero at the arc centerline 225 such that the inner surface 22 of the sidewall 14 is located at a tangent point of the second radius of curvature 221 along the arc centerline 225. The valley thickness 224 may constantly decrease from each ridge 210 toward the centerline 225. The constant decrease in thickness is gradual in the illustrative embodiment due to the inner surface of each valley 220 having the second radius of curvature 221. In some embodiment the constant decrease in thickness may be linear such that at least a portion of each valley 220 has no radius of curvature and each valley 220 includes a v-shape when viewed in cross section.

[0031]Each vertically-extending valley 220 includes a first ramp 226 coupled to a first ridge 210A included in the plurality of ridges 210 and a second ramp 228 coupled to the first ramp 226 and to a second ridge 210B included in the plurality of ridges 210 and adjacent to the first ridge 210A. The first ramp 226 and the second ramp 228 are joined at the centerline 225 of each valley 220.

[0032]Each of the ridges included in the plurality of ridges 210 has a first height 230 and each of the valleys included in the plurality of valleys 220 has a second height 232 less than the first height 230. The first height 230 is defined between a fillet 234 included in the sidewall 14 at a lower end thereof and an upper end 236 of each ridge 210. The second height 232 is defined between the fillet 234 and an upper end 238 of each valley 220.

[0033]Each of the plurality of scalloped segments 200 further includes a gradient upper region 100 coupled to the upper end 236 of two vertically-extending ridges 210 included in the plurality of vertically-extending ridges 210 and to the upper end 238 of a single valley 220 included in the plurality of valleys 220 as shown in FIG. 2. Each gradient upper region 100 has an upper region edge 110 joined with the upper ends 236, 238 of the two ridges 210 and the single valley 220. Owing to the height differences between the ridges 210 and the valleys 220, the upper region edge 110 varies in height as it extends circumferentially between the two ridges 210. In the illustrative embodiment, each upper region edge 110 has an arcuate shape located a first distance from the brim 11 at the two ridges and a second distance from the brim 11, greater than the first distance, at the centerline 225. The distance of the upper region edge to the brim 11 increases as the upper region edge 110 extends from each ridge 210 to the centerline 225 of each valley 220. The increase in distance is non-linear in the illustrative embodiment to provide each upper region edge 110 with the arcuate shape. In some embodiments, the upper region edge 110 may have a linear change in distance from the brim 11 as the upper region edge 110 extends from each ridge 210 toward the centerline 225 to provide the upper region edge 110 with a v-shape.

[0034]Each gradient upper region 100 has a gradient thickness 112 that may vary as each gradient upper region 100 extends from the upper region edge 110 toward the brim 11. In the illustrative embodiment, the gradient thickness 112 increases from the upper region edge 110 toward the brim 11. In some embodiments, the gradient thickness remains substantially constant from the upper region edge 110 toward to the brim 11.

[0035]Another embodiment of a container 300 is shown in FIGS. 15 and 16. The container 300 is similar to container 10 and includes a brim 311, a sidewall 314, and a floor 315. The container 300 further includes a plurality of scalloped segments 301 having a plurality of ridges 310, a plurality of valleys 320, and a plurality of gradient upper regions 330 like container 10. The container 300 differs from container 10 in that each scalloped segment 301 further includes an upper band 340 coupled to a top end 334 of each gradient upper region 330 and to the brim 311. The upper band 340 extends annularly around a central axis 321 of the container and has a substantially constant band thickness 342 greater than or equal to a gradient thickness 344. An apex 350 of each ridge 310 is also joined with a lower end of the upper band 340.

[0036]Some embodiments of a container 10, such as the exemplary embodiment shown in FIG. 1, may include a brim 11 defining a top opening into a storage region 19, a sidewall 14, and/or a floor 15. Sidewall 14 and floor 15 may cooperate to form storage region 19, which may be suitable for storing, containing, and/or holding contents for subsequent removal. Brim 11 may be configured to provide a structure for coupling a lid to container 10, for example, by extending radially outwardly, or for any other reason. Brim 11 may be, for example, suitable for connecting a lid via a snap fit engagement and/or a lid with tamper evident features. A bead 12 may be provided to protect an underside of a lid or for any other reason. A ring 13 may be provided axially below bead 12. Ring 13 may be provided for any of a variety of reasons, including but not limited to providing reinforcement for a handle attachment area 16 and/or protecting an underside of a lid when coupled to container 10.

[0037]Sidewall 14 may include one or more areas of reduced material or scallops or scallop segments 200, as shown for example in FIGS. 1 and 2. Scallops 200 may be formed on an inner surface of sidewall 14 to give the inner surface of sidewall 14 an undulating or wavelike form circumferentially. Scallops 200 may include and/or be separated by one or more ridges 210, which may represent a local maximum thickness, or ridge thickness. Ridges 210 may have a ridge thickness that represents a maximum thickness of sidewall 14. Ridges 210 may extend longitudinally or axially transverse to a radial direction and/or a circumferential direction. Scallops 200 may include troughs or valleys 220 interposed between adjacent ridges 210, which valleys 220 may include a valley thickness that represents a minimum thickness of sidewall 14. By providing valleys 220 that are thinner than ridges 210, container 10 may 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, container 10 may be used to store and/or transport a relatively high volume and/or a relatively high weight of material.

[0038]Sidewall 14 may include one or more gradient upper regions 100 proximate brim 11, a shown for example in FIGS. 1-3. Brim 11 may have a substantially uniform thickness circumferentially and/or gradient upper region 100 may have a gradually changing, blended, and/or gradient thickness as it extends longitudinally or axially downwardly away from brim 11 toward floor 15. Brim 11 and/or sidewall 14 at or near brim 11 may have a thickness that is greater than minimum thickness and/or valley 220 thickness such that the gradient thickness and/or blending of thickness takes the most distance from brim 11 to an upper region edge 110 at a circumferential location of valley 220, for example, if the gradient or transition of thickness is linear in gradient upper region 100. Upper region edge 110 may represent a boundary where a thickness of upper gradient region 100 is approximately equal to a thickness of scallop 200. Less blending may be needed at ridge 210 relative to brim 11, and in some embodiments the thickness at ridge 210 may approximately equal the thickness at brim 11 such that no blending is needed, resulting in an apex 150 that is axially at the highest point of upper region edge 110 and/or at brim 11.

[0039]Referring to FIGS. 2 and 3, scallops 200 may be arcuately shaped with a scallop radius of curvature having a center radially inward of sidewall 14. Sidewall 14 may have a sidewall radius of curvature that may be measured at ridges 210, which may represent a radius of curvature of a given diameter of container 10 having a uniform or constant sidewall thickness before incorporating scallops 200. By providing a minimum sidewall thickness at valleys 220 and a maximum sidewall thickness at ridges 210, 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 scallops 200 and/or valleys 220 that 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.

[0040]In some embodiments, container 10 may 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 10, or for any other reason or combination of reasons, sidewall 14 and/or scallops 200 may 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 10. In some embodiments, the ridges 210 are 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 210.

[0041]Sidewall 14 and/or scallops 200 may 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 container 10 to 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 container 10 to withstand sudden and/or prolonged forces to the top (e.g., brim 11), such as may occur from stacking one or more fully loaded containers 10 or other objects on top of it, which may occur for example during palletization and/or transport of containers 10 with contents therein. “Scrapability” may refer to the relative ability of a user to scrape out or otherwise remove material from container 10 stored in storage region 19, which material may be proximate and/or at least partially stuck to sidewall 14 or scallop 200, 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 10. Moreover, it is understood that an outer surface of sidewall 14 may be uniform and/or consistent, as shown for example in FIG. 1, for any of a variety of reasons, including but not limited to aesthetic appearance and/or facilitating decorating the outer surface.

[0042]In order to optimize scrapability, container 10 weight, structural rigidity, impact resistance, and/or top load capacity, scallop 200 may have a radius of curvature and/or a ratio of its radius of curvature to that of sidewall 14 that is optimized. For example, in one illustrative embodiment shown in FIGS. 7 through 14, sidewall 14 may have a radius of curvature 211 of about 5.608″ measured at the inner surface of peaks or ridges 210 near the top of sidewall 14 (see FIG. 8), and/or scallop 200 may be arced with a radius of curvature 221 of about 5.320″ near the top of sidewall 14 (See FIG. 6) and/or of about 4.847″ near the bottom of sidewall 14 (see FIG. 7), with sidewall radius of curvature 211 and scallop radius of curvature 221 both having a center point located radially inwardly of sidewall 14. In this illustrative embodiment, the difference in the radii at the top of sidewall 14 is 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 FIG. 12), in a difference in thickness of about 0.025″ between ridge 210 and valley 220, for example, with a thickness of about 0.090″ at ridge 210 (see FIG. 8) and/or of about 0.065″ at valley 220 (see FIG. 9), representing a reduction in material within scallop 200. As shown in FIG. 14, the illustrative embodiment of container 10 may have a sidewall 14 having a taper angle A of about 2.3 degrees.

[0043]The scrapability of sidewall 14 may be expressed in terms of the radii 221 and 211, for example those listed above, and/or in terms of a first ratio 221/211 of the scallop radius to the sidewall radius at ridges 210. In the above example, the ratio at the top of sidewall 14 is 5.320 to 5.608, or about 0.945. A radius 231 may be provided for a circle tangent to valleys 220 at centerline 225, which in the illustrative embodiment above may be about 5.633″ (see, e.g., FIG. 9). In this embodiment, a second ratio at the top 221/231 may be about 5.320 to about 5.633 and/or about 0.944. Another first ratio 221/211 at the bottom may be about 4.847″ (see FIG. 7) to about 5.147″ (see FIG. 10) and/or about 0.942 and another second ratio 221/231 at the bottom may be about 4.847″ to about 5.174″ (see FIG. 11) 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.

[0044]As shown in FIGS. 4 and 5, scallop arc radius of curvature 221 may have a center point that is offset a distance 227 from the central axis of container 10. For example, distance 227 may be about 0.313″ near the top of sidewall 14 and/or about 0.327″ near the bottom of sidewall 14.

[0045]Container 10 and/or sidewall 14 are shown in FIGS. 1-14 having eight scallops 200, eight ridges 210, and eight valleys 220. It is understood that more or less scallops 200, ridges 210, and/or valleys 220 may be provided in container 10 and/or sidewall 14. For example, there may be between about 2 and about 40 of each of scallops 200, ridges 210, and valleys 220, there may be between about 4 and about 24 of each, and/or there may be between about 4 and about 16 of each.

[0046]Container 10 may be configured to hold a predetermined volume of contents. For example, container 10 may 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. Sidewall 14 and/or container 10 may have an inside radius and/or an outside radius of about 5″ to about 6″, for example, when configured to hold about 5 gallons.

[0047]It is understood that container 10 and/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.

[0048]It is further understood that container 10 or 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 10.

[0049]It is further understood that any of a variety of processes or combination thereof may be used to form container 10, any component thereof, or any layer or substrate used therein. In some embodiments, container 10 and/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 container 10 and/or any component thereof as will be understood by one of ordinary skill in the art. In some embodiments, container 10 may be substantially a one-piece design and/or substantially formed as an integral or unitary structure.

[0050]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.

[0051]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.

[0052]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.