Rigid structured polymer container

Large format rigid structured polymer container includes a hollow main body portion. The hollow main body portion includes four corner column configurations. Each corner column configuration has a top end and a bottom end. The top end of each corner column configuration defines a top reference plane, and the bottom end of each corner column configuration defines a bottom reference plane. The hollow main body portion has first and second end walls, and first and second sidewalls. Each end wall extends between two adjacent corner column configurations along a transverse direction of the main body portion. Each sidewall extends between adjacent corner column configurations along a longitudinal direction of the main body portion. The container has a recessed top surface extending between the top ends of the four of corner column configurations, and a raised bottom surface extending between the bottom ends of the four corner column configurations.

BACKGROUND

Field of the Disclosed Subject Matter

The present disclosed subject matter relates generally to plastic containers, for example a large format polymer container for packaging and storing liquids.

Description of Related Art

Many liquids, including edible oils, motor oils, agricultural chemicals, and the like, are often packaged, shipped, and stored in large format polymer containers. Furthermore, it is often desirable to dispense or otherwise pour the liquid contents from such large format polymer containers. However, such containers can be heavy, typically weighing 1100-1200 grams, or more, and can be expensive to manufacture. Such containers can also be difficult for a user to manipulate to pour the liquid therefrom. For example, large format polymer containers of conventional design can have unsuitably thin handles with seams, which can be uncomfortable on the hands of users manipulating the container.

Additionally, the large format polymer containers of conventional design can also cause the liquid to “glug” or abruptly fluctuate in flow when being poured. For example, as the container is tilted forward, the mouth or neck portion can generally be lowered below the liquid level in the container, thereby trapping the air in the container above the liquid. Unsuitable venting in the container can cause the flow of liquid out of the container to alternate with the flow of air therein, and thus can interrupt the continuous, smooth flow of liquid and produce a glugging or gulping action. The poured stream from the container can thus become difficult to control and can cause liquid to spill from the container.

Furthermore, it is often desirable to stack a plurality of large format polymer containers for shipping and storage. However, large format polymer containers often are unable to support a suitable load thereon, for example for stacking a plurality of similarly configured containers. The reduced or limited ability to stack several containers on top of each other can result in wasted space and inefficiency. It therefore is currently common practice to package large format containers individually in exterior cardboard boxes when stacking several containers on top of each other, which results in wasted space and materials, and increased costs.

As such, there is a continued need for a large format rigid structured polymer container with improved load strength, for example for stacking, yet being easy to manipulate, to prevent a glugging action from interfering with pouring fluid contents from the container.

SUMMARY

To achieve these and other advantages and in accordance with the purpose of the disclosed subject matter, as embodied and broadly described, the disclosed subject matter includes a large format rigid structured polymer container having a hollow main body portion. The hollow main body portion includes a plurality of corner column configurations. Each corner column configuration has a top end and a bottom end. The top ends of the plurality of corner column configurations define a top reference plane, and the bottom ends of the plurality of corner column configurations define a bottom reference plane. The main body portion further includes first and second end walls. Each end wall extends between two adjacent corner column configurations along a transverse direction of the main body portion. The main body portion also has first and second sidewalls. Each sidewall extends between an adjacent pair of corner column configurations along a longitudinal direction of the main body portion. The container further has a recessed top surface extending between the top ends of the four corner column configurations, and a raised bottom surface extending between the bottom ends of the four corner column configurations.

As embodied herein, the top ends of each corner column configuration can have a planar top surface. Alternatively, the top end of each corner column configuration can have a stabilizing tab, and the bottom end of each corner column configuration can have a recess feature configured to receive the stabilizing tab of a substantially similar large format container in a stacked relationship. The stabilizing tab of each corner column configuration can have a tapered sidewall in side view to facilitate centering the recess feature of a substantially similar large format container in a stacked relationship. Additionally or alternatively, the stabilizing tab at the top of each corner column configuration can have a partial circular shape in plan view. As embodied herein, each corner column configuration can define a partial cylindrical shape. The corner column configurations are designed to support the weight of similarly configured containers stacked above.

Additionally, and as embodied herein, each end wall can extend tangentially between adjacent corner column configurations along the transverse direction. As embodied herein, each end wall can be planar. Additionally or alternatively, the adjacent corner column configurations along the transverse direction can define the maximum width of the main body portion. The first and second sidewalls can be spaced apart in the transverse direction a width less than the maximum transverse width. As embodied herein, each corner column configuration can have a maximum height between the bottom end and the top end. Additionally or alternatively, the first and second sidewalls can each have an overall height less than the maximum height.

Furthermore, and as embodied herein, each sidewall can be arcuate in plan view. Each sidewall can have an arcuate top edge in side view. Additionally or alternatively, the top surface can be arcuate in end view.

As embodied herein, the container can have a finish portion proximate the top surface. The finish portion can define a mouth in fluid communication with an interior chamber of the main body portion. The container can include a hollow handle portion extending from the finish portion to the top surface of main body portion. The handle portion can define a conduit in communication between the mouth of the finish portion and the interior chamber of the main body portion. Alternatively, the handle portion can define a conduit isolated from the mouth of the finish portion and the interior chamber of the main body portion. As embodied herein, the container can have a reinforcing strut joining the top surface to the handle portion. Additionally or alternatively, as embodied herein, the hollow handle portion can be configured to receive a flexible tube for flushing container contents out of the handle. Furthermore and as embodied herein, the finish portion can have a ratcheted portion proximate the top surface.

In addition, and as embodied herein, the bottom end of each corner column configuration can have a planar bottom surface. Additionally, the bottom end of each corner column configuration can have a recess feature configured to receive the stabilizing tab at the top end of each corner column configuration of a substantially similar large format container. The recess feature of each corner column configuration can have a tapered sidewall in side view to facilitate centering the stabilizing tab of a substantially similar large format container in a stacked relationship.

The container can have a bottom support surface along a bottom end of each of the first and second sidewalls. Each bottom support surface can be aligned with the planar bottom surface of two adjacent corner column configurations along the transverse direction. Additionally or alternatively, the raised bottom surface can define a center channel disposed in the longitudinal direction between the two bottom support surfaces. As embodied herein, the raised bottom surface can be contoured to receive upper features of a substantially similar large format container in a stacked relationship in either the same or opposite orientation. Additionally or alternatively, the raised bottom surface can include a recessed hand grip feature. As embodied herein, the container can include a reinforced seam defined along the raised bottom surface.

The disclosed subject matter also includes a method of making a large format container having some or all of the features described herein. Additionally, the subject matter disclosed herein includes a stack of a plurality of large format rigid structured polymer containers. As recognized in the art, the large format rigid structured polymer container disclosed herein can include some or all of the features described herein, or any suitable combination thereof.

DETAILED DESCRIPTION

Reference will now be made in detail to the various exemplary embodiments of the disclosed subject matter, exemplary embodiments of which are illustrated in the accompanying drawings. The structure and corresponding method of operation of the disclosed subject matter will be described in conjunction with the detailed description of the system.

The apparatus and methods presented herein can be used for transport of perishable or nonperishable liquids. The disclosed subject matter is particularly suited for packaging, storing, and dispensing oils.

In accordance with the disclosed subject matter herein, the container generally includes a hollow main body portion. The hollow main body portion includes a plurality of corner column configurations. Each corner column configuration has a top end and a bottom end. The top ends of the plurality of corner column configurations define a top reference plane, and the bottom ends of the plurality of corner column configurations define a bottom reference plane. The main body portion further includes first and second end walls. Each end wall extends between two adjacent corner column configurations along a transverse direction of the main body portion. The main body portion also has first and second sidewalls. Each sidewall extends between an adjacent pair of corner column configurations along a longitudinal direction of the main body portion.

The container further has a recessed top surface extending between the top ends of the four corner column configurations, and a raised bottom surface extending between the bottom ends of the four corner column configurations.

The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the disclosed subject matter. For purpose of explanation and illustration, and not limitation, exemplary embodiments of the container in accordance with the disclosed subject matter are shown inFIGS. 1-33. The container is suitable for use with a wide variety of liquids. As used herein, the terms “front,” “rear,” “side,” “top,” and “bottom” are used for the purpose of illustration only, and not limitation. That is, it is recognized that the terms “front,” “rear,” “side,” “top,” and “bottom” are interchangeable and are merely used herein as a point of reference.

For purpose of illustration, and not limitation, reference is made to the exemplary embodiment of a container100shown inFIGS. 1-8 and 10-16. The surface profile lines shown inFIGS. 1-16depict contours of exemplary container surfaces for illustration only, and are not necessarily representative of seams or edges. As shown inFIGS. 1-2, container100generally includes a main body portion with a first end wall10and a second end wall11. Each end wall extends between two adjacent corner column configurations12along a transverse direction of the main body portion.

The main body portion also has first sidewall13with respect to the front view as shown, for example, inFIG. 6. As embodied herein, the rear of container100is a mirror image of the front and therefore has an identical and opposing second sidewall14as shown, for example, inFIG. 7. Each sidewall13and14extends between an adjacent pair of corner column configurations12along a longitudinal direction of the main body portion a distance d1, which for purpose of illustration and not limitation, and as embodied herein can be about 177 mm. For purpose of illustration, and not limitation, as shown for example inFIG. 7, column configurations12can have a radius of curvature r7within a range of about 35 mm to about 51 mm, and as embodied herein, radius of curvature r7can be about 43 mm. Additionally, for purpose of illustration, and not limitation, the intersection of the sidewalls13,14with corner column configurations12can have a radius of curvature r10within a range of 10 mm to 45 mm, and as embodied herein radius of curvature r10can be about 20 mm. Column fillets26can be defined at the intersection of the sidewalls13and14and corner column configurations12. As embodied herein, column fillets26can have a concave shape relative to the corner column configurations12and the sidewalls13and14. As such, column fillets26can form a transition region between corner column configurations12and sidewalls13and14, which can distribute stress from a load placed thereon over a larger area to allow the main body portion to bear increased loads without deformation. For purpose of illustration, and not limitation, as shown inFIG. 6, column fillets26can extend between corner column configurations12, proximate top surface15, at a radius of curvature r9within a range of 10 mm to 40 mm, and as embodied herein radius of curvature r9can be about 20 mm.

As embodied herein, top end29of each corner column configuration12can have a planar top surface. Furthermore, with reference toFIGS. 7-8, top end29of each corner column configuration can have a stabilizing tab17, and bottom end22of each corner column configuration can have a recess feature18configured to receive the stabilizing tab17of a substantially similar container. Alternatively, top end29of each corner column configuration can have a recess feature18disposed at the bottom end of each corner column configuration. Recess feature18can be configured to receive a stabilizing tab17of a substantially similar container.

With reference toFIG. 6, the top end29of each corner column configuration12defines a top reference plane (“TRP”) and the bottom end22of each corner column configuration12defines a bottom reference plane (“BRP”). The cross-sectional view container100shown inFIG. 11is taken along line11-11inFIG. 6. Likewise, the cross-sectional view of container100shown inFIG. 12is taken along line12-12inFIG. 6.

Stabilizing tab17and recess feature18can facilitate stacking of similarly configured containers100, as discussed further herein. With reference toFIG. 5, stabilizing tab17of each corner column configuration can have a tapered sidewall19in side view to facilitate locating or centering stabilizing tab17within recess feature18of a substantially similar large format container in a stacked relationship. Similarly, recess feature18can have a tapered sidewall in side view, which can facilitate locating or centering stabilizing tab17of a substantially similar large format container within recess feature18in a stacked relationship.

With reference toFIG. 4, stabilizing tab17of each corner column configuration can have a partial circular shape in plan view. Alternatively, stabilizing tab17of each corner column configuration can have a full circular or other suitable geometric shape in plan view, and the recess, if provided, can have a corresponding or mating shape in profile.

Referring now toFIG. 17, an alternative embodiment of a stabilizing tab and recess feature is illustrated. As shown for example inFIG. 17, recess feature18′ can be formed as an indentation formed in an end corner of corner column configuration12′ of a container100. As such, stabilizing tab19′ of corner column configuration12′ of a similarly configured container100can be formed as a corresponding indentation or tapered shape of a corresponding end corner of corner column configuration12′ to engage recess feature18′ of container100.

Further in accordance with the disclosed subject matter, and with reference toFIG. 7, each corner column configuration12can define a partial cylindrical shape in plan view. Alternatively, each corner column configuration12can define a prism shape of suitable configuration to provide desired column strength and support for the container. The cross-sectional view of container100shown inFIG. 14is taken along line14-14inFIG. 7. Furthermore, and as embodied herein, each corner column configuration12can be arcuate, with a curvature that extends slightly inward, towards the interior of the container100at each end at curvatures having radii r1, r2, respectively, as depicted for example inFIG. 6. For purpose of illustration and not limitation, radii of curvature r1and r2each can be within a range of 350 mm to 725 mm, and as embodied herein, r1and r2each can be about 520 mm. The radii of curvature r1, r2of each corner column configuration12can increase the top load strength of container100, as discussed further herein.

As embodied herein, with reference toFIGS. 1 and 2, each end wall10and11extends between two adjacent corner column configurations12along the transverse direction. As embodied herein, such as embodied herein, each end wall can have a generally convex shape relative to the interior of container100. For purpose of illustration and not limitation, as shown for example inFIG. 7, each end wall10,11can have a radius of curvature r8within a range of about 367 mm to about 3920 mm, and as embodied herein, radius of curvature r8of each end wall10,11can be about 1164 mm. Each end wall10,11can also have a straight top edge or an arcuate top edge in side view.

As embodied herein, with reference toFIGS. 1 and 2, each sidewall13and14extends between two adjacent corner column configurations12along the longitudinal direction. As embodied herein, each sidewall13,14can have a generally convex shape relative to the interior of container100. For purpose of illustration and not limitation, as shown for example inFIG. 7, radii of curvature r5and r6of sidewalls13,14each can be within a range of about 288 mm to about 2866 mm, and as embodied herein, r5and r6each can be about 1078 mm. Each sidewall13,14can also have a straight top edge or an arcuate top edge in side view. With reference toFIG. 13, the convex shape of end wall10and11and sidewall13and14provides structural integrity to container100by transferring the weight of a load placed thereon to corner column configurations12, to allow the main body portion to bear increased loads without deformation. Each sidewall13and14can be offset inward a distance d2toward the interior of container100relative the opposing corner column configurations12at each end of the sidewalls13,14. For purpose of illustration and not limitation, as shown inFIG. 7and as embodied herein, the inward offset distance d2of each sidewall13,14can be about 1.5 mm. The inwardly offset position of sidewalls13,14can inhibit or prevent sidewalls13,14from engaging sidewalls13,14of a similarly configured container100disposed alongside container100. Additionally or alternatively, the inwardly offset position can accommodate a label, a folded pamphlet, or other printed material attached to the sidewall13,14and can protect the label or printed material from contact with the sidewall13,14of a similarly configured container100.

With reference toFIGS. 3-4, 6 and 7, container100further has a recessed top surface15extending between top ends of the four corner column configurations12. Top surface15can be concave as embodied herein. For purpose of illustration, and not limitation, as shown inFIG. 6, top surface15can extend between corner column configurations12at a radius of curvature r4within a range of 150 mm to 500 mm, and as embodied herein radius of curvature r4can be about 262 mm. Alternatively, top surface15can be convex relative to the interior of container100, or can have any other suitable arcuate shape. As a further alternative, top surface15can have a generally planar shape. A seam27can be defined along the top surface15extending beneath the length of handle20. For example, seam27can define a pinch-off seam resulting from the formation of the container during blow molding. Extrusion blow molded containers can fail at the parison pinch-off seam of the mold parting line, which include cracking from impact, fatigue failure from flexing, or chemical stress cracking. Seam27therefore provides structural integrity to container100. Additionally or alternatively, top surface15can have a curved portion extending to side walls13,14. For purpose of illustration, and not limitation, as shown inFIG. 6, top surface15can extend to side walls13,14at a radius of curvature r3within a range of 13 mm to 20 mm, and as embodied herein radius of curvature r3can be about 16 mm.

Containers according to the disclosed subject matter can be provided in alternative sizes and dimensions from those described herein, for example and not limitation, by increasing or decreasing the scale of dimensions described herein. For purpose of illustration and not limitation, sidewalls13,14can have a ratio of radius of curvature r5, r6over distance d1between corner columns12(r5, r6/d1) between about 1.627 to about 16.192, and as embodied herein, r5, r6/d1can be about 6.090. Additionally or alternatively, sidewalls13,14can have a ratio of radius of curvature r5, r6compared to radius of curvature r7of corner columns12(r5, r6/r7) between about 5.647 to about 81.886, and as embodied herein, r5, r6/r7can be about 25.070.

For purpose of illustration and not limitation, as embodied herein, end walls10,11can have a ratio of radius of curvature r8compared to radius of curvature r7of corner columns12(r8/r7) between about 7.196 to about 112, and as embodied herein, r8/r7can be about 26.070. For example and without limitation,FIG. 16shows an alternative embodiment of a container100′ having end walls10′,11′ with a different radius of curvature. For purpose of illustration, and not limitation end walls10′.11′ can have a radius of curvature r11, r12within a range of about 150 mm to about 245 mm, and as embodied herein, radius of curvature r11, r12of each end wall10′,11′ can be about 195 mm. As such, end walls10′,11′ can have a ratio of radius of curvature r11, r12compared to radius of curvature r7of corner columns12(r11, r12/r7) between about 2.941 to about 7.000, and as embodied herein, r11, r12/r7can be about 4.535. Additionally or alternatively, and as embodied herein, the intersection of the end walls10′,11′ with corner column configurations12can have a radius of curvature r13, r14within a range of about 26 mm to about 66 mm. and as embodied herein radius of curvature r13can be about 44 mm.

With reference toFIG. 8, the container further has a raised bottom surface16extending between the bottom ends of corner column configurations12. Furthermore, and as embodied herein, bottom surface16can be concave relative to the interior of container100. For example, bottom surface16can have a generally arcuate shape. Alternatively, bottom surface16can have a generally planar shape. Furthermore, a bridge section31defines an intersection between each end wall10and11and the raised bottom surface16, as shown inFIGS. 1-5. Bridge section31can provide additional structural integrity to the container100by distributing stress from a load placed thereon to the corner column configurations12, to allow the main body portion to bear increased loads without deformation.

With further reference toFIG. 8, bottom fillets32can be defined at the intersection of the planar bottom surface22of the corner column configurations12, bottom support surfaces21, and center channel23. As embodied herein, bottom fillets32can have a concave shape relative to the planar bottom surface22of the corner column configurations12, the bottom support surfaces21, and center channel23. As such, bottom fillets32can form a transition region between planar bottom surface22of the corner column configurations12, the bottom support surfaces21, and center channel23, which can distribute stress from a load placed thereon over a larger area to allow the main body portion to bear increased loads without deformation.

In an alternative embodiment, as depicted inFIGS. 19-21 and 25, for purpose of illustration and not limitation, a reinforced seam33can be defined along the bottom surface16to the bridge section31of container300. Reinforced seam33thus can be configured to provide additional structural integrity to container300. It will be understood that the reinforced seam33can be formed using any suitable technique, including compression molding, etc.

In accordance with another aspect of the disclosed subject matter, a finish portion can be provided. For example, and as embodied herein, the container can have a finish portion30proximate the top surface as depicted inFIGS. 1-7. Finish portion30can define a mouth in fluid communication with an interior chamber of the main body portion of container100. Finish portion30can be circular, oval, or any other shape suitable for pouring fluid contents from the container. As embodied herein, finish portion30can have an engagement to receive a cap to cover the mouth, as shown for example, inFIG. 10. The engagement can be threaded, friction fit, snap fit, or any other suitable engagement to provide a liquid-tight engagement with cap to retain the container contents when cap is engaged. In an alternative embodiment, as depicted inFIGS. 27-29 and 32, for purpose of illustration and not limitation, finish portion30of container400can have a ratcheted portion34proximate the top surface15, which can accommodate a ratcheted cap thereon.

In accordance with another aspect of the disclosed subject matter herein, the container can have a handle. For example, and as depicted inFIGS. 1-7, the container can further comprise a handle portion20extending from finish portion30to the top surface15of main body portion of container100. As embodied herein, handle portion20can define a conduit in communication between the mouth of finish portion30and the interior chamber of container100. Furthermore, handle portion20can be hollow and can be configured to receive a flexible tube for flushing container contents out of the handle, for example by directing water or air through the handle.

Handle portion20can be arcuate, U-shaped, or any other shape suitable for handling the container. Furthermore, the handle can define a cavity or opening between handle portion20and top surface15of the container to facilitate gripping of the handle portion20. Alternatively, handle portion20can be integrally formed with the main body portion of container100and include one or more recesses to facilitate gripping. Handle portion20can extend to a height corresponding to a recess in the bottom surface16of a similarly configured container100to avoid interference of handle portion20with the center channel23of bottom surface16of similarly configured container100when stacking. With reference toFIGS. 2-3, a support web28defined at an intersection of seam27proximate finish portion30can provide a transition portion between seam27and finish portion30. As embodied herein, support web28is triangular, but can have any suitable geometric shape. Support web28can provide additional structural integrity to the handle20by distributing stress from a load placed thereon over a larger area to allow the main body portion to bear increased loads without deformation.

With reference toFIG. 15, the handle portion20can further define a conduit in communication between the mouth of the finish portion30and the interior chamber of the main body portion of container100. If provided, the conduit can provide suitable venting in the container to allow the flow of air into the container along with the flow of liquid out of the mouth of the container, which can reduce or prevent gulping or glugging when pouring fluid contents from the container.

In an alternative embodiment, as depicted inFIGS. 19, 21-24, and 26, for purpose of illustration and not limitation, the handle portion20of plastic container300can be isolated from the mouth of the finish portion30and the interior chamber of the main body portion of container300. For example, and as embodied herein, the handle portion20can define a conduit sealed off at a portion36proximate the finish portion30. Additionally or alternatively, the handle portion20can be sealed off at a portion37proximate the top surface15. It will be understood that the handle portion20can be sealed off using any suitable technique, including compression molding, etc.

With reference toFIGS. 19, 21-24, and 26, the container300can further include at least one reinforcing strut38joining the top surface15to the handle portion20. For example, and as embodied herein, the container300can further include a plurality of reinforcing struts joining the top surface15to the handle portion20. As depicted inFIGS. 19, 22, and 24, for purpose of illustration and not limitation, the container300can further include a plurality of reinforcing struts joining the top surface15to the portion36of the handle portion20, which can be isolated from the finish portion30as described herein. Additionally or alternatively, the container300can further include a plurality of reinforcing struts joining the top surface15to the portion37of the handle portion20, which can be isolated from the top surface15as depicted inFIGS. 19, 21, and 24. For example, and as depicted inFIGS. 19, 21-24, and 26, for purpose of illustration and not limitation, a large format rigid polymer container can be provided with four reinforcing struts38joining the top surface15to the portion36of the handle portion20and four reinforcing struts38joining the top surface15to the portion37of the handle portion20.

Furthermore, and as embodied herein, reinforcing strut38of container300can have radii of curvature, as depicted, for example inFIG. 26. For purpose of illustration, and not limitation, as shown for example inFIG. 26, reinforcing strut38can have a radius of curvature r15within a range of about 0.016″ to about 0.036″, and as embodied herein, radius of curvature r15can be about 0.026″. Additionally or alternatively, reinforcing strut38can have a radius of curvature r16within a range of about 0.018″ to about 0.038″, and as embodied herein, radius of curvature r16can be about 0.028″. Additionally or alternatively, reinforcing strut38can have a radius of curvature r17within a range of about 0.017″ to about 0.037″, and as embodied herein, radius of curvature r17can be about 0.027″. Additionally or alternatively, reinforcing strut38can have a radius of curvature r18within a range of about 0.029″ to about 0.049″, and as embodied herein, radius of curvature r18can be about 0.039″. Additionally or alternatively, reinforcing strut38can have a radius of curvature r19within a range of about 0.104″ to about 0.164″, and as embodied herein, radius of curvature r19can be about 0.134″. Additionally or alternatively, reinforcing strut38can have a radius of curvature r20within a range of about 0.018″ to about 0.038″, and as embodied herein, radius of curvature r20can be about 0.028″. Additionally or alternatively, reinforcing strut38can have a radius of curvature r21within a range of about 0.016″ to about 0.036″, and as embodied herein, radius of curvature r21can be about 0.026″. As depicted inFIG. 25, for purpose of illustration and not limitation, the reinforcing strut38can have an angle θ within a range of 30° to 90°, and as embodied herein angle θ can be about 60°.

Referring now toFIGS. 8, 10 and 15, bottom surface16can have a bottom support surface21along a bottom end of each of the first and second sidewalls. Each bottom support surface21can be aligned with the planar bottom surface22of adjacent corner column configurations12along the transverse direction. As embodied herein, bottom surface16can be raised to define a center channel23disposed in the longitudinal direction between the bottom support surfaces21. Center channel23can have a contour configured to receive a handle portion of a similarly configured large format container in a stacked relationship, as shown inFIG. 10. Additionally or alternatively, bottom surface16can have a contoured surface24configured to receive the finish portion30of a substantially similar large format container in a stacked relationship in either the same or opposite orientation. As depicted inFIG. 33, bottom surface16can have a contoured surface35configured to receive the ratcheted portion34of finish portion30of container400in a stacked relationship in either the same or opposite orientation. Additionally or alternatively, bottom surface16can include a recessed hand grip feature25, as shown, for example, inFIGS. 8 and 15.

With reference toFIG. 4, adjacent corner column configurations12along the transverse direction can define the maximum width Wmaxof the main body portion of container100. The first and second sidewalls can be spaced apart in the transverse direction a width less than the maximum transverse width Wmax. As embodied herein, each corner column configuration12has a height less than the maximum height Hmaxof each corner column configuration12. Additionally or alternatively, first sidewall13and second sidewall14can each have an overall height less than the maximum height Hmax. It is to be recognized that the dimensions and relative proportions of the main body portion of container100will vary according to the size and intended use of the container. While an essentially rectangular container100is illustrated inFIGS. 1-10, one of ordinary skill in the art will recognize that the size and relative ratios of various dimensions of the container can be modified as desired. For example,FIG. 9shows an alternative embodiment of a container200having sidewalls13and14and end walls10and11with a height less than the maximum height Hmaxof each corner column configuration12. As such, and as embodied herein, the ratio of the height and width of the container200can be the same as or different than that of container100ofFIGS. 1-8. One of ordinary skill in the art will therefore recognize that the container can be scaled to any ratio or dimensions, for example, by making any or all of the dimensions shorter, taller, wider, narrower, etc.

In accordance with another aspect of the disclosed subject matter, a plurality of containers100having substantially similar configuration can be stacked together, as shown for example inFIG. 10. Any suitable number of containers can be stacked. For example, as embodied herein, four or more containers100can be stacked, one on top of another, to obtain a stack having four or more levels of containers in height. The corner column configurations12of the disclosed subject matter provide additional top load strength, for example to support containers100stacked thereon by distributing a portion of the weight of the stacked containers100among each of the corner column configurations12. As embodied herein, the disclosed large format rigid polymer container can achieve more than 40% greater top load strength than conventional containers. For example, large format rigid polymer containers of the disclosed subject matter can exhibit top load strength of over 1220 lbs.

The thickness of the walls can be selected to provide a lightweight container having any desired or suitable top load to weight ratio. For purpose of illustration and not limitation, as embodied herein each wall can have a thickness of approximately 0.075-0.081 inches. For purpose of illustration and confirmation of the disclosed subject matter,FIG. 18Ais a finite element analysis of a conventional container having a wall thickness of 0.081 inches.FIG. 18Aillustrates deformation of the conventional container due to a virtual top load of 597 pounds.FIG. 18B, shown side-by-side withFIG. 18Afor purpose of comparison, illustrates a finite element analysis of container100according to the disclosed subject matter and having a wall thickness of 0.081 inches.FIG. 18Billustrates that container100can be substantially free of deformation with a virtual load of 1152 pounds. In this manner, for purpose of illustration, container100can hold about twice the load of a conventional container with a similar wall thickness, and thus can support being stacked in a stacking relationship, for example in a shipping container, beneath a greater number of similarly configured containers100.

In accordance with another aspect of the disclosed subject matter, a method of making a container100is provided. It will be understood that the container can be made using any suitable technique, including blow molding, thermoforming, etc. For example, the disclosed large format rigid polymer containers can be made by the methods disclosed in U.S. Pat. Nos. 8,636,944, 8,585,392, 8,632,867, 8,535,599, 8,544,663, and 8,556,621, incorporated herein by reference. The container can be made from any suitable polymeric materials, including but not limited to low and high density polyethylene, polyethylene terephthalate, polyvinyl chloride, polypropylene, polystyrene, fluorine treated high density polyethylene, post-consumer resin, K-resin, or bioplastic.

In addition to the specific embodiments claimed below, the disclosed subject matter is also directed to other embodiments having any other possible combination of the dependent features claimed below and those disclosed above. As such, the particular features presented in the dependent claims and disclosed above can be combined with each other in other manners within the scope of the disclosed subject matter such that the disclosed subject matter should be recognized as also specifically directed to other embodiments having any other possible combinations. Thus, the foregoing description of specific embodiments of the disclosed subject matter has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosed subject matter to those embodiments disclosed.