Abstract:
An interlocking, stackable container is provided, including sides with protrusions and sides with cavities, and with the bottom portion of each container including a spout pocket and a cap pocket adapted to receive a top spout and cap of a second container, allowing for easy vertical stacking. The protrusions and cavities of different containers can interlock with one another to form a horizontal layer of containers in a space-saving design. Stacking and interlocking many units of the container forms a stable structure that will not tip or fall. The container can be used as a space saving transportation medium for food, water or other liquid products, and can also be used as a structural building block for a barrier wall or similar structure. The container can also be used by children as a building block and learning device.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The present invention relates generally to containers and, more particularly, to a reusable, stackable and interlocking container.  
         [0002]     Liquids such as edible liquids, for example, milk, liquid dairy products, mineral water, fruit and vegetable juices and oils, and non-edibles, e.g. liquid bleach and detergents, are often sold in molded plastic containers. The containers are often configured to provide a body portion and a capped spout or pouring portion of more or less reduced width. These containers are usually non-refillable and are treated as disposables, and in most cases are discarded by the consumer after its contents are spent. The discarding of the empty containers represents an economic loss of the materials and resources. Moreover, known containers of this type tend not to be stable when stacked one on another, and therefore are not conveniently stackable for display purposes.  
         [0003]     Various containers adapted for either stackable or interlocking connection one to another are known in the prior art. For example, U.S. Pat. No. 3,194,426 to L. E. Brown, Jr. discloses a container that can be laterally interlocked with other containers to form a unitary and compact arrangement. U.S. Pat. No. 3,391,834 to A. P. J. Wiseman discloses a stackable container that can also be placed in rows which are in staggered relationship with one another, such that a stable structure can be formed. U.S. Pat. No. 5,779,051 to Boutin, and U.S. Pat. No. 6,588,612 to Dorn et al. also disclose stackable water containers that create a space-saving array of containers useful in transport. Further, U.S. Pat. No. 3,374,917 to C. T. Troy, U.S. Pat. No. 4,624,383 to Moore, U.S. Pat. No. 4,889,254 to Vola, U.S. Pat. No. 4,485,920 to Fritz, and U.S. Pat. No. 6,276,549 to Fasci et al. all disclose a container which is stackable and also includes interlocking elements to allow the containers to fit together in a stable manner.  
         [0004]     While these patents are useful for the particular problems they solve, it is still highly desirable to provide a container which, after its initial use, can be securely stacked and interlocked with other similar containers. It would also be desirable to provide a container for use in the storage of liquids or solid foods that is inexpensive and yet has a dual purpose as a stable building block element. It would likewise be advantageous to provide an interlocking, stackable container which can readily be made in a variety of container sizes.  
       SUMMARY OF THE INVENTION  
       [0005]     The present invention provides a container for liquids which can also function as a storage medium for food or liquids, or as a building block after the product has been consumed. The empty container can be used with other empty containers of the same or similar construct to make structures of all types and applications, such as recreational, functional, ornamental, etc. For example, the empty containers can be arranged in multiple tiers and/or rows for play by children, or for use as a flood or fire barrier around a home, a street, or a small land area. The containers can also be filled with other items, such as sand, dirt, concrete or water for adding weight and inertia to the structure, and even food for storage.  
         [0006]     In accordance with the present invention, a container is described herein which is typically adapted to interlock and stack in abutting relationship with another identical container, the container comprising four sides, a top with an asymmetrically-shaped spout having a cap covering the opening of the spout, the spout configured to protrude vertically from the top, and a bottom with a spout pocket having a cap pocket therein, the spout pocket and cap pocket being symmetrically identical to the spout and the cap, respectively, wherein the container includes an outwardly extending longitudinal protrusion along the entire vertical length of two sides of the container, the protrusions being wider in cross section at their outer edges, a longitudinally extending cavity along the entire vertical length of the remaining two sides of the container, the cavities extending inwardly from the outer surface of the sides of the container, open at either end and adapted to slidably mate with the extending protrusion of any other container.  
         [0007]     In one embodiment, the container typically comprises two sides having a protrusion, two sides having a cavity symmetrically identical to and slightly larger than the protrusion, a top having an asymmetrical spout including a cap, the cap operable to cover the opening of the spout, and a bottom having a spout pocket including a cap pocket, wherein the sides extend downwardly from the top and interconnect the top to the bottom, and wherein the sides each are configured to interlock laterally with a matching protrusion or cavity of another container of similar configuration, and wherein the spout and cap are configured to nest within the spout pocket and a cap pocket, respectively, of another container of similar configuration.  
         [0008]     The present invention also provides a container system comprising a plurality of containers, wherein each container comprises two sides having a protrusion, two sides having a cavity symmetrically identical to and slightly larger than the protrusion, a top having an asymmetrically-shaped spout protruding vertically therefrom and including a cap covering an opening in the spout, and a bottom having a spout pocket including a cap pocket therein, the spout pocket and cap pocket being symmetrically identical to the spout and the cap, respectively, and wherein the sides extend downwardly from the top and interconnect the top to the bottom, the sides each being configured to slidably mate with a matching protrusion or cavity of another container of similar configuration, and wherein the spout and cap are configured to nest within the spout pocket and a cap pocket, respectively, of another container of similar configuration.  
         [0009]     The nature and advantages of the present invention will be more fully appreciated from the following drawings and detailed description. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     The accompanying drawings illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the principles of the invention.  
         [0011]      FIG. 1  is a top view of one embodiment of the container of the present invention;  
         [0012]      FIG. 2  is a perspective view of three laterally assembled containers;  
         [0013]      FIG. 3  is a bottom view of the container of  FIG. 1 ;  
         [0014]      FIG. 4  is a perspective view of three containers assembled both laterally and vertically; and  
         [0015]      FIG. 5  is a side view of two containers of the present invention stacked upon one another. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0016]     The present invention provides a container that can be interconnected for multiple uses after the initial contents have been consumed. The empty container can be used as a storage container for foods, liquids, or other items, and can also be used with other empty containers of the same or similar construct to make structures of all types and applications, such as recreational, functional, ornamental, etc. For example, the empty containers can be arranged in multiple tiers and/or rows for play by children. The containers can also be filled with other items, such as sand, dirt, concrete or water for adding weight and inertia to the structure for use as a flood or fire barrier around a home, a street, or a small land area.  
         [0017]     The present invention also provides a conservation aid to the public. Reducing the water, milk, juice and other container trash on a national basis can reduce the amount of solid waste disposal. Typically there are three ways for handling empty disposable containers (that are not biodegradable): (1) Destruction of the containers through various means, such as by mechanical shredding or crumbling, burning, or by chemo-destructive agents; (2) the reusing of the containers; and (3) the recycling of the container material. Practically speaking only a small number of plastic disposable containers are ever reused or recycled, leaving the bulk of disposable containers to be destroyed. The present invention constitutes an ingenious resource that facilitates the reusing of disposable containers with a different utilitarian end. In essence, the present invention provides a container with a means of reciprocal interconnection with other containers of the same characteristics, so that, instead of throwing them away, a user can use the empty containers to compose structures for recreational, functional, or ornamental use. For example, the containers can be interconnected to form walls or small buildings for recreational or didactic games for children and youngsters in the backyard or playground, or they may be filled with water or sand and be used to build barrier walls to protect homes from flood or fire. The containers are also adapted so that a user can screw the entire spout off of the top so that non-perishable food or other larger objects that cannot fit through the cap can be stored therein. However, the storage of food may be limited because the reusing of disposable containers is not always allowed by law when perishable foodstuffs or medicinal products are concerned.  
         [0018]     Referring now to the drawings,  FIG. 1  shows a top view of a preferred embodiment of a container  10  of the present invention. The container  10  is a unitary body which may be formed of a thermoplastic material (by blow molding, for example) or of metal. The container  10  includes a planar top  11  with an asymmetrically-shaped spout  12  having a typically circular cap  14  covering an opening (not shown) in the spout. As illustrated, the spout is typically in the shape of a hexagon and has outer threads (not shown) which engage inner threads on the cap  14 . The container further includes sides  16  and  18  which are parallel to each other, and sides  17  and  19  which are parallel to each other and extend normally (perpendicularly) to sides  16  and  18 . In cross section, sides  16 - 19  inclusive form a rectangle (best seen in  FIG. 5 ). Sides  16  and  17  each have formed integral thereon an outwardly extending protrusion,  20  and  22 , respectively. Opposing sides  18  and  19  each have formed integral therein a cavity,  24  and  26 , respectively, extending inwardly from the outer surface thereof, which are similar in shape to protrusions  20  and  22  and are slightly larger in size in order to receive and slidably mate with the extending protrusion of any other container, as will be explained in more detail below.  
         [0019]      FIG. 2  illustrates a plurality of containers  10 A,  10 B and  10 C assembled in a laterally-interlocked pack forming an L-shaped bend. Throughout this description of the FIGURES, it is assumed that containers  10 A- 10 C are geometrically identical and therefore bear like reference numerals. Side  18 A of container  10 A is engaged with side  16 B of container  10 B. This is accomplished by engaging the protrusion  20 B of container  10 B with the cavity  24 A of container  10 A and sliding the containers longitudinally with respect to each other until a flush position is reached by the tops  11 A,  11 B of each container. Similarly, side  17 A of container  10 A is engaged with side  19 C of container  10 C by engaging the protrusion  22 A of container  10 A with the cavity  26 C of container  10 C. Once connected in this manner, laterally-applied pulling forces will typically not be able to dismantle the containers from one another, because the interlocking protrusions and cavities resist such forces from separating the containers. This is because the shape of the protrusions and cavities are such that the distal portion of each protrusion is wider in cross section at its outer edges than the proximal portion thereof, and the cavities extend inwardly from the outer surface of the sides of the container and are open at either end. This configuration allows the cavities to slidably mate with the extending protrusion of any other container, yet once engaged can only be disengaged by sliding longitudinally, not laterally. This allows the protrusion to be “locked” into each cavity and to resist being removed by lateral pulling forces. To remove a container from a pack of containers, one must lift one of the containers vertically out of position.  
         [0020]      FIG. 3  illustrates a bottom perspective view of the container  10  of  FIG. 1 . The bottom of container  10  includes a planar bottom  31  with an asymmetrically-shaped spout pocket  32  having a cap pocket  34  therein. The spout pocket  32  is slightly larger in size than the spout  12  at the top  11  of the container, and likewise the cap pocket  34  is slightly larger in size than the cap  14 , in order for the spout pocket  32  and the cap pocket  34  to receive a spout  12  and a cap  14 , respectively, of any other container. The pockets  32  and  34  of the bottom of the container permit proper vertical alignment of one container over another so that multiple layers of interlocking containers can be stacked upon one another, as will be explained in more detail below.  
         [0021]      FIG. 4  shows three containers  10 A,  10 B and  10 C in an arrangement wherein  10 A is laterally interlocked with container  10 B, and container  10 C is stacked on top of container  10 B. Side  19 A of container  10 A is engaged with side  17 B (not seen) of container  10 B, however this cannot be seen due to container  10 C being on top of container  10 B. However, it is easily perceived that side  17 B of container  10 B is directly beneath side  17 C, just as side  18 B of container  10 B is directly beneath side  18 C of container  10 C, which can easily be visualized in  FIG. 4 . Further, it can be appreciated that protrusion  22 B (not seen) of container  10 B is located directly beneath protrusion  22 C of container  10 C and within cavity  26 A of container  10 A. Further viewing  FIG. 4 , it is clear that cavities  24 B and  24 C align one over the other, such that if a protrusion of a fourth container were to slidably engage cavity  24 C it would slide down into cavity  24 B until a flush position is reached by the tops of container  10 B and the fourth container.  
         [0022]     Close inspection of  FIG. 4  reveals that the containers  10 B and  10 C stack together such that all “like” sides, cavities and protrusions of the containers must necessarily face in the same direction. For example, protrusions  22 B and  22 C, sides  18 B and  18 C, and cavities  24 B and  24 C must necessarily face in the same direction. The reason for this is due to the asymmetrical shape of the spout  12  of each container. While lateral interlocking of protrusions and cavities can be varied to create a corner, as shown in  FIG. 1 , once vertical stacking begins, the container which is stacked directly above another container must be aligned in the same orientation as the container it is stacked upon. The asymmetrical shape of the spout  12  of each container (see  FIG. 1 ) requires proper alignment of the spout pocket  32  and cap pocket  34  of the second container with the spout  12  and cap  14  of the first container. This requires like protrusions  20 ,  22  and like cavities  24 ,  26  to be aligned on top of one another. As shown in the FIGURES, the spout  12  is typically in the shape of a hexagon, with flat sides of the hexagon facing protrusion  20  and cavity  24 .  
         [0023]     The spout section  12  of each container  10  can be adapted to be removed, such as with a screw cap which is asymmetrically shaped, thereby revealing a larger opening into the container, so that food and other larger items can be stored within the container. Indeed, if the spout  12  can be screwed off of the container, the required stacking modality described immediately above can be overcome, and in one embodiment of the invention this is intended. In this embodiment, the containers are adapted so that a user can screw the entire spout  12  off of the top  11  so that non-perishable food or other larger objects, which typically cannot fit through the cap  14 , can fit through the larger opening left by the removed spout, and be stored therein. However, the storage of food may be limited because the reusing of disposable containers is not always allowed by law when perishable foodstuffs or medicinal products are concerned.  
         [0024]     Nevertheless, with the ability to screw the spout  12  off of the container, the required stacking of like elements over one another described above is no longer required, because the “lock and key” fitting of the spout pocket  32  and cap pocket  34  of one container with the spout  12  and cap  14  of another container is no longer an issue. That is because once the spout of the container is removed only a large opening at the top of the container remains, such that the container which is stacked directly above can be oriented in any manner the user chooses. While this is convenient for making turns or for varying the way in which the containers align, the absence of the “lock and key” orientation mandated by the asymmetrical spout will typically detract from the stability of the stacked structure, such that the height of any structure made with the containers may be limited.  
         [0025]      FIG. 5  illustrates a side cross-sectional view of two containers  10 A and  10 B stacked together in which both containers still retain their spouts and caps. As indicated earlier, each container has a rectangular cross section. The spout  12 A and cap  14 A of container  10 A fits within the spout pocket  32 B and cap pocket  34 B, respectively, of container  10 B, as can be seen in phantom. As described above, the asymmetrically shaped spout  12 A requires container  10 B to be aligned above container  10 A in a precise manner, such that all like sides (e.g.  18 A and  18 B), protrusions (e.g.  22 A and  22 B) and cavities (e.g.  24 A and  24 B) must align.  
         [0026]     It can be appreciated by one of skill in the art that similarly-engaging components of the containers can be manufactured on other building items to mate with a container of the present invention to form roof structures, window sills, door frames, or other structures that would make building of structures more appealing. In addition, the containers may each have matching components, but be shaped and sized differently to build specific structures. For example, the containers may be shaped to resemble narrow walls to be assembled into a dog house or a playhouse.  
         [0027]     The container of the present invention can be any convenient and desirable size, although the configuration is particularly convenient for large size containers, as 1 to 5 gallon containers. The height that one can stack layers of interlocked containers will depend on the size and strength of each individual container. For example, for 2 to 5 gallon containers, it may be desirable to stack no more than 3 or 4 containers high if the containers are made of plastic. Any desired plastic material, such as polyethylene, is typically used to manufacture the container of the present invention; however, the containers can be made of any type of material, including metal having thick walls, such that theoretically many layers of interlocked containers can be stacked upon one another without causing the containers at the lower layers to buckle or burst under the pressure above, assuming each container is filled with water, sand or the like.  
         [0028]     While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will be readily apparent to those skilled in the art. Accordingly, departures may be made from such details without departing from the scope or spirit of the invention as defined by the claims.