Abstract:
A plastic container set for holding paint is disclosed. The plastic container set comprises a first plastic container having a body with a first transverse cross dimension and a threaded upstanding collar defining an opening to the interior of the first container body. The plastic container set also comprises a second plastic container having a body with a second transverse cross dimension and a threaded upstanding collar defining an opening to the interior of the second container body. Further, the plastic container set comprises a cover having a top portion, a substantially circular annulus coupled to the top portion, the annulus defining the outer perimeter of the cover, the annulus having a diameter, and a thread inside the cover for coupling with the collar of both of the first plastic container and the second plastic container. The first transverse cross dimension is substantially the same as the diameter and the second transverse cross dimension is substantially greater than the diameter.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS  
       [0001]    This application is a continuation of U.S. patent Application Ser. No. 10/006,985 entitled Paint Container, which is incorporated herein by reference; U.S. patent application Ser. No. 29/1 57,524 entitled Container, which is also incorporated herein by reference; U.S. patent application Ser. No. 29/159,661 entitled Container, which is further incorporated herein by reference; and U.S. patent application Ser. No. 10/132,682 entitled Container, which is further incorporated herein by reference. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    The present invention relates generally to the field of containers and more specifically a container for the distribution, sale, and use of paint.  
           [0003]    Typically, paint for application to a house or building for both interior and exterior applications is sold in a cylindrical one gallon metal container. The metal container includes a round base and a cylindrical side wall attached to and extending from the base. The side wall terminates in an upper rim or chime having a u-shaped channel that frictionally receives and engages a plug or lid having a downwardly extending u-shaped annular ring that is frictionally engaged by the walls of the u-shaped channel.  
           [0004]    The lid of a conventional paint container is removed by prying the annular ring out of the channel. This is accomplished by using a lever between an outer upper edge of the cylinder and the outer edge of the lid. In order to ensure that the lid does not fall off of the container, the channel of the container is sufficient to require the use of tools to remove the lid. Accordingly, a lever such as a screwdriver is used to pry the lid off of the upper rim by using the edge of the side wall as a fulcrum to apply sufficient force to the outer edge of the lid to remove the annular ring form the u-shaped channel. Depending on the amount of friction that must be overcome, a user usually has to apply pressure at a number of points about the circumference of the lid and container. The repeated insertion of the lever may result in damage to the lid or the coating on the inner surface of the metal lid that is intended to prevent rust or contamination of the paint.  
           [0005]    The paint may be poured from the container into a tray or other smaller container to be used by the painter to apply the paint to the intended surface either by brush, pad, roller or other mechanical or electrical system. Almost any time paint is poured, paint drips down the outside of the cylindrical wall and covers any identifying label. If the drips are significant, the paint may streak down the outer edge of the cylindrical wall and drip to the supporting surface that the paint container has been placed on. In any event, a certain amount of paint will be trapped within the u-shaped annular ring of the upper edge of the cylindrical side wall.  
           [0006]    When the lid is placed back onto the top of the container, the downwardly extending u-shaped ring on the lid will be soiled by the paint in the annular receiving area of the cylindrical wall. This creates a potential problem the next time the lid is removed and placed on a supporting surface. The paint on the annular surface may soil the surface upon which the paint lid rests or the hands of the user when they replace the lid again after use. If latex paint is in the container then the latex may dry in the channel and act as an adhesive between the lid and container making subsequent removal of the lid more difficult. The dried paint in the channel may prevent an air tight seal as result of paint buildup preventing the lid from being fully seated within the channel. Further, paint trapped in the channel may be splattered about the room when the lid is replaced and the trapped paint will likely spill over the edge and streak down the side of the container.  
           [0007]    Additionally, if the can itself is used as the container from which a brush is dipped by the painter, a significant amount of paint will accumulate in the channel as the brush is removed and excess paint is wiped against the edge of the can. Further, the inner annular edge of the container channel makes it difficult to uniformly wipe paint off of the brush. This results in an uneven application of paint on the brush and on the surface to be painted.  
           [0008]    Further the cylindrical container provides other disadvantages in the shipping, display and handling of the container by the end user. First, since the containers are round, the area between the cans represents wasted space when the container are shipped from the factory to the retail outlet. This wasted space must be paid for in terms of shipping costs. Similarly, shelf space at the retail outlet is wasted by the area between the cans. Since the cans are cylindrical, the label must also be cylindrical and therefore does not present the ideal display surface for the consumer at the retail outlet. As the consumer typically walks down the isle, the customer views the container at an angle which reveals only a portion of the label. Many display shelves also permit more than one can to be stacked in a front to back fashion. The cylindrical shape also limits the number of rows of cans that may be stacked on a display shelf.  
           [0009]    The handle of the typical paint container is a thin curved wire member comprised of a 0.105 gauge material that digs into the user&#39;s hand under the weight of the paint and the container. It is difficult to carry more than one paint container in each hand utilizing the curved wire. Additionally, the curved wire handle requires handle pivot or “ear” supports to be added to the outer surface of the cylindrical can. These pivot supports add assembly and material costs to the container. The pivot supports further affect how the containers must be packed for shipping and for display. Since the pivot supports extend outward from the container, additional space between products or placement such that the pivot supports are in the “dead” space zone between the containers is required.  
           [0010]    The cylindrical paint can does not provide a surface to support a paint brush. In order to balance a paint brush on the open container, the brush must be supported by two points on the outer lip. This is most easily accomplished with the bristles balanced at one point and the ferrule or handle balanced at another point. As discussed above, paint often collects in the channel of the container resulting in the ferrule or handle being soiled. Alternatively, if the channel does not contain paint, the placement of the bristles on the edge of the container will likely result in paint dripping into the channel and/or on to the edge of the container, which will likely soil the ferrule or handle if the ferrule or handle is subsequently placed on the soiled region.  
           [0011]    Paint that falls into the channel also presents a problem when the lid is being secured to the container after use. The paint in the channel is forced out of the channel as the annular ring of the lid is being located into the channel. Unless the lid is covered, the paint in the channel will splatter about the room as the lid is securely attached to the container. This result is due to the fact that the lid must be fully seated within the channel and a significant force is required. Typically a rubber mallet is used and the lid is struck a number of times with significant force.  
           [0012]    Another problem with the existing paint container is that if the paint is shaken in the container with the lid securely attached, the underside of the lid will become covered with paint and becomes difficult to handle when it is removed from the container.  
           [0013]    From the foregoing, it would be desirable to provide a paint container that would minimize shipping costs and permit a maximum number of containers to be stacked on a retail outlet shelf per linear foot of display. It would be further desirable to provide a product and method for displaying a paint product that allows for non-curved labeling. It would be desirable to provide a container that must be positioned correctly on the shelf, and is not easily rotated to a position that makes it difficult for a consumer to see the label. Another feature that would be desirable is a container system that facilitates stacking the containers one in front of the other.  
           [0014]    It would also be desirable to provide a container having a paint reclamation pouring mechanism in order to maintain a clean work area. It would also be desirable to provide a paint container that eliminates the need for handle supports or ears on the cylinder. It would also be desirable to provide a handle that is easy for the user to use and does not cut into the user&#39;s hand. Additionally, it would be desirable to provide a container with a lid that also serves as a paint container. It would still further be desirable to provide a lid that may be attached securely onto the container without the need for tools. It would also be desirable to provide a container with a spout that provides for a brush to be inserted into the container and includes a non-curved edge to provide for even wiping of the brush. It would also be desirable to provide a container that does not permanently dent when dropped or hit. It would also be desirable to provide secure surfaces for a container having one or more of the foregoing features to be employed in shaker equipment, to mix and or shake the paint. It would be desirable to provide a paint container with the foregoing features alone or in any combination.  
         SUMMARY OF THE INVENTION  
         [0015]    An exemplary embodiment relates to a plastic container set for holding paint. The plastic container set comprises a first plastic container having a body with a first transverse cross dimension and a threaded upstanding collar defining an opening to the interior of the first container body. The plastic container set also comprises a second plastic container having a body with a second transverse cross dimension and a threaded upstanding collar defining an opening to the interior of the second container body. Further, the plastic container set comprises a cover having a top portion, a substantially circular annulus coupled to the top portion, the annulus defining the outer perimeter of the cover, the annulus having a diameter, and a thread inside the cover for coupling with the collar of both of the first plastic container and the second plastic container. The first transverse cross dimension is substantially the same as the diameter and the second transverse cross dimension is substantially greater than the diameter.  
           [0016]    Another embodiment relates to a cover for a plastic container for holding paint. The plastic container comprises a top portion, a substantially circular annulus coupled to the top portion, the annulus defining the outer perimeter of the cover, and the annulus having a diameter, and a thread inside the cover. The cover is interchangeable with a first plastic container for holding paint, the first plastic container having a body with a transverse cross dimension that is substantially the same as the diameter and with a second plastic container for holding paint, the second plastic container body having a body with a transverse cross dimension that is substantially greater than the diameter.  
           [0017]    A further embodiment relates to a method of storing paint in containers of different sizes. The method comprises providing a first plastic container having a body with a first transverse cross dimension and a threaded upstanding collar defining an opening to the interior of the first container body, the first plastic container having a first volume. The method also comprises providing a second plastic container having a body with a second transverse cross dimension and a threaded upstanding collar defining an opening to the interior of the second container body, the second plastic container having a second volume. The method further comprises coupling a first cover on the first plastic container, the first cover having a top portion, a substantially circular annulus coupled to the top portion, the annulus defining the outer perimeter of the cover, and the annulus having a diameter, and a thread inside the cover for coupling with the collar of both of the first plastic container and the second plastic container. Further still, the method comprises coupling a second cover on the second plastic container, the second cover being of the same size as the first cover. The first transverse cross dimension is substantially the same as the diameter and the second transverse cross dimension is substantially greater than the diameter.  
           [0018]    Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]    [0019]FIG. 1 is a perspective view of a paint container.  
         [0020]    [0020]FIG. 2 is a side view of the paint container of FIG. 1.  
         [0021]    [0021]FIG. 3 is a top view of the paint container.  
         [0022]    [0022]FIG. 4 is a front view of the paint container.  
         [0023]    [0023]FIG. 5 is a front view of the paint container.  
         [0024]    [0024]FIG. 6 is a bottom view of the paint container.  
         [0025]    [0025]FIG. 7 is a cross-sectional view of the paint container taken generally along lines  7 - 7  of FIG. 1.  
         [0026]    [0026]FIG. 8 is bottom perspective view of the paint container.  
         [0027]    [0027]FIG. 9 is an exploded view of the paint container.  
         [0028]    [0028]FIG. 10 is a top view of the paint container without the cap. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0029]    Referring to FIG. 1 and FIG. 9, a paint container  10  includes a body  12 , a handle  14 , a cap or cover  16 , and a pour spout insert  18 . Referring to FIGS.  1 - 6 , body  12  has a general D-shape configuration and includes a bottom  20 , a front wall  22 , a back wall  24 , and a pair of opposing side walls  26 ,  28 . Additionally, body  12  includes a top  30  having a land region  32  and a neck  34  with external threads  36  to secure the cap  16 . In one embodiment, container  10  is formed from a plastic material that may be injection molded, blow molded, or injection blow molded. The container may be formed from any other method known in the art.  
         [0030]    Body  12  includes a recessed region  38  that extends across the front wall  22 , the side walls  26 ,  28  and a portion of the curved back wall  24 . The recessed region  38  may receive a label that could be applied during the forming operation such as in the mold, or a label may be affixed to the container after the container has been formed.  
         [0031]    Body  12  further includes a first hand or top recess  40  located on the top edge of the container between the front wall  12  and the top  30 . Top recess  40  enables a user to easily access the handle  14  when the handle  14  is in a first or rest position adjacent the top  30 . A user can easily raise the handle  14  by simply sliding his or her hand within the recess under handle  14 . The top recess  40  may be fully covered by the handle  14  on the top of the container as illustrated in FIG. 3, or the recess may be accessible from the top of the container when the handle is in the rest position. This would allow a user to reach under the handle from either the front of the container or from the top of the container.  
         [0032]    A second hand or bottom recess  42  is located on the bottom edge of the container between the front wall  12  and the bottom  20 . The bottom or access recess  42  allows a user to reach under the bottom  20  of the container  10  while the container is resting on a supporting surface. The bottom recess  42  further facilitates pouring paint from the container. The bottom recess  42  is connected to a finger recess  44  via channel  46  on the bottom  20  of the container. The finger recess  44  allows a user to insert his or her fingers into the recess  44  to provide support for pouring paint from the container in combination with handle  14 . Additionally, the height of the bottom recess  42  and channel  46  as measured from a supporting surface may be sufficient to allow a user to insert his or her fingers in the finger recess  44  while the container is on the support surface. This would aid in pulling a container off of the support surface or off of a lower container where the containers were stacked.  
         [0033]    Land  32  includes a pair of recess openings  48  to receive a pair of tabs  50  on handle  14 . Of course land  32  could include tabs that would be received in apertures located in the handle  14 . The tabs and apertures allow the handle  14  to pivot about the land from the rest position to a carrying position or intermediate pouring position. Other mechanical fastening structures that are know in the art may also be employed. Additionally, a snap in feature that releasably locks the handle  14  in the rest or in use position may be helpful to ensure the handle does not move. The snap or lock feature may be accomplished by irregular geometry of the handle tabs and land apertures, or any other known means for securing a handle in specific position relative to the container.  
         [0034]    The bottom  20  further includes additional recesses  52 ,  54  to provide structural rigidity to the container. The recesses  52  and finger recess  44  extend into the container. The geometry of the recesses  52  should be such that a user can still access the paint on the inside of the container with a brush. The spaces between the recesses  44  and  52  should be sufficient to allow a user to access the paint between the resulting raised areas with a brush. The recesses may also be constructed to permit a top to bottom nesting feature with an adjacent stacked container. The bottom  20  also includes an outer periphery  56  that defines a plane that is parallel with the top of the cap  16  and top of the handle  14  for use in a compression type mixing apparatus. The portions  58  between the recesses  44 ,  52  and  54  are in the same plane as the periphery  56  to provide additional support for the container.  
         [0035]    Handle  14  includes a top surface  60 , a front surface  62 , a rear surface  64 , and a pair of opposing side surfaces  66 ,  68 . When the handle  14  is in the rest position, the front and side surfaces  62 ,  66  and  68  are flush with the upper portion of the body. The handle may include a soft raised portion  69  that may be molded into the top surface  60  of the handle  14 . The handle  14  includes a lower contour  70  that substantially follows the contour of the land  32  and upper portion of the body  12 .  
         [0036]    As illustrated in FIGS. 7 and 9, cap  14  includes an outer wall  72  with inner threads  74  that allow the cap  14  to be threaded onto threads  36  of neck  34 . Cap  14  further includes an inner wall  76  extending from cap top  78  a distance greater than the distance that the outer wall  72  extends from the cap top  78 . Outer wall  72  includes a compression surface  80  that engages the top portion of neck  34  to seal the cap to the container. As the cap  14  is threaded onto the neck  34 , the inner wall  76  extends into the neck area of the container. Cap  14  further includes finger recesses  81  to facilitate closing and opening of the cap as well as holding the cap when the cap is being used as a paint dish. The top surface of cap  80  includes a substantially planar surface portion to enable the top to rest on a support surface to serve as a paint dish. Alternatively, the top of the cap includes geometry that enables the cap to rest on a support surface in a stable manner. This geometry could include a raised peripheral region. Finger recesses  81  form a land area  83  that facilitates use of the cap as a paint dish, since the land area allows for easy handling of the cap. Other embodiments of the cap could also be employed. For example, the cap could include more than two finger recesses or could include a knurled outer surface to help facilitate tightening the cap onto the body or removing the cap from the body. Further the cap could be ergonomically designed to conform to the palm of a user&#39;s hand when the cap is being used as a paint dish.  
         [0037]    The use of an inner wall  76  and outer wall  80  allows the cap to be used as a paint dish without the paint soiling the threads of the container, or dripping paint on to the outside of the body when the cap is secured to the body after it has been used as a container. Since the inner wall  76  extends beyond the outer wall, any paint that drips out of the cap when the cap is secured to the container will drip directly into the container. Additionally, any paint that drips into the channel  82  between the inner wall  76  and outer wall  72  will drip into the container between inner wall  76  and the spout insert  18 .  
         [0038]    The spout insert  18  includes an outer lip  84  that rests on the top rim  86  of the neck  34  of the body  12 . Insert  18  is secured to the body  12  by either an adhesive, friction fit, welding, or any other method known in the art. Insert includes an outer wall  88  and an inner wall  90  that includes a spout  92 . In one embodiment spout  92  extends upward above the outer lip  84  of the outer wall  88 . Spout  92  includes a “v” shaped recess with a circular recess  93  at the bottom portion of the “v”. Insert  18  includes an angled floor  94  connecting the inner wall  90  ad outer wall  88 . Floor  94  is angled downward from the rear wall  92  of the body and “v” region of the spout  92  toward the front wall  26  of the body  12 . Other spout configurations may also be employed. For example the shape of the spout recess could be a shape other than a “v” shape. The recess could be “U” shaped or rectangular. Alternatively, the spout could not include a recess portion at all but rather the spout could extend toward a single apex, where the apex is the highest of the spout and the paint is guided to pour over the apex.  
         [0039]    A channel  96  is formed between the inner wall  90 , and outer wall  88 . The angled floor  94  includes an opening  96  to connect the channel  96  with the interior of the container, to permit paint that drips over spout  92  to be reclaimed into the container via opening  96 .  
         [0040]    Insert  18  also includes a raised wipe portion  98  terminating in a straight edge  100 . The raised wipe portion  98  extends from the inner wall  90  into the opening  102  defined by the inner wall  98  and the straight edge  100  of the wiper portion  98 . The angle of the wipe potion  98  allows for reclamation of paint back into the container if the paint drips onto the top portion  99  of the wipe portion  98 . In one embodiment the opening  102  has a diameter of three and one half inches, allowing for easy insertion of a three inch brush. The straight edge has a width of at least three inches to permit the brush to be wiped along straight edge  100  without curving the bristles. It is possible to replace the straight edge with a comb or undulated edge feature. It is also contemplated that a comb feature could be releasably attached to the raised wipe portion to provide another type of wiping edge geometry if desired. The geometry of the opening  102  may be modified to allow for a larger or smaller brush width to enter the interior of the container to apply paint to a brush. For example the opening could be four inches or greater to allow for a four inch brush to be inserted.  
         [0041]    The “D” shape of the container allows for a convenient curved rear surface over which the paint is poured, and a substantially straight rear surface to allow for a label having a flat surface to be applied. The flat surface permits easier viewing of the label on the store shelf for the consumer. If the front of the container with the flat surface is facing the isle, the consumer can easily pick up the container by using both the handle  14  and the bottom finger recess  44  through recess  42  and channel  46  as discussed above. The curved rear surface guides the paint toward the spout  92  aiding in the removal of the last portion of paint in the container.  
         [0042]    The cap  16  is easily removed both in the retail outlet for easy tinting and at home or on the job site without requiring additional tools. Once the tinting coloring has been added the cap is screwed back on to the body of the container such that the top of the cap and the top surface of the handle are in the same plane. Since the top surface of the handle and cap are in a plane parallel to the button supporting surface, the paint in the container can then be mixed utilizing a standard mixing apparatus where the top and bottom of the container is trapped and compressed between two surfaces and subsequently shaken. The surface area of the handle and cap provide a stable surface for this type of compression apparatus. The container may employ other geometry to ensure that the container may be securely located in a compression type mixer. The mixer itself could employ a top member that matches the profile of the top of the container including the handle and cap. The container, cap and/or handle could include raised features to permit the top member of the mixer to effectively clamp onto the container for mixing.  
         [0043]    The geometry of the body facilitates access to the paint, once the level of paint drops. Since the recess  42 , channel  44  and finger recess  46  protrude into the interior of the container a greater amount than recesses  52  and  54 , a greater amount of paint will be in the region directly below the opening  102  to facilitate removal of the paint from the bottom of the container. Additionally, curved portion of the back wall  24  focuses the last amount of paint in a single area proximate the spout  92 , when the paint is being poured from the container.  
         [0044]    The container may also include features to promote stacking of the container. For example, the container may include four small bumps on the bottom periphery that would act as feet and interlocking features with structure on the top of the container. For example, the top of the container could include four small indents that would receive the bumps, or the bumps could be restrained from moving in a lateral direction by four offset guides. Of course there could be more or less than four locating features. Additionally, any locating feature could be arranged such that there is no impediment form sliding an upper stacked container off of a lower stacked container, by having the rear portion of the guides open. The raised portion or bumps could also be located on the top of the container and the recess or guides be located on the bottom of the container. The bumps could also be flexible such that they would be resiliently deflected when the container is clamped in a paint mixer that clamps the container on the top and bottom.  
         [0045]    Further modifications may be made in the design, arrangement and combination of the elements without departing from the scope of the invention as expressed in the appended claims For example a top member including one or more of the features discussed above such as the spout, reclamation structure, paint brush support, cap support, and others may be integrally formed with the body member or may be fastened to the container as a separate component. Additionally, the container may include transparent areas to allow the user to see the contents of the container. Further the cap attachment may include a transparent area to indicate whether the cap is securely attached to the container to prevent paint from accidentally being spilled. Although the container has been referred to as a paint container other liquids may be stored and poured as well. While some of the features have a unique application to the storage and application of paint, other features may be used for other liquids as well. Additionally, the label that is applied to the container may include a blank white portion to permit the user or manufacture to dab or paint an sample of the paint in the container to clearly show what color is contained within the container and how it will appear when painted on a white background. It is also noted that the features described in the specification and shown in the Figures either alone or in combination may also be combined with individual or multiple features disclosed in the priority applications noted above. These and other modifications may be made in the design, arrangement and combination of the elements without departing from the scope of the invention as expressed in the appended claims.