Patent Publication Number: US-2019177039-A1

Title: Plastic container

Description:
STATEMENT CONCERNING PRIORITY 
     This application claims priority to, and the full benefit of, U.S. provisional patent application No. 62/369,581 filed on Aug. 1, 2016. 
    
    
     FIELD OF THE INVENTION 
     The field of the invention is plastic containers for fluids. 
     BACKGROUND 
     Although the plastic container for fluids has evolved substantially in the last few years, there have been important needs unmet by the traditional cylindrical container. 
     One of the most important needs is to reduce transportation costs which the traditional cylindrical container has not solved. First, cylindrical containers have a large space between them even when touching, and this area means smaller volumes of the contents can be shipped in individual containers arranged within a space of a certain size, e.g., the van of a large trailer, compared to in the present invention. Second, a cylindrical container, when empty, cannot be nested, so stacking multiple empty containers for shipment to plants where they are filled also greatly increases the number of unfilled units which can be loaded into a shipment. 
     Another longstanding issue is that of dried paint which accumulates within the U-shaped channel of a container rim after fluids such as paint dry after collecting in the rim, for example, after pouring or dripping from a paintbrush. Dried fluids or paint in the rim tends to make resealing a container difficult because the channel in the rim (for receiving the lid) can become obstructed. 
     Additionally, the stability of loaded containers when stacked has been a continuing concern. 
     Also, pouring paint into a roller pan produces wasted paint in that paint is slathered in the pan and dries there, or at least paint that adheres to the roller pan cannot be returned to the container. 
     Thus, there is a need for a plastic container to address the above issues. 
     The invention disclosed herein is a non-cylindrical plastic container which has several novel features providing advantages over the prior art. In one or more embodiments the plastic container is a modified rectangular prism or, more specifically, a modified square prism. The use of the term “modified” here means that the prism has a substantially rectangular or square 3-dimensional shape, except that at least a portion of the rectangular or square prism has four tapered sidewalls and, in this sense, the container is rectangular or square at its top and, in various embodiments, may have rounded corners or angular corners. The modified rectangular or square prism is thus a rectangular or square frustum. Additionally, other embodiments at the top may have shapes other than rectangular or square, as long as they are non-cylindrical. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is a perspective view of one embodiment of the present invention without the lid. 
         FIG. 2  is a section view at 45 degrees of one embodiment of two buckets of the present invention without lids, one being nested inside the other. 
         FIG. 3  is a section view of one embodiment of the bucket of the present invention without the lid, in which one internal surface of a sidewall is shown having ridges in a chevron pattern, and showing a taper of the sidewalls, depicting a mouth of the bucket which is wider than the bottom of the bucket. 
         FIG. 4  is a section view of one embodiment of the present invention containing fluid with the lid sealed to the rim, and stacked on top of a lid of another instance of the invention, with circles around features enlarged in  FIGS. 4A and 4B . 
         FIG. 4A  is an enlargement of a portion of  FIG. 4 , showing how the stacking loop is positioned on the lid just outside the stacking ridge when one of the present invention containers is stacked on top of another. 
         FIG. 4B  is an enlargement of a portion of  FIG. 4 , showing the lid sealed to the rim, and the upper portion of a sidewall, the nesting ridge and the top most portion of the lower portion of a sidewall. 
         FIG. 5  is a top-down view of one embodiment of the bucket without the lid, showing the ridges (roller pan surfaces) on opposite internal walls, and also depicting how downward tapering of the sidewalls yields smaller dimensions for the bottom of the container compared to the dimensions of the mouth of the container, and the breakaway tab on the lower right corner. 
         FIG. 5A  is an enlargement of one embodiment of the breakaway tab. 
         FIG. 5B  is a perspective view of one corner of one embodiment of the container with the lid seated in the rim, and the breakaway tab removed. 
         FIG. 6  is a view of the top of the lid, that is, the side of the lid facing outwardly when the lid is seated in the rim, and a depiction of the stacking ridge near the outer edge of the lid. 
         FIG. 7  is a side view of a section of the lid. 
         FIG. 8  is a section view of a portion of one embodiment of two lids, showing how they may be stacked separately from the bucket. 
         FIG. 9  is a bottom plan view of the bucket of the present invention. 
         FIG. 10  is a section view of an embodiment of the bucket comprising sidewalls which are continuous in slope, that is, without three portions as in  FIGS. 1-4, 4B and 5B . 
         FIG. 11  is more detailed view of the locking mechanism of the lid and the rim as in  FIGS. 4 and 4B . 
         FIG. 12  is a plan view of the front side of one embodiment of the handle. 
         FIG. 13  is a side view of the handle of  FIG. 12 . 
         FIG. 14  is a top view of the tab on the strap, i.e, looking down onto the tab. 
         FIG. 15  is a side view of the tab on the strap. 
         FIG. 16  is a plan view of the rear side of the handle as in  FIG. 12 . 
         FIG. 17  is a section view of the tab on the strap. 
         FIG. 18  is a perspective view of the handle inserted into the slots on the brackets with the handle resting against a sidewall. 
         FIG. 19  is a perspective view of the handle inserted into the slots on the brackets with the handle in an upright position as it would be carried by a user. 
     
    
    
     In one embodiment the invention is a plastic container  1  comprising a bucket  1 A and a lid  16  sized to fit the bucket, said bucket comprising a rim  2  near a mouth  14  of the bucket, sidewalls  26 , corners  12 , and a bottom, each said sidewall having a width  29  and comprising two borders  30  integral, each border integral to one of the corners and also integral to the bottom  10 , each said sidewall also comprising an upper portion  15 , a nesting ridge  25  and a lower portion  3 , said upper portion comprising a first end near the mouth and a second end integral to the nesting ridge, and the lower portion comprising a first end integral to the nesting ridge and a second end integral to the bottom, each said lower portion of the sidewalls having a width  29  greater near the nesting ridge than at the bottom, such that the mouth of the bucket is wider than the bottom and one of the buckets may be nested inside another bucket when the lids are removed and the buckets are empty. The bucket and the lid are sized to fit each other and each has corners  12 . In one embodiment, the container comprises four sidewalls  26  and the mouth of the bucket, the rim and the lid are shaped as a rectangle or, in another embodiment, a square. The aforesaid shape of the bucket describes a rectangular frustum extending from near the nesting ridge to the bottom. In one embodiment, the corners  12  of the bucket  1 A, the rim  2  and the lid  16  are rounded. In one embodiment, the lower portion  3  of each of the sidewalls  26  comprises an internal surface  11 , and at least one of the internal surfaces  11  comprises ridges  7 . The ridges  7  can be disposed so that they are approximately horizontal or parallel to the bottom  10  of the bucket, that is, they are non-vertical. The shape of the ridges  7  can be selected from a group consisting of straight lines, curvy lines, wavy lines, a chevron, or a series of bumps or other shapes placed randomly or irregularly. Moreover, as used herein, “horizontal” or “parallel” means broadly that the ridges  7  are not vertical so that, when a paint roller is applied, the ridges are able to contact the majority of the width of the roller, so as to remove excess paint from the roller. 
     In one embodiment, the rim  2  comprises a breakaway tab  6  at one or more of the corners  12  which, when broken off the rim  2 , leaves no channel  20  in which fluids, such as paint, can collect and dry, hindering re-sealing of the lid  16 . 
     In one embodiment the lid  16  comprises an outer edge  28  and a stacking ridge  17  which is, in one embodiment, a continuous or nearly continuous ridge near the outer edge  28  of the lid, and the bucket  1 A further comprises a stacking loop  9  integral to the bottom  10 , the sidewalls  26  and the corners  12  of the bucket, the stacking loop  9  being slightly wider than the stacking ridge  17  of a lower container, so that the stacking loop  9  of one container can fit within close proximity around the stacking ridge  17  and prevent a bucket filled with contents (stacked on top of another bucket) from sliding. The stacking ridge  17  and stacking loop  9  are sized such that stability can be achieved in stacking two or more containers by placing the stacking loop  9  of one bucket on the lid  16  of another of the containers adjacent to the stacking ridge. 
     In all the embodiments of the invention, the lid  16  further comprises a U-shaped channel  18  which, when installed, faces toward the bottom  10  and the rim  2  further comprises a U-shaped channel  20  which faces away from the bottom, the U-shaped channel  18  of the lid comprising three projections E, F, I, and the U-shaped channel  20  of the rim comprises three projections D, G, H, each of said projections of the lid corresponding to one of said projections of the rim, so that pressing the U-shaped channel of the lid into the U-shaped channel of the rim forms three complementary or corresponding pairs A, B, C of said projections from the lid and the rim. 
     In another embodiment the container comprises a bucket  1 A and a lid  16  sized to fit the bucket, said bucket  1 A comprising a rim  2  and sidewalls  26  defining a mouth  14  at an open end of the bucket, each of said sidewalls comprising a width  29  and two borders  30 , each said border being integral to one of the corners  12  and said sidewalls also integral to a bottom, each width being greater near the mouth than at the bottom, such that one of the buckets may be nested inside another bucket when the lids are removed and the buckets are empty. That is, the bucket in this embodiment has no nesting ridge but the sidewalls  26  comprise a continuous slope commencing near the mouth of the bucket, and the sidewalls  26  are, at their other end, integral to the bottom of the bucket. The aforesaid shape of the bucket describes a rectangular frustum extending from near the mouth, i.e, from inward slope notch G, to the bottom. Further, in this embodiment, the sidewalls  26  have no upper portion or lower portion. Embodiments of the bucket with sidewalls  26  having a continuous slope may also be rectangular or square, have rounded corners, have ridges  7  on one or more of the internal surfaces of the sidewalls, have a breakaway tab  6  on the rim, have a stacking ridge  17  on the lid  16 , and a stacking loop  9  on the bucket, all as described in embodiments above. This embodiment may be, at the top, any shape which is non-cylindrical. The bucket and the lid are sized to fit each other and each has corners  12 . The overall dimensions of the mouth of the bucket are wider at the top than at the bottom of the bucket, and the sidewalls  26  taper inwardly to a bottom  10  which is narrower than the dimensions of the mouth  14  of the bucket. The tapering thus allows one version of the bucket, before being filled with fluid, to nest inside another instance of the bucket as needed, such as during shipment from the production facility to the paint producer&#39;s facility. This allows significant reduction in freight as opposed to prior art cans. 
     The invention, in one embodiment, has a breakaway tab  6  in one corner which will tear when pressed by the user thus turning this corner into a natural pour spout. The U-shaped channel on the rim of prior art containers, whether metal or plastic, fills up with paint during pouring. This is a cleanup issue for closing the container. Paint left in the U-shaped channel of the rim  2  then dries and makes the lid more difficult to open and close in future use. The breakaway tab  6 , along with moving the U-shaped channel  20  beyond the sidewall  26 , solves those issues. Moving the U-shaped channel beyond the sidewall also increases the size of the opening vis-à-vis a rim which is attached to the sidewall and extends inwardly from the sidewall. 
     There is at least one set of ridges  7  raised above the internal surface of at least one of the sidewalls  26 , which mimics the bottom of a traditional flat roller pan. This allows the bucket to be used with a 4″ roller without a separate roller pan, thus being more convenient and reducing waste of paint left in a separate roller pan. 
     In one embodiment, the plastic container comprises a bucket and a lid sized to fit the bucket, said bucket comprising a rim, a bottom, a mouth at an open end defined by four sidewalls and each said sidewall comprising two borders and integral to one of four corners on each of said borders, each of said sidewalls further comprising an upper portion, a nesting ridge and a lower portion, said rim integral to said upper portions of the sidewalls and said rim comprising a breakaway tab, each said upper portion integral to one of the nesting ridges integral to one of the lower portions integral to the bottom, said lower portion having a width greater near the nesting ridge than at the bottom, such that one of the buckets can be nested in another of the buckets without the lid attached. The aforesaid shape of the bucket describes a rectangular frustum extending from near the nesting ridge to the bottom. In this embodiment with the four sidewalls and the four corners, the mouth, the lid and the rim are in the shape of a rectangle with rounded corners and, in a further embodiment, the rectangle is a square. Herein, the lid comprises a stacking ridge near an outer edge, and the bucket further comprises a stacking loop integral to the bottom on the bottom&#39;s outer perimeter and sized slightly larger than the stacking ridge, so that the stacking loop of one instance of the bucket can be positioned for stability just outside the stacking ring of the lid of another container. 
     Exemplary embodiments of the invention are further described in the figures. 
       FIG. 1  is a first perspective view of one embodiment of the bucket  1 A without a handle or a lid  16  attached. The rim  2 , including its outer wall  21 , is affixed to the bucket comprising four sidewalls  26  (the three sections shown grouped together by brackets) which are generally planar and are comprised of an upper portion  15 , a nesting ridge  25 , and a lower portion  3 , each sidewall being integral to two corners  12  which may be, in different embodiments, rounded or angular. In  FIGS. 1-4  the upper portions  15  of the sidewalls  26  are approximately vertical, but the slope of the upper portion  15  may vary in other embodiments. Each lower portion  3  of the sidewalls is also integral to the bottom  10 . A bracket  4  is affixed to two opposite sides of the rim  2 , and each bracket has a hole  5  for receiving a handle having tabs  31 ,  32 . The breakaway tab  6  may be labeled “Press,” or something similar, and is molded to the upper corner of the rim  2 . The ridges  7 , partially shown, are raised projections on the internal surface  11  of one or more of the lower portions  3  of the sidewalls  26 , one of which is shown in  FIG. 1 . In one embodiment, there is one set of ridges  7  two or more internal surfaces  11 . The mouth  14  of the bucket  1 A is defined by the rim  2  and the upper portions  15  of the sidewalls  26 . 
       FIG. 2  is a section view of two buckets at 45 degrees which are not holding contents and which are nesting together. One set of ridges  7  is depicted on the internal surface  11  of the lower portion  3  of a sidewall  26  in the bucket which is nesting inside the other bucket. When one bucket is inserted into the other, the sidewall  26  and the stacking loop  9  of one bucket (which extends all around the bottom  10  of the bucket  1 A) descends as far as the width allowed between the internal surfaces of the other bucket, so that the bottom  10  of one container is near the bottom  10  of the other container.  FIG. 2  also shows, in one embodiment, the nesting ridge  25  on the inner bucket rests on the rim  2  of the bucket in which it nests. Other locations for a nesting ridge  25  on the upper bucket to rest on the lower bucket. On the internal side of the nesting ridge  25 , there is an inward slope  27  between the upper portion  15  and lower portion  3  of the sidewall  26  which narrows the internal width of the bucket  1 A. The mouth  14  is the open end at the top of the bucket  1 A. 
       FIG. 3  is a section view of a single instance of the entire container  1 , that is, the bucket  1 A and the lid  16  which is inserted to seal the bucket. The rim  2  showing the ridges  7  on an internal surface  11  of the lower portion  3  of the sidewall  26  and the tapering of the sidewall  26  from a wider mouth  14 , in this embodiment, by the narrowing dimension of the inward slope  27  and the lower portion  3  which also slopes inwardly to a bottom  10 . Thus, the bottom  10  has a narrower width than the mouth  14 , which allows an upper bucket to nest inside a lower bucket, as shown in  FIG. 2 . 
       FIG. 4  is a section view showing an entire container  1 , the bucket  1 A and the lid  16 , holding fluid, and the loaded container  1  is positioned on top of a lid  16  for a lower bucket (not depicted). The stacking loop  17  is also shown in cross-section. 
       FIG. 4A  is an inset of a portion of the section in  FIG. 4  showing the lower portion  3  of the sidewall  26  and the stacking loop  9  of an upper bucket which is resting just outside a stacking ridge  17  on the lid  16  of a lower container. The stacking loop  9  is prevented from sliding by the barrier of the stacking ridge  17 . In one embodiment, the lid has a U-shaped channel  18  which faces toward the bottom  10  of the container when the lid  16  is installed, and a channel foot  19 . 
       FIG. 4B  is an inset of the section view in  FIG. 4  of the locking mechanism of the rim  2  and lid  16  in one embodiment of the container  1 , but other mechanisms are possible in other embodiments. A structure of the lid  2  including the ridge E and the bump F is inserted into a U-shaped channel  20  of the rim  2 . The bottom of the channel  20  is what is broken off when the breakaway tab  6  is separated from the rim  2 . 
       FIG. 5  is a top view looking down into a bucket  1 A having a rim  2  and a breakaway tab  6  but no lid attached. In one embodiment the bottom  10  (narrower than the mouth  14 ) is integral to the sidewalls  26  (here shown as internal surfaces  11 ) at the lines labeled  23 , and sets of ridges  7  are shown on two of the sloping internal surfaces  11  of the sidewalls  26 . The joinder of the sidewalls and the bottom may be angular or rounded in various embodiments. 
       FIG. 5A  is a detailed view of the breakaway tab  6 , in one embodiment, which may be connected to the rim  2  by means of, in one embodiment, breakable joints  22  along the outer wall  21  of the rim  2  and also by additional breakable joints  22  on each end of the breakaway tab molded to the outer wall  21  of the rim  2 . The user breaks off the breakaway tab  6  by pressing downwardly to tear these breakable joints  22 , the number of which may vary. Or instead, in another embodiment, there can be a general weakening of the channel  20  in the area of the breakaway tab  6  so that the entire bottom of the U-shaped channel  20  or the rim  2  in the area of the breakaway tab  6  comprises a single breakable joint  22 . 
       FIG. 5B  is a detailed view of the lid  16  after the breakaway tab  6  is removed, in one embodiment, showing the breakable joints  22  after having been torn. 
       FIG. 6  is a top view of the lid  16  including the stacking ring  17  and the outer edge  28  of the lid. 
       FIG. 7  is a section view of the lid  16  showing the stacking ring  17 . The outer edge  28  of the lid is also shown. 
       FIG. 8  is a section view of two lids  16  as they stack for shipment. It also shows element  19  of the lid which is the outer wall of the U-shaped channel  18  of the rim  16 . 
       FIG. 9  is a bottom plan view of the bucket  1 A, showing that the bottom  10  is narrower than the upper part of the bucket as indicated by the rim  2 , in part because of the slope of the lower portion  3  of the sidewalls  26 . 
       FIG. 10  depicts an embodiment in which the sidewalls  26  and their internal surfaces  11  comprise a continuous slope starting from the mouth  14  and tapering down to a narrower width at the bottom, i.e., wherein the sidewalls do not have an upper and a lower portion and a nesting ridge as in, e.g.,  FIGS. 1-4 . This embodiment adopts the other features of the other embodiments described above, except for the upper and lower portions and the nesting ridge of the sidewalls. 
       FIG. 11  depicts the locking mechanism for embodiments of the convention herein.  FIG. 11  shows the same structures of the lid and rim from  FIGS. 4 and 4B  in more detail. Herein are shown three seal/latch combinations A, B, C (surrounded by circles for explanatory purposes only) produced by the coupling of corresponding pairs of projections from the lid&#39;s U-shaped channel  18  and the rim&#39;s U-shaped channel  20 .  FIG. 11  shows the lid  16  as installed in (sealed to) the rim  2 . In seal/latch A, the top H of the sidewall  26 , which has an inward slope J compared to the upper portion  15  of the sidewall  26 , is engaged by a cleft I. In seal/latch B, the inward slope notch G of the sidewall  26 , where the inward slope J of the upper portion  15  begins, is engaged by a bump F. In seal/latch C, a ridge E on the lid is engaged by a shoulder D on the rim  2 . 
     In one embodiment, upon installation of the lid  16 , there is over-travel K, i.e., unfilled volume in several places near combinations A, B, C to allow sufficient flexibility for the lid to be sealed and re-sealed to the rim with less damage to the structures if there were no spaces. The actual locations of the over-travel K may vary from those shown in  FIG. 11 , in that the movement of the lid and rim relative to each other are dynamic during and after insertion. In other embodiments of the invention, there may be less or even no over-travel in that the U-shaped channel  18  of the lid  16  and the U-shaped channel  20  of the rim  2  may be sized to fit as snugly as possible. 
     In another embodiment, the container  1  also comprises a handle  30 , which may be of unitary construction and made of plastic, comprising a strap  33  with tabs  31 ,  32  projecting from the strap near either end. As shown in  FIGS. 12-19 , each of the brackets  5  are affixed to the exterior of the bucket  1   a  opposite one another and each bracket comprises a slot  4 . The tab  31 ,  32  and slot  4  are sized and shaped to allow the tab  31 ,  32  to pass with force through the slot  4  in one orientation, but to interlock such that the tab  31 ,  32  cannot be removed from the slot in all other orientations, including when the handle  30  is in use in an upright position and bearing the load of the container  1 . 
     Referring to  FIGS. 12-17 , the handle  30  comprises the strap  33  with tabs  31 ,  32  projecting from the strap  33  near either end. In one embodiment not shown, each end of the strap  33  is integral to a cap recessed from the plane of the strap, in which the tabs  31 ,  32  are located. In  FIGS. 12-17 , the tabs  31 ,  32  project from the body of the strap  33 . The handle  30  is preferably symmetrical, with one end being a mirror image of the other, and therefore will be described with respect to one end only. It should be understood that such description is applicable to the corresponding features on the other end as well. 
     The strap  33  is sufficiently long with respect to the container  1  to form an arc above it, when the tabs are attached to the brackets, preferably with sufficient clearance between strap  33  and the lid  16  of the container for a person to grasp the handle without interference from the lid of the container. 
     The tab  31 ,  32  comprises a three-dimensional head N that tapers from a broader base R to a narrower top M. In one embodiment the head N is attached to the strap  33  or cap by a post O. The cross section of the head N of the tab  31 ,  32  may be of any shape that allows its insertion into the slot  4  of the bracket  5  in one orientation and which becomes interlocked with the bracket  5  at any other orientation, including without limitation an oval, rectangle or spheroid. This generally requires the cross section to have major and minor axes, with the major axis being longer than the minor axis. Thus, the shapes described below are in all respects illustrative. 
     The head N is a frustum which may be regular or irregular and the cross section defining its base may be any shape which generally has a major axis longer than a minor axis including, for example, a rectangle, an oval, squoval or a spheroid. The head N comprises a top M, opposing minor axis surfaces P defining the head&#39;s thickness in the direction of the minor axis, connected by opposing major axis surfaces Q defining its width in the direction of the major axis. In one embodiment, the surfaces Q of the head N taper from the broader base R to the narrower top M. As shown in  FIG. 14 , the thickness of the frustum need not be uniform from bottom to top and, in a preferred embodiment the thickness progressively decreases near the top M. In one embodiment, the cross section of the head N is rectangular and, in another embodiment, the shorter sides of the rectangle (in the direction of the minor axis) are convex. In one embodiment the major axis surfaces Q may be convex or arcuate. In the embodiment shown in  FIGS. 15, 17  the head N is of uniform cross section for some distance from the base R. In a preferred embodiment, the minor axis surfaces P may be convex, such that the cross section at the base R of the frustum is a rectangle with rounded corners and approaches a circle at the top M. This shape reduces deformation of the head N as it is inserted into the slot  4  of the bracket  5 . The post O of the tab  31 ,  32  may be substantially narrower than the width of the base R of the head N, and, in one embodiment, is circular in cross section. The tab  31 ,  32  is solid and of unitary construction with the strap  33  or the cap. The handle may rotate freely in a major arc defined by the opposite sides when the tabs  31 ,  32  are inserted into the slots  4 .