Patent ID: 12187526

DETAILED DESCRIPTION

Embodiments now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments are shown. Indeed, embodiments may take many different forms and the present disclosure should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification, and in the appended claims, the singular forms “a”, “an”, “the”, include plural referents unless the context clearly dictates otherwise.

The terms “substantial” or “substantially” may encompass the whole as specified, according to certain embodiments, or largely but not the whole specified according to other embodiments.

Some embodiments of a package5, such as the exemplary embodiment shown inFIG.1, may include a container10and/or a lid20. Container10may be configured to store product therein, and lid20may be configured to be movable between a closed position, as shown inFIG.1, and an open position, as shown for example inFIG.3. Lid20may include a cover portion210that may be movable relative to the rest of lid20and/or container10, such as by rotating via a hinge215. In the closed position shown inFIG.1, a user may be blocked from accessing a product storage region19of container10(product storage region is shown for example inFIGS.2and3). In the open position shown inFIG.3, a user may be allowed to access product storage region19and/or any contents therein. As discussed more below, container10may be configured in such a way as to have a reduced weight and/or a reduced amount of material used to form it, while having a relatively high top load for its weight and/or be stackable. In this way, for example, a relatively high number of relatively light weight containers10may be stacked and/or shipped to reduce freight costs, fuel, and the like.

Package5is shown in cross-section inFIG.2and illustrates features of container10and lid20in more detail. Container10may include a top portion or brim11, a shoulder12, a side wall13, a bottom or floor14, and/or a heel15any or all of which may cooperate to form product storage region19. Brim11may extend radially outwardly from shoulder12to a brim outer edge112. Brim11may include a brim top surface111configured to contact lid20or a portion thereof, for example, to support lid20in a vertical direction. Lid20may include a lower portion220, a lower skirt216, and/or a bead217. Brim11and/or brim outer edge112may engage lower skirt216and/or bead217to form a snap fit or attachment mechanism between container10and lid20. Shoulder12may extend downwardly and/or radially outwardly from brim11along a shoulder side wall121and/or to a shoulder bottom122. As discussed more below, shoulder12may be configured such that shoulder bottom122may rest on and/or stack with brim11of another container10(see, e.g.,FIG.8). Shoulder bottom122may be disposed proximate side wall13.

As discussed more below, side wall13may include an upper area131, an intermediate area132, and/or a lower area133, as shown inFIG.2for example, any or all of which may have relative thicknesses and/or material distribution to facilitate a relatively light weight yet rigid design of container10. Heel15may be interposed between side wall13and bottom14of container10. Heel15may provide a curved, angled, and/or gradual transition between side wall13and bottom14.

As shown inFIG.2, floor or bottom14may include a step, such as provided by the different heights of bottom flat area141and bottom raised area142. This step or other feature(s) may be included to add structural rigidity to container10and/or bottom14or for any other reason or combination of reasons. For similar reasons or for any other reason, container10may transition from side wall13to bottom14at heel15. Heel15may be rounded or chamfered, for example, to reduce stress concentrations where side wall13meets bottom14. In the embodiment shown inFIG.2, heel15may have a radius of curvature of about 0.200″.

FIG.3illustrates package5in an open position, showing elements of lid20in more detail. Lid20may include an attachment portion220. Covering portion210may move about hinge215relative to attachment portion220between a closed position and an open position. Covering portion210may include an outer perimeter211, a finger tab212, and/or an upper annular ring213. Upper annular ring213may be configured to engage channel228of attachment portion220to securely close and/or seal covering portion210relative to attachment portion220. Finger tab212may extend radially outwardly away from upper annular ring213, for example, to provide a surface that a user may engage with a finger, thumb, or the like, to disengage covering portion210from attachment portion220. Attachment portion220may include a landing223to facilitate a user opening covering portion210instead of or in addition to finger tab212. Lower skirt216and/or bead217may be disposed radially outwardly on attachment portion220to engage brim11. For example, lower skirt216may be disposed radially outwardly of an upper portion222of attachment portion220. Upper portion222may include an upper surface224configured to contact, support, and/or engage an underside of covering portion210, such as at or near outer perimeter211. Upper portion222may be provided radially outwardly of channel228. Channel228may include a channel outer wall225, a channel bottom,226, and/or a channel inner wall227, which may be substantially U-shaped as shown to receive upper annular ring213. The channel228may take another suitable form other than shown in the figures, such as V-shaped, for example.

Package5may include a dispensing portion230, which may be provided with lid20as shown for example inFIG.3. Dispensing portion230may include a panel231, and entry slot232, and/or a holding portion233, any or all of which may be provided to facilitate dispensing a flexible sheet like material such as a wipe. For example, package5, container10, lid20, and/or dispensing portion230may be configured to dispense healthcare wipes, sanitary wipes, cleaning wipes, and/or other wipes or similar materials. A wipe181(seeFIGS.4and5) may be caused to enter into holding portion233from a lid opening219via entry slot232. Holding portion233may be configured to hold wipe181without active engagement from a user, for example, even after covering portion210has been moved into the closed position. Holding portion233may extend transverse to entry slot232to hold wipe181, or for any other reason, and/or may take an X-shape, a cross shape, or other shape.

As shown inFIGS.4and5, this or other embodiments of package5and/or container10may be configured to hold contents, such as a wipe181or a plurality of wipes18, within it. Container10may be substantially enclosed with one or more openings or apertures to allow access to product storage region19, such as the opening defined by brim11. The opening defined by brim11or otherwise may be configured to allow insertion and/or discharge of contents from container10. Roll18may have a height HRand/or a diameter DR. In some embodiments, for example if roll height HRis about 7″, the height of container10from floor14to brim11may be about 8″. In these or other embodiments, roll18may have roll diameter DRof about 3.375″, for example, and/or container10may have a bottom diameter DBat or near where heel14meets side wall13of about 3.483″. The height of container10may vary, for example, to accommodate a different roll height HR. For example, container10may have a height of about 7″ for a roll height HRof 6.25″. Container10bottom diameter DBmay vary to accommodate a different roll diameter DR. For example, container10may have a bottom diameter DBof about 2.00″ for a roll diameter DRof about 1.875″.

Container10may be of any of a variety of shapes, including, but not limited to, the shape illustrated inFIGS.6and7. In this embodiment, container10may be broadest at brim11and/or shoulder12. Container10may be narrower at or near bottom14. Container10may have a substantially frusto-conical shape and/or tapered side wall13, as shown for example inFIGS.6and7, with side wall13extending upwardly and outwardly from bottom14toward shoulder12at a first angle α relative to a center line CL. If container10takes a conical shape, the widest dimension and/or diameter may be greater at or near brim11than it is at or near bottom14. In some embodiments, first angle α may be about 2.80 degrees as shown for example inFIG.7. First angle α may be in the range of about 1 degree to about 5 degrees, of about 2 degrees to about 4 degrees, in the range of about 2.5 degrees to about 3.5 degrees, and/or in the range of about 2.5 degrees to about 3 degrees.

As shown inFIG.7, shoulder side wall121may extend upwardly and radially inwardly at a second angle β from shoulder bottom122toward brim11and/or brim top surface111. For example, at least a portion of brim11and/or brim top surface111may be disposed radially inwardly of at least portion of shoulder12and/or shoulder bottom122such that shoulder12of a first container10may rest on brim11of a second container disposed below the first container10. In this way, for example, a plurality of containers10may be stacked together to form a first stack31as shown for example inFIG.8. In some embodiments, second angle β may be about 87.75 degrees. Second angle β may be in the range of about 85 degrees to about 90 degrees, of about 86 degrees to about 89 degrees, in the range of about 87 degrees to about 88.5 degrees, and/or in the range of about 85.5 degrees to about 88 degrees. For first stack31, of the overall height of container10, more than about 50 percent of the height of an upper container10may be inside a lower container10, more than about 60 percent of the height of an upper container10may be inside a lower container10, more than about 70 percent of the height of an upper container10may be inside a lower container10, more than about 80 percent of the height of an upper container10may be inside a lower container10, and/or more than about 90 percent of the height of an upper container10may be inside a lower container10.

As also shown inFIG.8, brim11and/or shoulder12may be configured to allow or facilitate a capping or lidding operation, to facilitate stacking multiple containers together, to add structural rigidity to container10, and/or for any other reason or combination of reasons. Structural rigidity might be enhanced, for example, to allow a closure or a lid such as lid20coupled to container10to be opened and closed repeatedly and/or to allow container10to carry a relatively high top load. Shoulder12may be sized, shaped, and/or configured to provide, for example, a nesting or stacking feature for stacking or nesting multiple containers together. Shoulder12may have a height, shape, and/or configuration, to provide an air gap between stacked containers10to facilitate denesting. For example, shoulder12may have a height HSof about 0.787 inches, which may provide a first air gap G1of about 0.015″ at or near side wall upper area131, central area132, and/or lower area133, and/or a second air gap G2of about 0.021″ at or near heel15. Air gap G2may be greater than and/or larger than air gap G1at least partially due to the inward extension and/or radius of curvature at heel15.

In some embodiments, first air gap G1may be substantially similar and/or uniform along the height of side wall13, taking into account manufacturing and/or thermoforming tolerances. First air gap G1may be about 0.015″ plus or minus 0.005″, and/or in the range of about 0.010″ to about 0.020″. First air gap G1may vary based on geometry of container10and/or shoulder12. For example, with a first angle β of about 2.80 degrees and a second angle β of about 87.75 degrees, shoulder height HSmay be in the range of about 0.720″ to about 0.900″ to provide an air gap of about 0.010″ to about 0.020″. A height HBor distance between adjacent container bottoms14in stack31may be approximately equal to shoulder height HS. It is understood that compression of container10, for example when stacked, may cause HBto vary somewhat from HS.

In one example, an 8″ tall container10having a weight of about 34.5 grams may have a thickness of about 0.0243 inches at shoulder12, about 0.0223 inches below shoulder12on side wall13about 1.150″ from the top of container10and/or brim11, about 0.0206 inches on side wall13about 2.350″ from the top, about 0.0188 inches about 4″ from the top, about 0.0161 inches about 5.900″ from the top, about 0.0221 inches about 7.700″ from the top (or about 0.300″ from bottom14), about 0.0150 inches at or near a corner or heel15, about 0.0250″ at a bottom flat area141, and about 0.0634″ at a bottom raised area142. In this example, the thickest measurement on side wall13is about 0.0223″ and the thinnest measurement on side wall13is about 0.0161″, for a thickness difference or thickness delta of about 0.0062″.

In another example, an 8″ tall container10having a weight of about 35.5 grams may have a thickness of about 0.0260 inches at shoulder12, about 0.0230 inches below shoulder12on side wall13about 1.150″ from the top of container10and/or brim11, about 0.0232 inches on side wall13about 2.350″ from the top, 0.0214 inches about 4″ from the top, about 0.0179 inches about 5.900″ from the top, about 0.0201 about 7.700″ from the top (or about 0.300″ from bottom14), about 0.0126 inches at or near heel15, about 0.0202″ at bottom flat area141, and about 0.0530″ at bottom raised area142. In this example, the thickest measurement on side wall13is about 0.0232″ and the thinnest measurement on side wall13is about 0.0179″, for a thickness difference or thickness delta of about 0.0053″.

In yet another example, an 8″ tall container10having a weight of about 36.5 grams may have a thickness of about 0.0250 inches at shoulder12, about 0.0195 inches below shoulder12on side wall13about 1.150″ from the top of container10and/or brim11, about 0.0195 inches on side wall13about 2.350″ from the top, 0.0185 inches about 4″ from the top, about 0.0181 inches about 5.900″ from the top, about 0.0174 about 7.700″ from the top (or about 0.300″ from bottom14), about 0.0265 inches at or near heel15, about 0.0293″ at bottom flat area141, and about 0.0718″ at bottom raised area142. In this example, the thickest measurement on side wall13is about 0.0195″ and the thinnest measurement on side wall13is about 0.0174″, for a thickness difference or thickness delta of about 0.0021″.

In the three examples above, the thicknesses and/or locations may vary within a reasonable tolerance. For example, the height may be measured plus or minus 0.020″ and/or the thickness measurements may be plus or minus 0.020″. In these or other embodiments, the thickness measurements may be plus or minus 0.010″. In these or other embodiments, the thickness measurements may be plus or minus 0.005″. Container10may have a weight in the range of about 30 to about 50 grams. For example, in the three examples above, container10may have a weight of about 34.5 grams, of about 35.5 grams, or of about 36.5 grams. In another embodiment, container10may have a weight of about 40 grams.

FIG.9illustrates a shipping system50that may be employed to ship, transport, store, and/or deliver an array30of container stacks32, with each container stack32including a plurality of containers10. Virtually any number of containers10may be included in container stack32. For example, container stack32may include 2 or more containers10, 4 or more containers10, 10 or more containers10, and/or 20 or more containers10. Array30may be configured to fit inside shipping container40. For example, each stack32may include about 18 containers10, and array30may include about 12 stacks32arranged in a 3×4 rectangle. In this way, for example, a relatively high number of relatively light weight and/or relatively rigid containers10may be shipped. Array30may vary in height, width, length, in number of container stacks32in any direction, or in virtually any other way. In one example, an individual shipping container40may be limited to a weight of about 35 pounds for ergonomic reasons or for any other reason or combination of reasons. For container10weighing about 35 grams, about 450 containers10can be placed in one 35 pound shipping container40.

The example shipping system50shown inFIG.9shows a 3×4 array30of container stacks32each having 18 containers10. For a 35 gram container10, array30will weigh about 7,560 grams, or about 16.7 pounds. Shipping container40may be sized, shaped, and/or configured to fill out a 48″×40″ skid or pallet as efficiently as possible. This may be accomplished, for example, with one or more layers of shipping containers arranged on the pallet. Any or all of the shipping containers40may include, contain, and/or have inserted into it, a 3×4 array30of container stacks32, each container10in each container stack32having a top diameter, measured at brim11, of about 2 inches to about 10 inches, of about 3 inches to about 8 inches, of about 4 inches to about 5 inches, and/or of about 4.5 inches to about 4.6 inches. For container stack32, of the overall height of container10, more than about 50 percent of the height of an upper container10may be inside a lower container10, more than about 60 percent of the height of an upper container10may be inside a lower container10, more than about 70 percent of the height of an upper container10may be inside a lower container10, more than about 80 percent of the height of an upper container10may be inside a lower container10, and/or more than about 90 percent of the height of an upper container10may be inside a lower container10.

In use, a sheet of material having a thickness of about 0.160 inches to about 0.200 inches may be provided. The sheet of material may be thermoformed to a depth or container height in the range of about 4″ to about 10″, of about 6″ to about 10″, of about 4″ to about 8″, of about 6″ to about 8″ and/or to a height configured to be about 0.5 inches to about 2 inches, or about 1″, greater than the height of a roll of wipes or other material to be placed in container10. Container10may be thermoformed with first angle and/or second angle such that side wall13is wider at the top than at the bottom and shoulder12is narrower at the top than at the bottom. Containers10may be combined into an intermediary or first stack31and/or a container stack32. A plurality of container stacks32may be provided in an array, such as in a rectangle, for example a 3×4 rectangular array30. Array30may be provided in shipping container40, which may be configured to be efficiently stacked in layers on a skid or pallet, such as a 48″×40″ pallet.

One or more skids or pallets including shipping containers40and/or arrays30may be shipped or transported from a first location to a second location. For example, the first location may be a manufacturing facility and/or warehouse, and/or the second location may be a manufacturing facility, filling site, and/or warehouse that is different from the first location. Container10may be filled with contents such as a roll of wipes18and/or an impregnating solution for the roll of wipes18and/or each individual wipe181in roll of wipes18. Container10may be closed with lid20, which may include attachment portion220and/or covering portion210. Lid20may be provided with hinge215to allow covering portion210to move between a closed position and an open position relative to attachment portion220and/or container10. Package5may be provided with contents such as roll of wipes18contained within container10and/or lid20. Packages5may be stacked one on top of another with a top load sufficient for the purpose of stacking a plurality of packages, for example, having a top load of at least about 100 lbs., or at least about 110 lbs., at least about 120 lbs, at least about 150 lbs., and/or at least about 170 lbs.

It is understood that any or all of container10, brim11, shoulder12, side wall13, bottom14, and/or heel15may vary in shape and size from that shown inFIGS.1and2. The shapes and sizes illustrated inFIGS.1and2are merely exemplary and not meant to limit the shapes, sizes, or orientations available for forming container10.

An exemplary embodiment of container10may include dimensions shown inFIG.2. As shown, container10may have a height of about 8.000″ from top or brim11to bottom or floor14, an inner top diameter of about 4.255″ measured inside brim11, an outer top diameter of about 4.535″ measured outside brim11, and/or a bottom diameter of about 3.483″ measured at bottom14. Bottom14may include bottom raised area142, which may be concentric to and/or radially inside of bottom flat area141, and bottom raised area142may have a diameter of about 2.182″. Container10may have a longitudinal or vertical central axis C about which container10is disposed. Container10may include a draft angle of about 2.80 degrees of side wall13relative to central axis C. Any or all of these dimensions could vary considerably in other embodiments.

Side wall13may have a thickness or a variety of thicknesses. For example, in the first embodiment mentioned above having a weight of about 35 grams, side wall13may have a thickness in the range of about 0.010 inches to about 0.030 inches. Side wall upper area131may have a thickness of about 0.020 inches to about 0.024 inches, side wall intermediate area132may have a thickness of about 0.018 inches to about 0.022 inches, and/or side wall lower area133may have a thickness of about 0.018 inches to about 0.020 inches. Bottom flat area141may have a thickness of about 0.021 inches to about 0.025 inches and/or bottom raised area142may have a thickness of about 0.035 inches to about 0.049 inches.

To maximize top load and/or strength or rigidity of container10and/or package5while minimizing weight, or for any other reason, side wall13or any part thereof may have a substantially uniform thickness, subject to manufacturing tolerances. A substantially uniform thickness may reduce areas of minimum thickness, which may provide fail points from a top load perspective, and reduce the overall integrity of package5and/or container10. For example, a thickness delta over side wall13may be the difference between the maximum thickness and minimum thickness. The thickness delta may be at most about 0.015″, at most about 0.010″, at most about 0.007″, at most about 0.006″, and/or at most about 0.005″. For example, side wall13may have a thickness of about 0.015″ to about 0.025″, plus or minus about 0.005″, a thickness in the range of about 0.010″ to about 0.020″, a thickness in the range of about 0.015″ to about 0.025″, a thickness in the range of about 0.020″ to about 0.030″. Side wall13may have a thickness of about 0.015 to about 0.25″ plus or minus about 0.010″, and/or a thickness in the range of about 0.010″ to about 0.030″. The thickness delta of side wall13may be in the range of about 0.005″ to about 0.010″. Container10may be thermoformed from a sheet of material. The sheet may have a gauge or thickness of about 0.180 inches plus or minus 0.020 inches.

The top load, as predicted theoretically by finite element analysis (FEA), may be about 173 lbs. with a side wall thickness of about 0.020″, and about 278 lbs. with a side wall thickness of about. 0.025″. In some embodiments, the side wall thickness may be such that the top load rating is about 159 lbs. plus or minus 50 lbs. For example, the top load may be at least about 100 lbs., or at least about 110 lbs., or at least about 120 lbs. The rigidity may be, for example, about 0.6 kgf plus or minus about 0.4 kgf.

An example of a process for testing or ascertaining rigidity on container10is provided herein. Gather parts for testing rigidity after all dimensional tests are complete. Set a force gauge to desired dimensions, such as kgf. Choose the correct plate for the size of container10. Place the plate on a rigidity machine and use the machine to record the distance of deflection of container10. The target travel distance may be about 0.250″ for example. Once there has been 0.250″ of travel, the required force will be measured. Ignition—Thermoforming may be used to record the test results, for example.

The variability of wall thickness may be achieved in any of a variety of ways, or combination thereof. For example, container10may be substantially formed of polypropylene that is thermoformed. In some embodiments, container10may be formed substantially of polypropylene, which may be substantially about 100% polypropylene. In some embodiments, the polypropylene used may be commercially available, such as, for example, BRASKEM 6023N. In these or other embodiments, FORMOLENE HB5502B may be used instead of or in addition to BRASKEM 6023N. In another example, container10may be substantially formed of HDPE that is thermoformed.

The container10, or any component thereof, may take the form of a cylinder or cone with varying diameter, such as is shown inFIGS.1and2. However, the container10may take any of a variety of suitable shapes and/or diameters and/or dimensions, virtually without limitation. For example, container10or any portion thereof, such as sidewall13or bottom14for example, may take the form of an extending square or rectangle, triangle, polygon, oval, sphere, half-sphere, free form, or any other shape or any combination thereof. Moreover, a different portion of container10may be of different shapes than any or all other portions of container10. Any of a variety of suitable shapes and combinations thereof may be used to form container10or any component thereof.

A portion of container10, brim11, and/or shoulder12may be configured to receive, fasten, attach, and/or couple to a closure, such as the container closure discussed above (not shown). Exemplary mechanisms to couple a container closure to container10that may be used is a threaded screw on closure, or a snap or friction fit closure. Container closure and/or another type of closure may be provided with one or more tamper evident features, child resistant features, sealing features, and/or other types of features or any combinations thereof.

The container10and/or any component thereof may be made of any of a variety of materials, including, but not limited to, any of a variety of suitable plastics material, any other material, or any combination thereof. Suitable plastics material may include, but is not limited to, polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP), polystyrene (PS), high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), crystallized polyethylene terephthalate (CPET), mixtures and combinations thereof, or any other plastics material or any mixtures and combinations thereof. Multiple layers of material may be used for any of a variety of reasons, including to improve barrier properties, or to provide suitable functions related to multiple layer structures. The multiple layers, if included, may be of various materials, including but not limited to those recited herein.

The container10or any component thereof may be substantially rigid, substantially flexible, a hybrid of rigid and flexible, or any combination of rigid, flexible, and/or hybrid, such as having some areas be flexible and some rigid. These examples are merely illustrative, are not limiting, and are provided to illustrate the versatility of options available in various embodiments of container10.

Any of a variety of suitable processes or combination thereof may be used to form container10, any component thereof, or any layer or substrate used therein. For example, any component, layer, or substrate, or combination thereof, may be thermoformed, injection molded, injection stretch blow molded, blow molded, extrusion blow molded, coextruded, subjected to any other suitable process, or subjected to any combination thereof. In some embodiments, container10and/or any component thereof may be formed substantially of thermoformed PP, although other materials and forming processes may be used instead of or in addition to PP and thermoforming, respectively. Various materials and/or processes may be used to form container10and/or any component thereof as will be understood by one of ordinary skill in the art. In some embodiments, container10may be substantially a one-piece design and/or substantially formed as an integral or unitary structure.

It may be desirable to provide a container that can be used to hold contents such as a liquid. For example, it may be desirable to provide a container that can store contents such as sanitary or healthcare wipes. Such a container may be configured to receive a closure as well.

A variety of materials may be employed to provide containers. For example, containers may be made of a variety of plastic materials. Such materials may be used, at least in part, because they securely contain contents and keep them fresh while also providing sufficient structural rigidity and integrity to survive filling, bottling, distributing, shipping, and other operations.