COMPRESSION-RESISTANT THIN-WALL CONTAINER

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/643,823, filed May 7, 2024, and entitled “Compression-Resistant This-Wall Container,” the contents of which are incorporated by reference herein in their entirety.

FIELD OF THE DISCLOSURE

This disclosure is generally related to the field of bottles and containers and, in particular, to compression-resistant thin-wall containers.

BACKGROUND

Single-use water bottles may be made of recyclable plastics, such as poly (ethylene terephthalate) (PET), yet the majority of plastic bottles are landfilled. Many municipal curbside recycling programs will not accept lightweight disposable plastic water bottles because they are easily flattened, then incorrectly separated with paper materials at Material Recovery Facilities (MRFs), and ultimately contaminate the paper recycling stream. A 2015 Material Flow Study demonstrated that, on average, 15% of PET water bottles and 34% of non-bottle PET containers end up in the paper recycling stream as contamination.

SUMMARY

Disclosed is a compression-resistant container that overcomes at least one of the shortcomings described above. In an embodiment, the container incorporates alternating cylinders and spheres across the body of the container. As the container is compressed, the spheres distribute the load across the surfaces, which increases the amount of force that is required to compress the container. This shape makes the container more difficult to flatten during recycling, thereby preventing plastic bottles from commingling with paper during the automated sorting process.

In an embodiment, a compression-resistant container includes a wall at least partially enclosing a volume. A shape of the wall includes a set of spheroidal surfaces having at least a first spheroidal surface and a second spheroidal surface. The shape of the wall further includes a set of cylindrical surfaces having at least a first cylindrical surface, where the first spherical surface adjoins at least the first cylindrical surface and is positioned between the first cylindrical surface and the second cylindrical surface.

In some embodiments, the wall is made from a synthetic resin. In some embodiments, the wall is made from poly(ethylene terephthalate). In some embodiments, a thickness of the wall is between 0.05 mm and 0.5 mm. In some embodiments, at least some surfaces of the set of spheroidal surfaces and the set of cylindrical surfaces are positioned in an alternating pattern along an axis. In some embodiments, a ratio of a diameter of each of the set of spheroidal surfaces to each of the set of cylindrical surfaces is between 1.5:1 and 4:1. In some embodiments, each of the set of spheroidal surfaces has a shell thickness ratio of between 1:500 and 1:200. In some embodiments, a tangential surface angle between each of the set of spheroidal surfaces and each of the set of cylindrical surfaces is between 30 degrees and 80 degrees. In some embodiments, the container has an internal volume between 10 mL and 10 L. In some embodiments, the mass of the container is between 0.05 g and 2 kg.

In an embodiment, such as in the case of a bottle, the wall has rotational symmetry around an axis, where the set of spheroidal surfaces corresponds to a set of spheroidal segment shells having at least a first spheroidal segment shell corresponding to the first spheroidal surface and a second spheroidal segment shell corresponding to the second spheroidal surface, each spheroidal segment shell of the set of spheroidal segment shells having rotational symmetry around the axis, and where the set of cylinder surfaces corresponds to a set of cylinder shells having at least a first cylinder shell corresponding to the first cylinder surface, each cylinder shell of the set of cylinder shells having rotational symmetry around the axis, and where the first cylinder shell is positioned between the first spheroidal segment shell and the second spheroidal segment shell.

In some embodiments, the set of spheroidal segment shells and the set of cylinder shells define at least a portion of a body of the shape of the wall, and the shape of the wall further comprises a neck and a base. In some embodiments, the base has a diameter between 4 mm and 1000 mm. In some embodiments, the base has a length between 4 mm and 1000 mm. In some embodiments, a total length of the container is between 20 mm and 2000 mm. In some embodiments, the set of spheroidal segment shells further includes a third spheroidal segment shell, the set of cylinder segment shells further includes a second cylinder segment shell and a third cylinder segment shell, where the second cylinder segment shell is between the first spheroidal segment shell and the second spheroidal segment shell, and where the third cylinder segment shell is between the second spheroidal segment shell and the third spheroidal segment shell.

In an embodiment, such as in the case of a box or clamshell, the set of spheroidal surfaces and the set of cylindrical surfaces define at least a portion of a body, and the body defines a container shape. In some embodiments, the set of spheroidal surfaces further includes a third spherical surface and a fourth spherical surface, the set of cylindrical surfaces further includes a second cylindrical surface and a third cylindrical surface, where the set of spheroidal surfaces alternate with the set of cylindrical surfaces with the second spheroidal surface positioned between the second cylindrical surface and the third cylindrical surface and the third spheroidal surface positioned between the third and fourth cylindrical surface. In some embodiments, the container includes a hinged opening between a top of the body and a bottom of the body. In some embodiments, the container is a box, a clamshell, or other container for food.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an embodiment of a compression-resistant container.

FIG. 2 is a side view of an embodiment of the compression-resistant container depicting various angles and diameters.

FIG. 3 is a table comparing finite element analysis results for an embodiment of a compression-resistant container with a standard container.

FIG. 4 is a stress-strain diagram comparing the pre-yield elastic behavior (using a linear finite-element analysis) of an embodiment of the compression-resistant container compared to a typical container.

FIG. 5 is a stress-strain diagram comparing the post-yield plasticity behavior (using a non-linear finite-element analysis) of an embodiment of the compression-resistant container compared to a typical container.

FIG. 6 is a perspective view of an embodiment of a compression-resistant container.

FIG. 7 is a side view of an embodiment of a compression-resistant container.

FIG. 8 is a side view of an embodiment of a compression-resistant container depicting various angles and radii.

FIG. 9 is a side view of an embodiment of a compression-resistant container in an opened state.

FIG. 10 is a compression strain simulation image for a standard container.

FIG. 11 is a compression strain simulation image for an embodiment of a compression-resistant container.

While the disclosure is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and will be described in detail herein. However, it should be understood that the disclosure is not intended to be limited to the particular forms disclosed. Rather, the intention is to cover all modifications, equivalents and alternatives falling within the scope of the disclosure.

DETAILED DESCRIPTION

Referring to FIG. 1, an embodiment of a compression-resistant container 100 is depicted. The compression-resistant container 100 may include a wall 120. The wall 120 may be made from a synthetic resin and/or from poly(ethylene terephthalate). The compression-resistant container may be a bottle for liquids, including water, drinks, or other packaged liquids. In other embodiments, as described herein, the compression-resistant container may be a thin-walled container for food, such as a clamshell, box, or other protective package for food.

A shape of the wall 120 may include a set of spheroidal surfaces 142, 143, 144 having at least a first spheroidal surface 142 and a second spheroidal surface 143. The shape of the wall 120 may further include a set of cylindrical surfaces 152, 153, 154 having at least a first cylindrical surface 152. The first cylindrical surface 152 may adjoin at least the first spheroidal surface 142 and may be positioned between the first spheroidal surface 142 and the second spheroidal 143. The set of spheroidal surfaces 142, 143, 144 may also include a third spheroidal surface 144 and the set of cylindrical surfaces 152, 153, 154 may also include a second cylindrical surface 153, and a third cylindrical surface 154. The set of spheroidal surfaces 142, 143, 144 and the set of cylindrical surfaces 152, 153, 154 may alternate, as shown in FIG. 1.

In some embodiments, the wall 120 may define a bottle shape. In this embodiment, a shape of the wall may include a set of spheroidal segment shells 102, 103, 104 having at least a first spheroidal segment shell 102 and a second spheroidal segment shell 103. The set of spheroidal segment shells 102, 103, 104 may also include a third spheroidal segment shell 104. Each spheroidal segment shell of the set of spheroidal segment shells may have rotational symmetry around an axis 122.

The compression-resistant container 100 may further include a set of cylinder shells 112, 113, 114 having at least a first cylinder shell 112. The set of cylinder shells 112, 113, 114 may also include a second cylinder shell 113 and a third cylinder shell 114. Each cylinder shell of the set of cylinder shells 112, 113, 114 may also have rotational symmetry around the axis 122. As shown, the first cylinder shell 112 and the second cylinder shell 113 may be positioned between the first spheroidal segment shell 102 and the second spheroidal segment shell 103. The positioning of the set of spheroidal shells 102, 103, 104 relative to the set of cylinder shells 112, 113, 114 is described further herein.

The set of spheroidal segment shells 102, 103, 104 and the set of cylinder shells 112, 113, 114 may define at least a portion of a body 132 of the shape of the wall 120. The wall 120 of the compression-resistant container 100 may also include a neck 130 and a base 134.

At least some spheroidal segment shells of the set of spheroidal segment shells 102, 103, 104 and the set of cylinder shells 112, 113, 114 may be positioned in an alternating pattern along the axis 122. For example, the second spheroidal segment shell 103 and the third spheroidal segment shell 104 may alternate with the second cylinder shell 113 and the third cylinder shell 114 along the axis 122. As shown, the first spheroidal segment shell 102 and the first cylinder shell 112 may begin an alternating pattern. However, instead of alternating with another spheroidal segment shell, a larger cylinder shell 110 may replace the other spheroidal shell that would ordinarily occur in the pattern to provide a label surface between the first cylinder shell 112 and the second cylinder shell 113.

While the embodiment described herein includes three spheroidal segment shells and three cylinder shells, this is for example purposes only. In application, the set of spheroidal segment shells 102, 103, 104 may include more or fewer than three. Likewise, the set of cylinder shells 112, 113, 114 may also include more or fewer than three.

Referring to FIG. 2, an embodiment of a compression-resistant container is depicted showing various diameters and angles. A ratio of a semimajor diameter of each of the set of spheroidal segment shells to each of the set of cylinder shells may be between 1.5:1 and 4:1, and more specifically between 1.5:1 and 2:1. As an example, the first spheroidal segment shell 102 may have a diameter 222 of 65.20 mm, the second spheroidal segment shell 103 may have a diameter 230 of 63.56 mm, and the third spheroidal segment shell 104 may have a diameter 234 of 59.99 mm. The first cylinder shell 112 may have a diameter 224 of 42.21 mm, the second cylinder shell 113 may have a diameter 228 of 42.21 mm, and the third cylinder shell 114 may have a diameter 232 of 52.89 mm. Other dimensions are possible.

Each of the set of spheroidal segment shells may have a shell thickness ratio (defined as a ratio of a wall thickness to an outer semimajor radius of each of the set of the spheroidal segment shells) of between 1:500 and 1:200. In some embodiments, the wall 120 may have a thickness between 0.05 mm and 0.5 mm.

Further referring to FIG. 2, each of the spheroidal segment shells 102, 103, 104, as well as the larger cylinder shell 110, may adjoin the cylinder shells at a tangential angle. For example, in FIG. 2, a tangential surface angle between the first spheroidal segment shell 102 and the first cylinder shell 112 may be designated by the angle numbered 204. A tangential surface angle between the larger cylinder shell 110 and the first cylinder shell 112 may be designated by the angle numbered 206. A tangential surface angle between the larger cylinder shell 110 and the second cylinder shell 113 may be designated by the angle numbered 208. A tangential surface angle between the second spheroidal segment shell 103 and the second cylinder shell 113 may be designated by the angle numbered 210. A tangential surface angle between the second spheroidal segment shell 103 and the third cylinder shell 114 may be designated by the angle numbered 212. A tangential surface angle between the third spheroidal segment shell 104 and the third cylinder shell 114 may be designated by the angle numbered 214. Finally, a tangential surface angle between the cap portion and the first spheroidal segment shell 102 may be designated by the angle numbered 202. In order to resist compression, each of the tangential surface angles 202, 204, 206, 208, 210, 121, 214 between each of the set of spheroidal shells and each of the set of cylinders may be between 30 degrees and 80 degrees.

Other dimensions associated with the compression-resistant container 100 may affect its compression resistance. As an example, the base 134 may have a diameter between 4 mm and 1000 mm, and more specifically between 40 mm and 70 mm. The base may have a length between 4 mm and 1000 mm, and more specifically between 40 mm and 70 mm. A total length of the container may be between 20 mm and 2000 mm, and more specifically between 100 mm and 400 mm. The container may have an internal volume between 10 mL and 10 L, and more specifically between 150 mL and 500 mL. The mass of the container may be between 0.05 g and 2 kg, and more specifically between 5 g and 20 g.

Referring to FIGS. 3-5, 10, and 11, the mechanical behavior of the embodiments described herein were modeled and a simulation was performed to determine the response to compression forces. Performance was determined using Finite Element Analysis in CAD and was compared to typical bottle designs.

FIG. 3 is a table presenting the results of this comparison under a linear elastic explicit dynamics analysis and a non-linear plastic explicit dynamics analysis. Under both the linear and non-linear analysis, the compression-resistant container (for purposes of these results, a bottle) exhibited a higher total force reaction for both a fixed support (not allowing free rotation) and with displacement (allowing movement and rotation) as compared to a typical bottle. As such, overall, the compression resistant container described herein is more compression-resistant than typical containers.

FIG. 4 is a stress-strain diagram comparing the pre-yield elastic behavior (linear FEA analysis) of an embodiment of the compression-resistant container (Compression Resistant Container) compared to a typical container (Standard Container).

FIG. 5 is a stress-strain diagram comparing the post-yield plasticity behavior (non-linear FEA analysis) of an embodiment of the compression-resistant container (Compression Resistant Container) compared to a typical container (Standard Container).

FIG. 11 shows a simulation image for an embodiment of the compression-resistant container described herein. Based on the simulations, it was determined that the design described herein spreads the stress of a 25 lb distributed compressive load across the spheroidal segment shell, and resists flattening. As seen in FIG. 11, the container exhibits an even distribution of force across the spheres, where the greatest amount of stress is contained in the flat portions (e.g., brand label panel) and at the top and base of the container. The shaded regions along the spheres show the least amount of force concentrated along the spheres and cylinders of the body. This is in contrast to a standard container shown in FIG. 10, where stress is concentrated throughout the body.

By making this change to the shape of disposable water bottles, recycling facilities could capture an additional 15% of plastic bottle waste that currently is lost to the paper stream during the separation process. Furthermore, broad implementation by major water bottle corporations would incentivize municipalities to accept plastic water bottles in their curbside recycling programs. It is estimated that widespread acceptance of disposable plastic water bottles in municipal recycling systems would capture an additional 400 million lbs of waste that is sent directly to the landfill every year.

Derivations of this design may be applied to other plastic containers to capture an even higher volume of lost waste, such as the clamshell containers, boxes, and drinking cups that also are flattened and lost at high rates during the sorting process. These containers make up an additional 11% of plastics in the average municipal recycling stream, with a loss rate of 39% that is separated with paper during recycling. The combined impact of design changes across all lightweight plastic containers would have a substantial impact on the recovery of plastics, and in particular PET, and ultimately increase the supply of recycled plastics.

Referring to FIG. 6, an embodiment of a compression-resistant container 600 may include a body 620 having a set of spheroidal segments 602 and a set of cylinder segments 612. For clarity and convenience, only three of the spheroidal segments 602 are labeled and only four of the cylinder segments 612 are labeled. Together, the spheroidal segments 602 and the cylinder segments 612 may form a container shape, which may be referred to herein as a box or a clamshell. A top 610 of the body 620 may be separable from a bottom 611 of the body, thereby opening the container 600. Each of the spheroidal segments 602 may have an associated spheroidal surface 640 and each of the cylinder segments 640 may have a cylindrical surface 650. The spheroidal segments 602 may be alternated with the cylinder segments 640, to provide resistance against compression of the container 600.

Referring to FIG. 7, a side view of the container 600 is depicted. The set of spheroidal segments 602 (labeled in FIG. 6) may include a first spheroidal segment 702, a second spheroidal segment 703, a third spheroidal segment 704, and a fourth spheroidal segment 705. Likewise, the set of cylinder segments 612 may include a first cylinder segment 712, a second cylinder segment 713, and a third cylinder segment 714. The number of spheroidal segments and cylinder segments is for illustrative purposes, and this disclosure contemplates containers having more or fewer segments than illustrated.

The first spheroidal segment 702 may have a first spheroidal surface 742, the second spheroidal segment 703 may have a second spheroidal surface 743, the third spheroidal segment 704 may have a third spheroidal surface 744, and the fourth spheroidal segment 705 may have a fourth spheroidal surface 745. Likewise, the first cylinder segment 712 may have a first cylindrical surface 752, the second cylinder segment 713 may have a second cylindrical surface 753, and the third cylinder segment 714 may have a third cylindrical surface 754. When the container 600 is opened, the surfaces may be split apart between the top 610 and the bottom 611.

The first cylindrical surface 752 may adjoin at least the first spheroidal surface 742 and may be positioned between the first spheroidal surface 742 and the second spheroidal surface 743. The second cylindrical surface 753 may adjoin at least the second spheroidal surface 743 and may be positioned between the second spheroidal surface 743 and the third spheroidal surface 744. The third cylindrical surface 754 may adjoin at least the third spheroidal surface 744 and may be positioned between the third spheroidal surface 744 and the fourth spheroidal surface 745. As such, the spheroidal surfaces 742-745 and the cylindrical surfaces 752-754 may alternate, as shown.

Referring to FIG. 8, an embodiment of a compression-resistant container 600 is depicted showing radii and angles associated with the spheroidal segments 702, 703, 704, 705 and cylinder segments 712, 713, 714 of the container 600. As an example, the three spheroidal segments on the left (e.g., the spheroidal segments 702, 703, 704) may have a first radius 802, which may be 32.50 mm, and the spheroidal segment on the right (e.g., the spheroidal segment 705) may have a second radius 806, which may be 32.40 mm. A diameter 804 of each of the cylinder segments 712, 713, 714 may be 42 mm. A tangential angle 808 between each of the spheroidal segments 702, 703, 704, 705 and cylinder segments 712, 713, 714 may be 49.75 degrees. The ratio of the radii 802, 806 to the diameter 804 may increase resistance to compression as compared to shallower angles and the tangential angle 808 is sufficient to provide support during compression while also enabling storage within the container 600. Other dimensions and advantages are possible.

Referring to FIG. 9, the spheroidal surfaces 702, 703, 704, 705 and the set of cylindrical surfaces 712, 713, 714 may define at least a portion of the body 620 (labeled in FIG. 6), which may define a box, a clamshell, or another like container. A hinged opening may be positioned between the top 610 of the body and the bottom 611 of the body as depicted in FIG. 9.

Although various embodiments have been shown and described, the present disclosure is not so limited and will be understood to include all such modifications and variations as would be apparent to one skilled in the art.