Dual container system and method of manufacturing the same

Abstract

Provided is a container system adapted to withstand repeated impacts. The container system features a first container having a first container body and a second container having a second container body. The second container defines a second body height and a second body wall thickness. A body recess which is adapted to releasably engage the first container body of the first container is formed on the second container body and is extended along the second body height. The body recess defines at least one recess bottom corner having a recess bottom corner wall thickness which is at least identical to the second body wall thickness of the second container body. This specified bottom corner wall thickness of the body recess allows the second container to withstand the single impact or repeated impacts. Polyethylene, extrusion blow-moldable copolyester, polycarbonate, and clarified polypropylene may be used to fabricate the second container.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This is a continuation-in-part application of pending U.S. patent application Ser. No. 10 / 614,438 entitled RECESS CONTAINER DISPENSER AND METHOD OF MAKING SAME and filed on Jul. 3, 2003, the entirety of which is expressly incorporated by reference herein.STATEMENT RE: FEDERALLY SPONSORED RESEARCH / DEVELOPMENT [0002] (Not Applicable) BACKGROUND OF THE INVENTION [0003] The present invention relates generally to dual container systems, and more particularly to an improved dual container system featuring an impact-resistant container which possesses one uniform wall thickness throughout the entirety of its body and provides a unique horizontal support for its counterpart container that engages therewith. [0004] It is a common practice for manufacturers and / or retailers to employ the use of containers for packaging their products and making them available in the marketplace. These containers not only protect the products from contamination, b...

AI Technical Summary

Benefits of technology

[0013] The present invention specifically addresses and alleviates the above-referenced deficiencies associated with dual container systems of the prior art. More specifically, the present invention is an improved dual container system which is specially designed and manufactured to withstand a single impact or repeated impacts undesirably caused thereupon. This prevents the present container system from tearing or rupturing at any specific portions thereof so as to effectively contain its associated product (e.g., shampoo, body wash, candies, toys, pet food, detergent, etc.) therewithin. In addition to this beneficial characteristic, the improved dual container system of the present invention provides a unique horizontal support for its smaller container to prevent any problems associated with inadvertent slippage as amply described above. Furthermore, the improved dual container system of the present invention is preferably formed of a relatively clear plastic such that an observer may accurately discern the visual attributes of product contained within the dual container system.

[0016] In a most preferred embodiment, the second container is fabricated from clarified polypropylene. In addition to its relatively low cost, clarified polypropylene has a relatively low density and possesses favorable processing characteristics that make it ideal as an injection or blow molding material. Furthermore, clarified polypropylene exhibits high stiffness characteristics as well as favorable stress crack resistance that, with the addition of certain plastomers, allow it to perform well in drop impact tests.

[0017] Fabricating the second container from clarified polypropylene, extrusion blow-moldable copolyester material or from polycarbonate material results in a relatively glossy surface finish to the second container. In addition, fabricating the second container from extrusion blow-moldable copolyester material such as Eastar Copolyester EB062 advantageously results in less shrinkage of the second container than when the second container is fabricated using polyethylene. Furthermore, fabricating the second container from clarified polypropylene, extrusion blow-moldable copolyester material or from polycarbonate material results in improved clarity in the finished product while allowing the container system to withstand repetitive impacts such as may occur when the container system is repeatedly dropped or mishandled during shipment, storage and everyday use.

[0022] The second container body preferably includes a plurality of lateral body extensions. Each of the lateral body extensions is extended generally perpendicular to the second body height. In addition, each of the lateral body extensions is further extended partially into the body recess. By such configuration, the lateral body protrusions can capture and retain the accommodated portion of the first container body within the body recess.

[0032] By providing the at least one injection scallop, the flow of the preform material to selected portions of the expandable molding balloon may be increased. As such, the at least one recess bottom corner which is thickened at least identical to the second body wall thickness may be derived. Due to the specified bottom corner wall thickness of the body recess, the second container may withstand the single impact or repeated impacts undesirably caused thereupon.

Problems solved by technology

Although the current dual container systems may achieve their primary objective of product user-friendliness, they possess certain deficiencies which detract from their overall utility.

Perhaps the greatest deficiency of the conventional dual container systems is the inability to withstand repeated or repetitive impacts originating from their environment.

The dual container systems of the conventional art are frequently subjected to tear and / or rupture as many of them are repeatedly dropped and / or mishandled during their shipment and / or storage.

In particular, the recess of the larger container which is used for engaging the smaller container is vulnerable to tear and / or rupture as its edges forming the outer boundaries thereof are not sufficiently thickened.

Even more vulnerable than the recess edges are the corners formed on the bottom portion the recess.

More particularly, these bottom corners of the recess are extremely thin compared to the other portions of the larger container.

This is understood to be a result of a manufacturing deficiency in which insufficient amounts of preform materials are distributed to that region.

As such, while the rest of the larger container is uniformly thickened to a sufficient degree, it is often the case that the bottom corners of its recess fail to reach the same, or even similar, thickness.

In this regard, the bottom recess corners are especially prone to being torn or ruptured.

Obviously, this has the inevitable negative effect of spilling or discharging some, if not all, of the products contained within the larger container.

The product loss resulting from such structural failure may become burdensome when translated into dollars and cents in lost profits.

Another significant deficiency that casts a shadow upon the dual container systems of the conventional art is the inability of the larger container to provide an adequate horizontal support for the smaller container.

However, those mechanisms cannot account for certain situations such as the smaller container being inadvertently slipped out through the underside of the recess due to the force of gravity.

This scenario is more likely to happen over time since the mechanisms for engaging the smaller container would eventually become weakened.

As such, the risk of container slippage is a possibility which can detrimentally undermine the overall utility and value of the dual container system.

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