Method for manufacturing an attachable container and containers so manufactured - Patents.com

Abstract

The present invention relates to a method of making a plastic container (24) comprising the steps of making a base element (21), a parison or preform, inserting a magnet (44) into a cavity (52) of an open blow mold (54), inserting the base element into the open blow mold, and closing the mold and introducing air into the base element to form a container in the mold, whereby the magnet becomes integrated into and attached to the formed container. The present invention also relates to containers made by this method.

Description

[Technical field]

[0001] The present invention relates to containers for products for personal use, and in particular to containers that can be attached to one another for ease of use. [Background technology]

[0002] There are many different products that individuals use every day, such as shampoo, conditioner, shower cream, body lotion, to name just a few. These types of products are often sold in containers that function well when placed and stored in a stationary position in the bathroom and toilet.

[0003] However, when traveling, especially when several containers are carried, these containers are usually too large and bulky. Moreover, when traveling by plane, there are restrictions on the amount of liquids allowed to be carried in cabin luggage, making these containers unsuitable due to their size.

[0004] Several travel containers have been developed that have a volume that makes them easy to carry and allow them to be placed in cabin luggage. A drawback with most of these containers is that they must be filled with the desired product by the user, and often the openings of these containers are quite small, making them difficult, cumbersome and messy to fill. Another drawback is that if some of these small containers are to be carried in, for example, a gym shower, a bag or a larger container is required.

[0005] Several solutions have been developed over the years to interconnect the containers and form a single, easily portable unit. Some solutions comprise form-locking elements, such as profiled protrusions that fit into corresponding recesses to make a detachable connection. Even when these solutions work, they are not very aesthetically appealing. Other solutions comprise magnets mounted on the outer surface of the container. One solution is disclosed in document US2015 / 0164003, which describes a modular container system in which each container is provided with a housing on a side. The housing is provided with a magnet arranged in a recess. To attach one container to another, a separate element called a container connector, which also contains a magnet, is used to attach to the housings of both containers. This means that an additional component is required, which, if lost, would result in the loss of the functionality of the container system. Furthermore, the protruding magnet housings are not very attractive.

[0006] Document CN107972954 discloses a box provided with magnetic elements on its outer surface for stacking. The document is silent as to how the magnets are attached to the box.

[0007] Thus, there is room for improvement in this area of ​​technology. Summary of the Invention

[0008] The object of the present invention is to provide an improved solution for containers which can be attached to one another. This object is solved by the features of the independent patent claims. Preferred solutions of the invention form the subject matter of the dependent patent claims.

[0009] According to one aspect, a method for producing a plastic container is provided, comprising the steps of producing a base element, a parison or a preform, inserting a magnet into a cavity of an open blow mold (die), inserting the base element into the open blow mold, closing the mold and introducing air into the base element to form a container in the mold, whereby the magnet is integrated into and attached to the formed container. According to this method, magnets for interconnecting several containers with each other are integrated in a very reliable and smooth manner when forming the actual container without additional methods or adhesives for attaching the magnets.

[0010] According to a further aspect, the magnet can be placed in a magnet holder, which is inserted into the cavity. In this regard, the magnet holder can be made from the same material as the material of the preform. The magnet holder provides a very good bond with the container, firmly integrating the magnet to the container.

[0011] To improve the appearance of the container, the method may further comprise a step in which at least one label is attached to the outer surface of the formed container by inserting the at least one label into the cavity. According to this solution, there is no need for additional adhesive to attach the label, it is only the material of the container being formed that provides the attachment.

[0012] According to another aspect of improving the appearance of the container, at least a portion of the cavity can be structured to provide a structured exterior surface on the formed container. Furthermore, to reduce the cost of manufacturing the molding tool and to increase the number of different structures on the formed container, the cavity can be arranged to receive an insert, which can be provided with a structured surface. Changing the structure on the formed container is then easily accomplished by replacing one insert with a differently structured insert, without having to change the entire molding tool.

[0013] Preferred methods for forming the container include injection blow molding, extrusion blow molding, or stretch blow molding.

[0014] A container manufactured using this method can be formed with two generally planar opposing sides on which magnets are integrated for attaching several containers side by side by interaction of the magnets of one container with the magnets of a further container. Thus, several containers so manufactured can be removably attached to one another in a very convenient and simple manner.

[0015] The formed container may further comprise an opening formed by a threaded neck, with a closure attachable to the threaded neck. In this regard, the closure may comprise a tubular element arranged to fit into the neck of the container to stabilize the neck. This is advantageous if the container is made from a relatively soft material that allows the user to squeeze the contents out of the container, without the risk of the neck being deformed by the closure during its attachment.

[0016] Preferably, the closure may comprise a lid for opening and closing the dispensing passage in the closure. And, to prevent dripping, the lid may be provided with a first sealing element arranged to fit into the dispensing passage when the lid is closed. For additional safety against dripping, the lid may be provided with a second sealing element in the form of an annular protrusion arranged to fit into a corresponding annular recess surrounding the dispensing passage. To facilitate dispensing of the contents, the dispensing passage may be provided with a flexible membrane, which may be provided with a slit that can be opened by pressure from the dispensing liquid in the container.

[0017] A manufacturing unit may also be provided having a subunit capable of producing a preform or parison for placement in the open mold. The manufacturing unit further comprises a subunit capable of picking up a magnet from a storage and placing the magnet in the open mold. The subunit may further comprise a storage of a magnet holder, the magnet holder being moved to a position where the magnet can be attached to the holder before being placed in the mold. The subunit for picking up the magnet may be a robot with a gripping element, where the robot may be movable both linearly and rotationally to place the magnet inside the open mold. The gripping element may use vacuum suction to pick up the magnet. Additionally, vacuum may also be used to hold the magnet inside the mold.

[0018] The manufacturing unit may further comprise a subunit with a robot that can pick up the labels from the storage and place the labels inside the open mould. The subunit for labels may use a vacuum to pick up the labels. The robot may be able to move both linearly and rotationally to place the labels in the open mould.

[0019] These and other aspects of the present invention, as well as advantages thereof, will become apparent from the following detailed description of the invention and from the accompanying drawings.

[0020] In the following detailed description of the invention, reference is made to the accompanying drawings. [Brief description of the drawings]

[0021] [Figure 1] 1 shows a schematic diagram of an example of a manufacturing process in which the method according to the invention can be used; [Diagram 2] 1A-1C show schematic diagrams of examples of placing different objects in a molding die prior to forming a container. [Diagram 3] FIG. 1 shows an example of a magnet holder that can be used in the method according to the invention. [Figure 4]FIG. 1 shows an example of a magnet holder that can be used in the method according to the invention. [Diagram 5] FIG. 1 shows an example of a container manufactured by the method according to the invention. [Figure 6] FIG. 2 shows a schematic representation of an insert that can be used in the method according to the invention. [Figure 7] FIG. 2 shows a schematic representation of an insert that can be used in the method according to the invention. [Figure 8] 1A-1C show examples of closures that may be attached to containers made in accordance with the present invention. [Figure 9] 1A-1C show examples of closures that may be attached to containers made in accordance with the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] A method for manufacturing containers is described below. One example of a manufacturing process is injection blow molding. Figure 1 shows a schematic of an injection blow molding machine 10. The injection blow molding machine 10 comprises a central turret 12 indexable with at least three stations. In the first station A, a core rod or metal shank 14 is placed in an injection mold 16. Granular material stored in a storage container 18 is melted and fed in an extruder 20 into the mold to form a so-called parison or preform 21. Preferably, a neck portion is formed at the end of the preform, which may be threaded.

[0023] The injection mold 16 is then opened and the turret 12 is rotated to a second station B with the preform 21 on the core rod 14. At the second station B, the preform is placed in a blow mold 22 having a cavity 23 formed as the container to be manufactured. Air is introduced into channels in the core rod 14 which are provided with outlets so that the preform is blown and expands or expands to the surface of the cavity to form a container 24. The blow mold 22 is opened after the container is cooled and the turret 12 is rotated with the formed container 24 to a third station C where the formed container is pushed off the core rod 14. The turret 12 is provided with three core rods so that each step of the described process at all positions of the turret is performed to provide a continuous manufacturing process.

[0024] According to the present application, the machine further comprises a unit 26 arranged at the second station B for handling the magnets. The unit 26 comprises two successive movable bands 28 placed opposite each other, as can be seen in FIG. 2. Each band 28 is divided into segments 30, where each segment comprises a recess 32 in which a magnet holder 34 can be placed. The magnet holder 34 is placed in a vertical rack 36 above the successive bands. The magnet holder 34 in the embodiment is a flat piece of plastic with two recesses 38 with a thin bottom layer 40 (see FIGS. 3 and 4). Downstream of the rack 36 with the magnet holders 34 are arranged two vertical racks 42 in which the magnets 44 are housed. In the embodiment shown, the magnets 44 are circular, whereby the racks 42 can be tubes with a suitable internal diameter. Thus, for each band, a first magnet holder 34 is placed in a recess 32 in a first position I. The band 28 is then moved to a second position II, where the magnet holder 34 is placed under the magnet rack 42, so that the magnets 44 are introduced into the respective recesses 38 of the magnet holder 34. The segment 30 with the magnet holder equipped with the magnets is then moved to a third position III, where the segment 30 is rotated, for example, by 90 degrees around the pulley of the band 28.

[0025] The machine further comprises two robot arms 46 each provided with a gripping element 48 capable of gripping a magnet holder with a magnet. The gripping element 48 can be a vacuum suction cup or a mechanical gripper. The two robot arms 46 are preferably mounted on a common base 50 movable along an axis X1 in FIG. 2 and are individually movable in a direction generally perpendicular to the axis X1. Thus, when picking up a magnet holder with a magnet, the robot arm 46 is first moved towards the magnet holder in a third position III, in which the gripping element 48 grips the magnet holder 34. The base 50 and the arm 46 then move the magnet holder 34 along the axis X1 into a cavity 52 in a section 54 of the open blow mould. In FIG. 2 only one section 54 is shown, but it should be understood that a second section is arranged vertically above the section shown with its cavity facing the cavity of the section shown. Although not shown in FIG. 1 for reasons of clarity, the robot arm 46 is preferably designed such that it can pass a core rod with a preform disposed between the mold sections.

[0026] In that position, the base 50 with the robot arms 46 is rotated 90 degrees about the axis X1, and then each arm 46 is moved perpendicular to the axis X1 towards the mold section. The cavity 52 of the blow mold section is provided with a holding element 56 capable of holding the magnet holder 34 against the cavity wall of the blow mold section. The holding element 56 may be an orifice connected to a vacuum source. Once the magnet holder is in place as shown with dotted lines in FIG. 2 and oriented so that the bottom layer 40 of the recess 38 faces the cavity wall, the mold is closed around the core rod. The cylindrical section of the core rod 14 fits into the tubular cavity section of the closed mold, as shown at station B in FIG. 1, with an annular gap 58 between the core rod and the cavity section, which forms the neck of the container to be manufactured. In that regard, the cavity section is preferably provided with a recess forming a threaded section in the formed neck. In turn, air from a source of pressurized air (not shown) is introduced into the mold through an opening in the core rod.

[0027] The parison or preform is then blown to expand it to the surface of the cavity. The magnet holder 34 is then covered by the blown material and is adhered to it by the heat in the mold and material. In this way, the magnet is "integrated" into the blown container 24 and is protected by the layer 40. Preferably, the material of the magnet holder 34 is the same as the material of the container and also preferably has the same melting point to make the magnet holder and magnet very well integrated with the container. After cooling, the blown container is removed from the molding die and pushed off the core rod. An example of the container 24 is shown in FIG. 5.

[0028] The outer surface of the container may be provided with a label to provide information on the container and / or to give it a clean and individual appearance. The label may be applied on the finished container, but may also be attached during the forming and blowing process. In the latter case, a robot arm 60 is provided that is movable along an axis X2. The robot arm 60 is further provided with a gripping element. In the embodiment shown in FIG. 2, the gripping element comprises a cylindrical drum 62 rotatably mounted on the robot arm 60. The drum 62 is provided with a number of orifices 64 connected to a vacuum source (not shown). A stack of labels 66 is placed adjacent to the axis X2. To pick up a label 66, the robot arm 60 moves the drum 62 so that the outer periphery of the drum 62 is in contact with the top label in the stack. The robot arm 60 is moved while the drum 62 is rotated, so that the vacuum at the orifices 64 of the drum 62 causes the label 66 to adhere around the outer surface of the drum 62. The robotic arm 60 then moves along axis X2 towards the open mold, rotates 90 degrees and moves the drum 62 into the open mold.

[0029] When the drum 62 is in position relative to one of the mold cavities, as shown in dotted lines in FIG. 2, the robot arm lowers the drum 62 so that it is located inside the mold cavity 52 in section 54. The vacuum is turned off, which causes the label 66 to be released from the drum 62 and spread out to contact the surface of the cavity. Since the cavity opening faces upward, the label stands in the cavity with one side edge resting on the lower cavity wall. Air can be used to blow on the label or a vacuum can be used to ensure that the label is held in place against the surface of the cavity. When the mold is closed and the container is blown, the exterior surface of the container comes into contact with the label, and the heat of the container material causes the label to adhere to the exterior surface of the container. Therefore, no adhesive or other sticky material other than the container material is used to attach the label. The label material is selected both to withstand the heat in the cavity as well as to provide good adhesion to the container.

[0030] Another way to give a container a nice appearance is to provide a structure on the outside of the container. In that case, the mold cavity can of course be shaped so that the structure is provided. However, to have the possibility to provide many different structures, the mold cavity can be arranged to receive inserts 70 (see FIG. 6) with different structures 72. FIG. 7 shows an example of the inner surface of the insert 70. Suitable mounting elements can be provided to fix the insert inside the mold cavity. In this way, containers with many different structures can be manufactured by using different inserts without the large cost of making complete molding molds with different internal structures.

[0031] The container is preferably molded and blown, as described above. In this regard, apart from injection blow molding, extrusion blow molding or stretch blow molding can be used. Furthermore, there are, of course, other ways of introducing the magnet into the mold and other ways of providing the magnet in the magnet holder.

[0032] The manufactured container 24 shown by way of example in FIG. 5 is designed with two generally planar sides 78 with magnets embedded in their faces. In this way, two or more containers can be attached next to each other by magnets. The container 24 is further provided with an opening 80 with a preferably threaded neck 84. The opening 80 is selected relatively large to facilitate the user to fill and refill the container 24 from a larger container without spilling and without the use of a tool such as a funnel, and is selected large enough to allow fingers to reach inside the container. The threads also provide for attachment of the closure after filling and refilling.

[0033] An example of an opening closure 86 is shown in Figures 8 and 9. The closure 86 has a generally planar base 88. A central support tube 90 is integrated into the base 88 and has an outer diameter that generally corresponds to the inner diameter of the neck 84 of the container 24 to provide stability to the neck and to prevent inward deformation of the neck when the closure is screwed on. This is advantageous, especially if the container is made from a relatively soft material. Such a soft material is preferred because it allows the contents to be squeezed out of the container.

[0034] The base is further provided with a central passage 92, preferably smaller than the diameter of the neck. To provide a metering function, the central passage may be provided with an elastic membrane 91 having a slit 93, which opens when liquid is pressed against the membrane (see FIG. 8a). The closure is further provided with a lid 94, preferably hinged to the base by a living hinge 96. The inner surface of the lid 94 is preferably provided with a protrusion 98 having the same shape and dimensions as the central passage 92 to fit within it, providing a sealing function when the lid is closed. The length of the protrusion is preferably selected such that the end of the protrusion contacts the membrane 91 and blocks the slit 93.

[0035] A further sealing function may be provided by an annular recess 100 in the base around the passage 92. The inner surface of the lid 94 is then disposed with an annular protrusion 102 dimensioned to fit into the recess 100 when the lid 94 is closed. Furthermore, to prevent the lid 94 from opening unintentionally, walls 104 are provided on both sides of the lid such that the lid 94 rests between the walls 104 when the lid 94 is closed. It is then possible to open the lid 94 only from the side of the lid opposite the hinge 96. A cutout 106 for opening the lid 94 with a fingertip or nail may be provided on that side.

[0036] As mentioned, the material of the container is preferably relatively soft, and a preferred material in this regard is an elastomer, which is suitable for forming blowing and also has hygienic properties, although it will of course be understood that other types of plastic materials may be used to fabricate a container according to the present invention.

[0037] The containers and closures according to the present application can be used for many liquids and products. One area is health and beauty, with products such as shampoo, hair conditioner, body lotion, liquid soap, etc. The present solution makes it easy to carry these products on trips, at the gym, etc. Another area is grocery, with products such as ketchup, barbecue sauce, mustard, salad dressings, oils and vinegar, to name a few. The present solution is very convenient for outdoor adventures, picnics, etc., where one does not want to carry large containers. In this regard, the containers can be filled with dish detergent and other detergents. In short, only imagination defines the limits of the products for which the present solution can be used.

[0038] It is to be understood that the embodiments described above and shown in the drawings should be considered only as non-limiting examples of the invention, and that the embodiments can be modified in many ways within the scope of the patent claims.

Claims

1. A method of manufacturing a plastic container (24), comprising the steps of: Manufacturing a base element (21), a parison or a preform; Inserting a magnet (44) into a cavity (52) of an open blow mold (54); inserting the base element into the open blow mold; closing the mold and introducing air into the base element to form the container in the mold, thereby integrating the magnet into the formed container and attaching it to the formed container; A method for manufacturing a plastic container (24), comprising:

2. The method of claim 1, wherein the magnet (44) is placed in a magnet holder (34) and the magnet holder is inserted into the cavity.

3. The method of claim 2 , wherein the magnet holder is made from the same material as the preform.

4. 4. The method of any one of claims 1 to 3, further comprising attaching at least one label (66) to an exterior surface of the formed container by inserting the at least one label into the cavity.

5. The method of claim 4 , wherein the label is inserted such that the label stands up with an edge on one side resting on a cavity wall.

6. 6. The method of any one of claims 1 to 5, wherein at least a portion of the cavity is structured (72) to provide a structured exterior surface on the formed container.

7. The method of claim 6, wherein the cavity is arranged to receive an insert (70), the insert being provided with a structured surface (72).

8. 8. The method of any one of claims 1 to 7, wherein the container is formed by injection blow molding, extrusion blow molding or stretch blow molding.

9. A container made by the method of any one of claims 1 to 8.

10. 10. The container of claim 9, wherein the container is formed with two generally planar opposing sides (78) in which the magnets (44) are integrated for mounting several containers side by side by interaction of the magnets of one container with the magnets of a further container.

11. Container according to claim 9 or 10, further comprising an opening (80) defined by a threaded neck (84).

12. The container of claim 11, further comprising a closure (86) attachable to the threaded neck.

13. Container according to claim 12, wherein the closure comprises a tubular element (90) arranged to fit within the neck of the container to stabilize the neck.

14. Container according to claim 12 or 13, wherein the closure comprises a lid (94) for opening and closing a dispensing passage (92) in the closure.

15. 15. The container of claim 14, wherein the lid is provided with a first sealing element (98) arranged to fit within the dispensing passage when the lid is closed.

16. Container according to claim 14 or 15, wherein the lid is provided with a second sealing element in the form of an annular protrusion (102) arranged to fit within a corresponding annular recess (100) surrounding the dispensing passage.

17. Container according to any one of claims 14 to 16, wherein the dispensing passage is provided with a flexible membrane (91) having a slit (93) which can be opened by pressure from dispensing liquid in the container.

18. 18. A container according to any one of claims 14 to 17, wherein the closure further comprises walls (104) on either side of the lid, the walls extending to at least an outer surface of the lid.

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