FIELD OF THE INVENTION

The present invention relates generally to containers, and more particularly to a system of stackable bottles.

BACKGROUND OF THE INVENTION

It is known to provide a storage bottle which permits stacking of bottles on the bottles' sides. Examples of such bottles include U.S. Patent No. 4,892,207 to Cullis entitled: "Bottled Water Container", U.S. Patent No. 5,002,199 to Frahm entitled: "Stackable Bottle", U.S. Patent No. 4,308,955 to Schieser et al. entitled: " Interfiling, Stackable Bottles"; and U.S. Patent No. 3, 889, 834 to Harris entitled: "Container Construction". Such stackable bottles are not ideal as the sideways stacking of bottles may increase the likelihood that the contents of the bottles will leak out of the bottles, particularly where the bottle contents are liquid.

It is also known to provide stackable bottles which permit the nesting of the neck of one bottle into a recess in the bottom of another bottle. Examples of such bottles include those described in U.S. Patent No. 1,042,998 to Climalene entitled: "Improvements in Stackable Containers", U.S. Patent No. 5, 133,469 to Mehta et al. entitled: "Stackable Bottle", U.S. Patent No. 4,805,793 to Brandt et al. entitled: "Stackable Bottle", U.S. Design Patent No. D466,413 to Justice entitled: "Stackable, Nesting Beverage Container" and PCT Patent Application No. PCT/AU93/00380 to Preston entitled: "Stackable Water Bottles". These nesting, stackable bottles do not include means for interlocking the sides or tops and bottoms of the bottles to provide stability to a stack of such bottles.

In addition, stackable bottles are known which incorporate a nesting neck and interlocking means to connect their top and bottom surfaces. Examples of such bottles include U.S. Patent No. 3,474,843 to Maris entitled: "Blow-Molded Containers" and U.S. Patent No. 2,641,374 to Der Yuen entitled: "Container". Such bottles, however, do not include means for interlocking their side walls.

Other bottles are known which incorporate a nesting neck and interlocking means to connect the sides of the bottles, including U.S. Patent No. 6,588,612 to Dorn et al. entitled: "Plastic Container with Stacking Recesses" and U.S. Patent No. 3,369,658 to Hasselmann entitled:

"Portable Container Transport Unit". These bottles, however, do not include means for interlocking their top and bottom surfaces.

In the bottle described in U.S. Design Patent No. D407,020 to Doty entitled: "Stackable Polymeric Container for Liquids", a stackable bottle is described in which the handles of the bottle are components of the horizontal interlocking means. Such a structure is less than ideal in that the handles of the bottle will not be accessible when the bottle is in a stack.

In PCT Patent Publication No. WO/03055756 to Clark entitled: "Modular Bottle", a bottle is described which permits snug nesting of the neck of one bottle into a recess in the bottom of another, as well as side interlocking means. The bottle is intended for use as a construction toy after consumption of the beverage contained therein. The bottle does not provide a planar top and bottom support surface for stable vertical stacking of bottles containing consumables.

Ideally, a stackable bottle for use in a system of stackable bottles should have a neck and floor recess which generally are of a size to fit with corresponding necks and recesses in other stackable bottles of the system. Such bottles should provide interlocking means for connecting the sides of adjacent bottles, interlocking means for connecting the top of one bottle to the bottom of another and interlocking means for connecting the neck of one bottle into the floor recess of another bottle. The overall geometry of the bottles should be planar and ideally cubical to optimize stacking volume. Each such bottle should include at least one handle which is accessible when the bottle is incorporated into a stack of such bottles.

While the prior art contains some of these elements, none of the prior art bottles incorporate all of the desired characteristics of a stackable bottle and system of stackable bottles according to the present invention.

SUMMARY OF THE INVENTION

In one of its aspects, the invention comprises a stackable storage bottle and a system of interlocking stackable storage bottles, each bottle having a storage chamber with an upper surface, a conical ceiling extending upwardly from the upper surface, a lower surface, and at least four generally planar side walls; a cylindrical neck extending from the center of the conical ceiling and having an opening at its top end; a conical recess in the lower surface of a size sufficient to envelop the ceiling and neck of another storage bottle insertable therein; vertical interlocking means for releasably connecting each side wall to the side wall of

another storage bottle stackable adjacent thereto; and horizontal interlocking means for releasably connecting the upper surface to the lower surface of another storage bottle stacked thereabove.

In another aspect, each storage bottle may be stacked in an upright position above, below or beside another upright storage bottle to form a stable bottle stack.

In still another aspect, the neck of each storage bottle may be comprise interlocking means for locational friction fit engagement with the floor recess of another storage bottle.

In a further aspect, each bottle may have at least one aperture between adjacent side walls, each aperture forming a handle. There may be a recess in at least one of the side walls for application thereto of a label.

In yet another aspect, each of the storage bottles may be blow-molded and may be a liquid storage bottle. The storage bottles may be manufactured of a polyethylene material.

In still another of its aspects, the size of each storage bottle may be selected for use with industry standard drinking water dispensers.

In still a further aspect, the vertical interlocking means may comprise at least one recess on the side wall for engaging a corresponding protrusion on the side wall of another storage bottle and the horizontal interlocking means may comprise at least one recess in the lower surface for engaging a corresponding protrusion on the upper surface of another storage bottle.

In yet a further aspect, the neck of each bottle may further comprise an external thread for attachment thereto of a screw cap.

Other aspects of the invention will be appreciated by reference to the description of the preferred embodiment which follows and the drawings thereof, and to the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described by reference to the preferred embodiment and the drawings thereof in which:

Figure 1 is an isometric view of a stackable bottle, according to the invention;

Figure 2 is a perspective bottom view of a stackable bottle, according to the invention;

Figure 3 is an isometric cut-away view of a stackable bottle, according to the invention;

Figure 4 is a perspective front view of a stackable bottle, according to the invention;

Figure 5 is a cross-section of two stackable bottles, demonstrating the nesting of the neck portion of one bottle with the floor recess of the other bottle; and

Figure 6 is an isometric view of a stack of stackable bottles according to the system of the invention.

Figure 7 is a top perspective view of a pallet.

Figure 8 is a bottom perspective view of the pallet.

Figure 9a is a top plan view of the pallet.

Figure 9b is a side cross sectional view of the pallet showing a row of stackable bottles.

Figure 9c is a perspective view related to Figure 9b.

Figure 10a is a top plan view of the pallet.

Figure 10b is a side cross sectional view of the pallet showing two stacked pallets.

Figure 11 is a perspective view and partial cross sectional view of the pallet with stackable bottles.

Figure 12 is a perspective view of the pallet and one row of the bottles.

Figure 13 is a perspective view of the pallet and four rows of bottles.

Figure 14 is a perspective cross sectional view of the pallet.

Figure 15 is a cross sectional perspective view of two stacked pallets.

Figure 16 is a side view of a pallet.

Figure 17 is a perspective view of two stacked pallets.

Figure 18 is a top plan view of two adjacent stacked pallets with interlocks.

Figure 19 is a perspective view showing stacked bottles with three pallets.

Figure 20 is a perspective view of another embodiment of the bottle with a recess to accommodate a strap.

Figure 21 is a perspective view of strapped bottles.

Figure 22 is another perspective view of strapped bottles.

DETAILED DESCRIPTION OF THE BEST MODE AND PREFERRED EMBODIMENT OF THE INVENTION

Referring first to Fig. 1, a stackable bottle 2 according to the present invention comprises a storage compartment having an upper surface 4 with a conical ceiling 6, a centrally disposed neck 8 extending from the conical ceiling with an opening 10 therein, and a lower surface (not shown). The bottle has four side walls 12, 14, 16, 18, vertical interlocking means comprising side wall protrusions 20, 22 corresponding to side wall recesses 24, 26, and horizontal interlocking means comprising at least one upper surface protrusion 28 corresponding to at least one lower surface recess (not shown).

The side wall protrusions are of a size, relative to the size of the side wall recesses, which permits a releasable locational transition fit engagement of the protrusions into the recesses. Similarly, the upper surface protrusions are of a size, relative to the size of the lower surface recesses, which permits a releasable locational transition fit engagement of the protrusions into the recesses.

The neck 8 may have an external thread 30 for attachment of a screw cap (not shown).

One or more apertures 32 between adjacent side walls 12, 18 may form a handle 34 at the side edge of the bottle. A second handle 36 may be formed between the remaining side walls 14, 16. The bottle may include one or more shallow recesses 38, 40 in the side wall surfaces for application of labels or other marking devices.

As shown in Fig. 2, the lower surface 42 of the bottle incorporates a centrally disposed conical recess 44 and at least one peripheral recess 46 for engagement with an upper surface protrusion (not shown).

As best seen in Fig. 3, the storage compartment 48 of the bottle is intersected by the aperture 32 forming the handle 34.

Fig. 4 shows one face 12 of a stackable bottle of the present invention, demonstrating the planar construction optimal for stable stacking which optimizes stack volume.

In Figure 5, two bottles are shown in stacked configuration. The neck 8 and conical ceiling 6 of the upper surface of the lower bottle 50 are dimensioned to fit within the recess 44 in the lower surface of the upper bottle 52. The fit permits stacking of bottles without causing damage to labels or seals disposed over the mouth of the bottle. In one embodiment, as shown in Fig. 5, the clearance between the neck and the recess in which the neck is nested is minimal to provide a close fit between the neck and the recess. The side walls of the upper bottle 52 are fully supported by the side walls of the lower bottle 50 aligned below. As well as providing a stability function, the horizontal interlocking means provides an alignment function to ensure stack stability.

Figure 6 demonstrates the system of the invention, showing a stack 54 of stackable bottles 2. Bottles are aligned and interlocked vertically as well as horizontally. The system of the invention permits stacking of bottles in an upright position to discourage leakage and spillage during storage and transport. Even where a seal fails, spillage will be much less than would be the case were the bottles stacked with the neck in a horizontal position. One of the handles 34, 36 of each bottle on the periphery of the stack is accessible to a handler. No rack is necessary to hold the bottles, as the vertical and horizontal interlocking means provide stability to the stack.

The bottles of the invention may be stacked in both empty and filled conditions. Bottles may be stacked during filling, transportation, storage prior to use, storage after use, cleaning and during consumption of the consumable materials in the life cycle of the bottles.

The bottles of the invention may also incorporate means for identifying the contents of the storage bottles. Such identification means may include colour coding, distinguishing structural features, or other identifying features for content identification purposes.

As shown in Fig. 5 the stacked bottles are vertically disposed about an axis defined through the stacked necks 8.

The recess 44 in the embodiment shown in Fig. 5 presents a convex surface 51 which deflects the bottle towards the axis when the recess 44 of a bottle is mounted over the neck 8 of the bottle below. In other words, there is a self-centering aspect to the invention when stacking

the bottles together which becomes useful especially when the bottles are filled with liquid. When a bottle is filled with liquid it is difficult to accurately center the bottles when stacking and accordingly the convex surface 51 of the recess 44 will tend to deflect the bottle being mounted over the next adjacent bottle towards the center of the axis.

In another embodiment of the invention a pallet 60 can be utilized.

Figs. 7 and 8 shows that the pallet has a top surface 62 and a bottom surface 64.

The top surface 62 includes a locating means 67 which comprise pallet protrusions 68 and bottle locating means which in one embodiment comprise circular protrusions 65. A boss or land 63 is also provided, which in the embodiment shown in Fig. 7 comprises a plurality of spaced strips 63a intersecting with a plurality of spaced intersecting strips 63b. The intersecting strips or lands 63a and 63b assist in registering the bottles previously described relative to the pallet 60. The top surface 62 also includes a plurality of bottle support surfaces 66 for contacting or placing the bottles previously described. In particular the bottle support area 66 includes a plurality of pallet protrusions 68 which are adapted to align with and be received by the peripheral recesses 46 of a bottle stacked thereon. The pallet protrusions 68 are disposed diagonally the strips in the embodiment shown; however they may be disposed in other manners as well.

The bottle support area 66 is adapted to support the lower surface 42 of the bottles.

The locating means 67 include circular protrusions 65 which are located at the intersection of the pallet protrusions 68. Also the peripheral edge of the circular protrusions may be bevelled or conically shaped at 69 so as to guide and register with the recess 44 of the bottles previously described.

Each bottle support area 66 is framed by the intersecting strips 63a and 63b of the lands 63. Intersecting pallet protrusions 68 are generally sized so as to project slightly above the bottle support area 66 so as to be placed within the recesses 46 of the bottles. The bottle placement area 66 is generally disposed slightly below the pallet protrusions 68. The strips 63a and 63b are disposed slightly higher than the pallet protrusions 68 as best seen in Figs. 10, 14 and 15.

The pallet 60 presents four sidewalls 72 which can include a pair of lifting holes.

The pallet 60 also includes a bottom surface 64 which includes a plurality of rece sses 84 that have been arranged and disposed in and array permitting aligned reception of stacked bottles as shown in Fig. 9. Each of the recesses axially taper inwardly presenting a. convex or trumpet shape and merge with a rounded cylindrical portion 82 which is also shown in Figs. 2 and 5. Furthermore the bottom surface of the pallet 80 includes a plurality of recesses 86 which are adapted to receive the protrusions 28 of the bottles 2 as previously described.

The pallet can comprise of plastic material or foam provided the material is sufficiently designed to enable users to lift the stacked bottles which are placed on the pallets shown in Figs. 10, 11 or 12. Alternatively, the openings 74 can be adapted to receive the fbrklifts of a forklift truck so as to lift the stacked bottles as shown in Fig. 12.

In operation the bottles 2 would be sequentially placed on the top surface 62 of the pallet whereby the pallet protrusions 68 would align with the lower surface recesses 46 of the bottles 2. The next horizontal bottle would also be placed on the next adjacent bottle placement area 66 whereby the vertical locking means comprising of the sidewall protrusions 20 and 22 of one sidewall would be engaged by the recesses 24 and 26 until the entire row is filled with bottle as shown in Fig. 10.

Thereafter the next adjacent rows can be stacked one upon the other as shown in Fig. 11. Thereafter another pallet 60 would be placed on top of the stacked bottles as shown in Fig. 12.

The pallet can be hollow and fabricated by rotational molding which generally comprises placing plastics resin in a hollow heated mold or die and spinning the mold. A hollow plastic pallet is thereby formed. However, other manufacturing processes can be employed with different materials including stamped sheet metal in accordance with the invention described herein.

Accordingly the pallet protrusions 68 are hollow. In other words, pallet protrusions 68 appear as a hollow channel starting at 68a and ending at 68b when viewed inside the pallet 60.

In the embodiment shown the top part 85 of the recess 82 is spaced from the circular protrusions 65 as best seen in Fig. 10 so as to permit the pallet to flex under the weight of the filled bottles, which minimizes the possibility of fracturing of the pallets.

Also it has been found that in one embodiment the weight of the pallet and stacked empty bottles utilizes only 25% of the comparable weight of the racks and empty bottles utilized in the prior art while at the same time providing double the fluid capacity in the stacked bottles for the same space. Accordingly more products can be shipped and stored.

Furthermore the stacked bottles with the pallet are locked or interlocked in three dimensions ie along two dimensions as the side walls 12 and 14 of the bottles have recesses 24 and 26 as well as protrusions 20 and 22; as well as a third dimension ie axially as the bottoms and tops of the bottles interfit, plus the pallet protrusions 68 and recesses 46 of the bottles. Such three dimensional inter fitting resists separation of the bottles in transit as well as concentrating the density of the stored materials packed in the manner described.

Also the pallets 60 includes along the side 72 thereof pallet protrusions 76 which are received by pallet recesses 75 as seen in Figs. 7 and 18; so that adjacent pallets interlock and assist in the proper alignment of the pallets.

Fig. 20 illustrates another embodiment of the invention where the sides 12, 14, 16, 18 include another or second recess 15 for reception of a strap or other fastener 17 to hold the stock together, to eliminate the use of the pallet 60.

In the embodiment shown the side wall 14 includes at least one side recess 15 disposed between the upper surface 4 and the lower surface for reception of the straps 17. The side recess 15 is disposed generally horizontally or substantially parallel relative the upper surface and lower surface 15.

Also the stacked array in Figs. 21 and 22 can include vertically disposed straps 19. In the place of a pallet, spacers 21 can be used to allow clearance for forklift slots 23.

It will he appreciated by those skilled in the art that other variations of the preferred embodiment may also be practised without departing from the scope of the invention.