HK40030139B - Inside out method of manufacturing a container with a leak resistant seal - Google Patents

Description

Method for manufacturing container with leakproof seal from inside to outside

Cross Reference to Related Applications

This application is a partial continuation of U.S. utility patent application serial No. 16/193,978 filed on day 11, month 16, 2018, which is incorporated herein by reference in its entirety.

Technical Field

Embodiments of the present invention generally relate to the field of manufacturing storage and shipping bags and containers and seals for such bags and containers. More particularly, but not by way of limitation, one or more embodiments relate to a method of inside-out manufacturing a container having a leak-proof seal, the method including forming an elastomer or plastic, or any combination thereof, into the container from inside-out to facilitate manufacturing (e.g., using fewer steps) and provide a seal with improved leak-proof properties, e.g., the seal can maintain a seal during storage and transportation, preventing liquid and solids from leaking from the container, without the need to maintain a seal by means of an external structure.

Background

Sealable bags and containers have been manufactured for many years, but are difficult to manufacture when using seals that must be joined to maintain a closure. For example, the manufacture of sealable plastic bags typically requires a pressing member, including a seal that may be part of the container or subsequently bonded to the container, where the container is cut with a hot knife to create a sealing edge. Plastic bags are typically manufactured for single use only and have chemicals that are not suitable for storing food, for example. The number of plastic bags that are thrown away each year is very high. Elastomeric bags made for reuse have been molded (e.g., by compression molding or liquid injection molding). The resulting elastomeric bag is highly elastic compared to plastic bags, and the seals of the elastomeric bag are typically bonded or molded to the interior of the bag. The flexible sealable bags are more durable than plastic disposable bags, and a reusable bag can save hundreds or even thousands of plastic bags. For example, Munguia in U.S. patent publication 2013/0105352 and LeBoeuf in U.S. patent publication 2009/0110335 both teach silicone food storage bags having a seal. A problem with both of these devices is that they require an external clamp or other external structure to seal the bag because their sealing strength is not sufficient to prevent leakage. Svec in us patent 2,780,261 shows one embodiment in which liquid may be retained within, i.e. as shown and described in relation to figure 7. This is another example of a device that requires a structure external to the seal (i.e., a sidewall) that allows the liquid in the container to extend up and around the seal, i.e., the device requires more material during manufacture and creates difficult to clean areas that are not easily cleaned, even when the container is inverted, for example, to remove liquid and solids from the container. Other attempts to make silicone containers with leak-proof seals have failed, including U.S. patent application publication No. 2014/0270579, also known as WO 2014/163712, which includes a seal that is susceptible to leakage at both ends when configured without a "fastening mechanism" attached to both ends.

A limitation of existing sealable bags is that the sealing force provided by the integrated seal design is relatively weak based on the elastomeric properties of the elastomer. The weakness of the sealing force provided by the plastic bag is due to different reasons, mainly due toThe seal is very small, having a 0.1mm ridge that is about 10 times thinner than a human nail. For example,the bag is closable, but it is not leak-proof. This lack of leak resistance is due to the relatively small sealing area andthe track and groove shape of the sealing element is simple. In order for the spine to be leak-proof and not subject to internal forces when stored, when the seal is made so small, the stiffness of the seal must be outside the shore a scale and well into the shore D scale, i.e. 45-85 shore D, typically in the range of 45-60 shore D and typically above 50 shore D. In addition, when the seal is made to have this rigidity, a crush defect causes a slight variation in the thickness of the seal, which makes the yield of containers with acceptable leak resistance low. The need to make the seal strong requires the use of a slider to open and close the bag, i.e. to allow a child or elderly or infirm to open and close the bag. The leaky end of the slider usually has an opening. In these devices, additional structure must be utilized to form a seal around the separate slider portion in the retention seal, i.e., to seal the slider portion itself against leakage. When the slider is dropped, it also creates a choking hazard for children.

Koeppel, 1946, teaches the difficulty of providing an integrated leak-proof seal in U.S. patent 5,000,363. As described by Koeppel: "closures for containers of this nature have been formed in various ways, but when the opening in the bag or container is large enough to receive ice cubes or relatively large ice cubes, it is difficult to effectively seal the opening. This difficulty has been overcome by providing the container with a thickened portion around the mouth of the opening, the thickened portion having complementary serrated or tongue-shaped and groove surfaces to form a seal. However, even such a structure cannot effectively prevent leakage unless they are pressed together with a considerable force. "then, Koeppel teaches a design that uses an external mechanical clip attached to the bag to provide the necessary sealing force. In this sense, Koeppel gave a similar solution to LeBoeuf using an external buckle.

U.S. patent No.2,674,289 to Silverman teaches a rubber container, i.e. a pouch of tobacco formed from the inside out. This eliminates the step of bonding the seal to the container and simplifies the mould since the container can be inverted after moulding. However, the seal of Silverman tapers at the ends and when used upside down results in no sealing force at the ends at all, as the seal tapers so that the ridges and depressions do not touch at the ends of the seal, i.e. there is no seal at the ends. Thus, the Silverman design requires rivets, leather sheaths and separate zippers, such as external structures, to hold the seals together. Silverman also requires additional manufacturing steps to rivet the ends of the seal, etc., and is not leak proof unless external structures, such as rivets, are used.

While the use of external clips or mechanical clasps may provide a seal, they are less convenient for the user and require additional manufacturing costs and are more complex. Heretofore, forming the flexible container from inside to outside to simplify the mold design has not provided any advantage for manufacturing due to the additional structure and steps required to add the structure. Accordingly, there is a need for a method of manufacturing a container having a leak-proof seal from the inside out, such as in a single step to form the container and seal, and the resulting seal such that no such additional elements are required to enhance the sealing force to maintain leak-proof, such as when an external force is applied to the container or when the container is inverted.

Disclosure of Invention

Embodiments of the present invention generally relate to a method of inside-out manufacturing a container having a leak-proof seal that includes forming an elastomer or plastic, or any combination thereof, into a container from the inside-out. In at least one embodiment, the method includes forming an outside portion of the container on an inside surface of the container prior to inverting the container, and forming an inside portion of the container on an outside surface of the container prior to inverting the container. By at least one embodiment, the method includes forming or coupling a leak-proof seal on an exterior surface of the container prior to inverting the container. In at least one embodiment, the leak-proof seal provides access to the inside portion of the container when the leak-proof seal is open after inverting the container, and retains at least the liquid inside the container when an external force is applied to the container after inverting the container without using an external structure to keep the leak-proof seal closed.

One or more embodiments include inverting the outer surface of the container and the leak-proof seal with the inner surface of the container such that the inner portion of the container and the leak-proof seal are located within the container and the outer portion of the container is located outside the container.

In at least one embodiment of the present invention, forming the inside portion of the container on the outer surface of the container comprises: a gap is formed on the outer surface between a first side of the leak-proof seal and a second side of the leak-proof seal, the first and second sides engaging each other after inverting the container. In one or more embodiments, the gap provides an abutment against which each end of the first and second sides of the leak-proof seal contacts to prevent the leak-proof seal from leaking when an external force is applied to the container. In one or more embodiments, the gap is less than or equal to the thickness of the leak-proof seal.

By at least one embodiment of the invention, each of the ends of the first and second sides of the gap or leak-proof seal comprises at least one gap seal, wherein the at least one gap seal is a protrusion protruding from the gap or from at least one of each of the ends of the first and second sides of the leak-proof seal. In one or more embodiments, the projections provide a serpentine path along the gap that provides longer distance for water to travel and thus increases leak resistance. In one or more embodiments, the material forming the gap is sufficiently thick such that when compressed upside down, the sealed ends compress together and the protrusions are compressed against the gap or the protrusion or depression of the seal, or any combination thereof, to increase leak resistance. Methods of forming a gap between sealed ends and forming a gap seal on the ends, where the thickness of the material forming the gap is thick enough to compress the seal and gap seal, are not known in the art.

In one or more embodiments of the present invention, forming or coupling the leak-proof seal includes utilizing a leak-proof seal having a first seal portion and a second seal portion that are coupled to each other along a boundary to seal the container and are separated from each other along the boundary to open the container.

In at least one embodiment of the invention, the first sealing portion and said second sealing portion are at least 1mm thick, or at least 2mm thick, or at least 3mm thick, or more than 3mm thick.

According to one or more embodiments of the invention, the boundary defines a contact path between the first sealed portion and the second sealed portion, the path being at least 2 times a horizontal distance between a start point of the path and an end point of the path. In one or more embodiments, the path is at least 2.5 times the horizontal distance between the start of the path and the end of the path, or at least 3 times, or at least 4 times, or at least 5 times the horizontal distance between the start of the path and the end of the path. Other metrics for measuring the seal may include measuring the path of the boundary of the seal, starting from the point where the seal diverges from its base or its flat portion along the path of contact between each side of the seal, and returning to a point near the original starting point on the flat portion of the seal. This metric for the winding path may yield a ratio of at least 4, 5, 6, 7, 8, 9, or greater than 10. In addition, the seal may have a gap therein to enable the seal to open more easily. The gap may be symmetrical, for example, on each side of any protrusion or cavity, or may be asymmetrical. By including a gap on one side of the projection, the seal can be opened more easily, for example from the side with the gap.

In at least one embodiment of the invention, the first and second sealing portions comprise at least one corresponding protrusion or depression comprising a wider geometry than another portion of the at least one corresponding protrusion or depression. The seal may also comprise a gap, which means that the shape of the ridges and depressions corresponding to each other, i.e. the shape of the ridges and depressions cooperating with each other, may have different shapes, whether or not they are in full contact over the entire boundary.

In one or more embodiments of the invention, utilizing a leak-proof seal includes utilizing a protrusion or depression having a height of at least 2mm and utilizing a geometry having a width that is at least 1mm thicker than the protrusion or depression.

By way of at least one embodiment, utilizing a leak-proof seal includes utilizing a protrusion or depression having a height of at least 2mm and utilizing a geometry having a width that is at least 2mm thicker than the protrusion or depression.

In accordance with one or more embodiments, utilizing a leak-proof seal includes utilizing two or more of the at least one corresponding protrusion and the at least one corresponding recess in the leak-proof seal.

At least one embodiment of the invention includes forming the container with a width proximate the leak-proof seal that is greater than the relative width of the container distal the leak-proof seal. In one or more embodiments, the leak-proof seal includes a first side and a second side that engage each other. In at least one embodiment, the first side comprises a different average thickness than the second side. In one or more embodiments, the first side is made of a different material than the second side. In at least one embodiment, the first side comprises a different hardness value than the second side.

By one or more embodiments, the leak-proof seal is made of a different material than the remainder of the container that does not include the leak-proof seal. In at least one embodiment of the present invention, the leak-proof seal comprises a different durometer value than the remainder of the container that does not comprise the leak-proof seal.

One or more embodiments of the present invention include forming the elastomer into a container having a hardness of between 70 and 80 shore a durometer. At least one embodiment of the invention includes forming the elastomer into a container having a hardness between 40 and 90 or at least less than or equal to 100 as measured on a shore a durometer.

In one or more embodiments of the invention, forming the container includes forming a leak-proof seal at opposing edges of the container, the opposing edges being at least as thick as the leak-proof seal between the opposing edges. By at least one embodiment, forming the elastomer into the container includes transfer molding, plastic injection molding, liquid injection molding, or compression molding.

One or more embodiments include utilizing an uncured, heat curable elastomer, wherein forming the elastomer into the container includes heat curing the container.

At least one embodiment of the present invention includes forming the container in one molding step without attaching any material to the container after molding. In other embodiments, multiple components may be formed and then joined together and the container inverted. One example would be to form the top and bottom shells separately, each defining a portion of the volume that creates the inside portion of the container, then join them together and then invert the container from the inside out. This requires an additional step of coupling the components together, for example via gluing, wherein the top and bottom shells are coupled together in one step with the same material when they are formed simultaneously in a mould. The container still has two parts designated as top and bottom shells, which in this example refer to the sides of the container only. Thus, "coupled to" covers a container made of two separate parts or two parts that are formed simultaneously and coupled within a mold (i.e., during the molding process).

In one or more embodiments, coupling the leak-proof seal includes gluing, bonding, or attaching the leak-proof seal to the container by co-molding the container and the leak-proof seal together or by overmolding the container to the leak-proof seal or by overmolding the leak-proof seal to the container.

At least one embodiment of the invention includes forming the leak-proof seal without bonding or gluing opposite sides of the leak-proof seal at opposite ends of the leak-proof seal, i.e., such that there is a gap between one side of the seal and the other side at the ends, wherein, when inverted from inside to outside, the two sealing portions eliminate the gap to provide the leak-proof seal. One or more embodiments of the present invention include forming a bottom on the container so that the container can stand upright.

At least one embodiment of the invention includes forming the container to have a thickness of 0.6mm, which increases to 1.8mm at opposite sides of the leak-proof seal at opposite ends of the container.

One or more embodiments of the present invention include forming the container to have a thickness between 0.3mm and 0.9mm, increasing to 1.2mm to 2.4mm on opposite sides of the leak-proof seal at opposite ends of the container.

Drawings

The above and other aspects, features and advantages of at least one embodiment of the present invention will become more apparent from the following more particular description, given in conjunction with the following drawings, in which:

FIG. 1 illustrates an exemplary flow chart of a method of manufacturing a container having a leak-proof seal.

Fig. 2 shows a perspective view of a container with a leak-proof seal formed on the outside from the inside out.

Figure 3 shows a cross-sectional view of the left side of the container from the inside out.

Figure 4 shows a front view of a container formed from the inside out.

Figure 5 shows a rear view of the container formed from the inside out.

Figure 6 shows a side view of a container formed from the inside out.

Figure 7 shows a top view of a container formed from the inside out.

Figure 8 shows a bottom view of the container formed from the inside out.

FIG. 9 shows a perspective view of an end of a leak proof seal.

FIG. 10 shows a side view of a first side of a leak proof seal.

FIG. 11 shows a side view of a second side of the leak-proof seal.

FIG. 12 illustrates a gap between the first and second sides of the leak-proof seal and a gap seal on the first and second sides of the leak-proof seal.

Figure 13 shows a cross-sectional view of the container, i.e. the inner surface of the container before inversion, showing the recess located on the outside of the container after inversion of the container. The grooves add rigidity to the container and allow the container to stand upright.

Fig. 14 shows a front view of the container after inversion.

FIG. 15 illustrates an exemplary winding or serpentine path calculation for an embodiment of a seal.

Fig. 16A shows an alternative embodiment of a sealing profile with a gap on the outside of the container, so that the container is easier to open from the outside than from the inside.

FIG. 16B illustrates a second alternative embodiment of a sealing profile with a gap.

Detailed Description

The following description is of the best mode presently contemplated for carrying out at least one embodiment of the present invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of describing the general principles of the invention. The scope of the invention should be determined with reference to the claims.

Fig. 1 shows an exemplary flow diagram of a method of manufacturing a container with a leak-proof seal from inside out according to one or more embodiments of the invention, and fig. 2 shows a perspective view of the container after manufacture and before inversion of the container, i.e., before being configured for use as a container with a leak-proof seal, according to one or more embodiments of the invention. Embodiments of the present invention generally relate to a method of manufacturing a container 200 having a leak-proof seal 203, the method including (step 101) forming an elastomer or plastic or thermoplastic elastomer, e.g., from inside to outside, into the container 200, the thermoplastic elastomer being a plastic that may behave in some way like an elastomer depending on its particular characteristics or any combination thereof. In at least one embodiment, the method includes (step 102) forming an outer portion 201 of the container 200 on an inner surface 211 of the container 200 prior to inverting the container 200, and (step 103) forming an inner portion 202 of the container 200 on an outer surface 212 of the container 200 prior to inverting the container 200. By at least one embodiment, the method includes (step 104) forming or coupling a leak-proof seal 203 on an exterior surface 212 of the container prior to inverting the container. In at least one embodiment, the leak-proof seal 203 provides access to the inside portion 202 of the container 200 when the leak-proof seal 203 is open after inverting the container 200, and the leak-proof seal 203 at least retains the liquid and/or other substances inside the container 200 when the container is sealed when an external force is applied to the container 200 without the use of an external structure to keep the leak-proof seal 203 closed after inverting the container 200. Part of the manufacturing process may optionally include (step 105) inverting the outer surface of the container and the leak-proof seal with the inner surface of the container. In other embodiments, the container may be delivered from the inside out where the end user or customer inverts the container. In one or more embodiments, a portion of the manufacturing process can optionally include forming a gap on an outer surface between a first side of the leak-proof seal and a second side of the leak-proof seal that engage one another after inverting the container, and wherein the gap provides (step 106) an abutment that each end of the first side and the second side of the leak-proof seal contact. By at least one embodiment, the leak-proof seal 206 provides access to the inside portion of the container 200 and allows the container 200 to hold at least liquid inside for storage, such as during transport, with a liquid-tight seal.

Fig. 13 shows a cross-sectional view, in particular an upper perspective cross-sectional view, of the inner surface of the container before inversion according to one or more embodiments of the invention, and fig. 14 shows a front view of the container after inversion according to one or more embodiments of the invention. As shown in fig. 13, the container 200 may include a tab 440 and a groove 350 on the inner surface 211, i.e., the inner surface 211 becomes the outer portion 201 of the container after the container is inverted.

As shown in FIG. 14, one or more embodiments of the present invention include inverting the outer surface 212 of the container 200 and the leak-proof seal 203 (not shown in FIG. 14) with the inner surface 211 of the container 200 such that the inner portion 202 of the container and the leak-proof seal 203 are located inside the container 200 and the outer portion 201 of the container is located outside the container 200 to form a container 1400 that is ready for use. In one or more embodiments, as shown in fig. 14, the tab 440 and groove 350 are shown on the outer portion 201 when the container 200 is inverted. In one or more embodiments, the shells shown in fig. 13 and 14 may be formed separately and coupled to each other by gluing, or coupled to each other while forming the shells, i.e., in a mold. In any case, the container as a whole has two shell portions defining an internal volume, whether specifying only a single container when formed simultaneously (i.e., coupled to one another during molding) or when formed separately and then coupled to one another (i.e., via adhesion). These parts may be formed as shown in fig. 13 and 14 or in any other way, for example, at least two parts may be made in the cross-sectional plane shown in fig. 3, with a mirror image part on the other side of the plane, and then, for example, the at least two parts are glued.

Fig. 3 shows a cross-sectional view of the left side of the container before inverting the container in accordance with one or more embodiments of the invention. As shown in FIG. 3, in at least one embodiment, the container 200 includes a leak-proof seal 203 having a first side 204 and a second side 205. One or more embodiments of the present invention include forming a base 330, such as a rim or foot, on the container 200 so that the container 200 can stand upright. As such, in at least one embodiment, the base 330 projects or faces outwardly from the container 200 when the container 200 is inverted, and after inversion, the base 330 projects or faces inwardly toward the container 200 and into the container 200. According to one or more embodiments, the edges of the leak-proof seal 203 on both edges of the container 200 project or face outwardly from the container 200 before the container 200 is inverted, and the edges of the leak-proof seal 203 project or face inwardly toward each other in the interior portion of the container 200 after inversion.

By one or more embodiments, the groove 350 of the container 200 can terminate at a predetermined distance from the top edge of the container 200, where the top edge is opposite the top edge of the bottom 330. For example, in at least one embodiment, the predetermined distance may be 15mm, less than 15mm, or greater than 15 mm. In accordance with one or more embodiments of the present invention, the groove 350 terminates at a predetermined distance from the top edge of the container 200 so as to avoid interference when the container 200 is inverted along the edge to form a seal with the leak-proof seal 203.

In one or more embodiments, the leak-proof seal 203 includes a first side 204 and a second side 205 that engage each other. In at least one embodiment, the first side 204 can comprise a different average thickness than the second side 205. In one or more embodiments, the first side 204 can be made of a different material than the second side 205. In at least one embodiment, first side 204 may comprise a different hardness value than second side 205.

By one or more embodiments, the leak-proof seal 203 can be made of a different material than the remainder of the container 200 that does not include the leak-proof seal 203. In at least one embodiment of the present invention, the leak-proof seal 203 may comprise a different durometer value than the remainder of the container 200 that does not comprise the leak-proof seal 203.

One or more embodiments of the present invention include forming the elastomer into a container 200 having a hardness between 70 and 80 as measured on a shore a durometer. At least one embodiment of the present invention includes forming the elastomer into a container 200 having a hardness of between 40 and 90 or in any case less than 100 as measured on a shore a durometer.

Fig. 4 shows a front view of a container before inversion according to one or more embodiments of the invention, and fig. 5 shows a back view of a container before inversion according to one or more embodiments of the invention.

At least one embodiment of the present invention includes forming the container 200 with a width that is greater proximate the leak resistant seal 203 than an opposite width that is distal from the leak resistant seal 203. In at least one embodiment of the present invention, the container 200 can include tabs 440, wherein the tabs 440 can include tab sides on each side of the container 200 and each side of the leak-proof seal 203.

In one or more embodiments of the invention, forming the container 200 includes forming the leak-proof seal 203 at opposing edges 550, 560 of the container 200, the opposing edges 550, 560 being at least as thick as the leak-proof seal 203 therebetween. By at least one embodiment, forming the elastomer into the container 200 includes liquid injection molding, plastic injection molding, or compression molding. One or more embodiments may include forming the container by utilizing a thermoplastic elastomer, wherein forming the container includes melting the elastomer and injection molding the material.

One or more embodiments include utilizing an uncured, heat curable elastomer, wherein forming the elastomer into the container 200 includes heat curing the container 200.

At least one embodiment of the present invention includes forming the container 200 in one molding step without attaching any material to the container 200 after molding. This provides an extremely fast method of manufacturing a leak-proof seal for storage and transport that does not require external structures or clamps to hold the seal together.

In one or more embodiments, coupling the leak-proof seal 203 includes one or more of gluing, bonding, and attaching the leak-proof seal 203 to the container 200 by co-molding the container 200 and the leak-proof seal 203 together or by overmolding the container 200 to the leak-proof seal 203 or by overmolding the leak-proof seal 203 to the container 200. This enables the use of different types of materials in the manufacture of the container, but requires more steps than the one-step method described herein.

At least one embodiment of the present invention includes forming the containment seal 203 at opposite ends of the containment seal 203, such as at ends 620 and 621, without bonding or gluing the opposite sides 204, 205 of the containment seal 203.

Fig. 6 shows a side view of a container before inversion according to one or more embodiments of the invention. In at least one embodiment of the present invention, forming the inside portion 202 of the container 200 on the outer surface 212 of the container 200 comprises: a gap 206 is formed on the outer surface 212 between the first side 204 of the leak-proof seal 203 and the second side 205 of the leak-proof seal 203, the first side 204 and the second side 205 engaging each other after inverting the container 200. In at least one embodiment, the gap 206 may be a flat area between the first side 204 and the second side 205. In one or more embodiments, the gap 206 provides an abutment against which each of the first side 204 and the second side 205 of the leak-proof seal 203 contact to prevent the leak-proof seal 203 from leaking when an external force is applied to the container 200. In one or more embodiments, the gap 206 is less than or equal to the thickness of the leak-proof seal 203. In this embodiment, the sealing portion on the end compresses and the relatively small gap elastically stretches and provides a force to hold the seal together at the end.

With at least one embodiment of the present invention, each end of the first side 204 and the second side 205 of the gap 206 or the leak seal 203 includes at least one gap seal 610, wherein the at least one gap seal 610 is an outwardly projecting protrusion, such as a raised rib. For example, in at least one embodiment of the present invention, the gap seal 610 protrudes from the gap 206 as shown in FIG. 6, or from each of the first side 204 and the second side 205 of the leak-proof seal 203 as shown in FIG. 12. According to at least one embodiment, the gap seal 610 is a protruding surface that creates a tight seal by contacting the inner surface of the flat edge of the gap 206 after the container 200 is inverted. This embodiment provides additional strength to the seal at the end, increasing the length of the path any liquid must travel to escape from the container, to provide, for example, more leak resistance.

By way of at least one example, each end of the first side 204 and the second side 205 may include a gap seal, or an end of one of the first side 204 and the second side 205 may include a gap seal, or the gap 206 may include a gap seal, or any combination thereof.

In one or more embodiments of the invention, forming or coupling the leak-proof seal 203 includes utilizing a leak-proof seal 203 having a first sealing portion 620 and a second sealing portion 621, the first sealing portion 620 and the second sealing portion 621 being coupled to one another along a boundary to seal the container 200 and being separated from one another along the boundary to open the container 200. In at least one embodiment, the boundary is a line defining an area between the first sealing portion 620 and the second sealing portion 621 that allows the first sealing portion 620 to contact or mate or couple or engage the second sealing portion 621.

According to one or more embodiments of the invention, the boundary defines a path of contact or coupling or mating or engagement between the first sealing portion 620 and the second sealing portion 621 that is at least 2 times the horizontal distance between the start of the path and the end of the path. In one or more embodiments, the path is at least 2.5 times the horizontal distance between the start of the path and the end of the path, or at least 3 times the horizontal distance between the start of the path and the end of the path, or at least 5 times the horizontal distance between the start of the path and the end of the path, as described below.

Fig. 15 shows an exemplary embodiment of the winding path of the seal with the leftmost horizontal length of the seal portion in contact with the corresponding portion on the other half of the seal. In this case, the length is 1.0. (the lengths shown are relative to each other only; they are not expressed in any particular unit.) in the embodiment shown, the total length 1503 of the winding boundary path is 17.5. The horizontal distance 1501 between the start and end points of the path is 7.0. Thus, the path length is approximately 2.5 times the horizontal distance. The ratio of path length to horizontal distance is a quantification of the degree to which the boundary path wraps and changes direction, which contributes to sealing force and leakage resistance. Some embodiments of the invention have a boundary path length of at least twice the horizontal distance between the start and end points of the path, e.g. if the horizontal part of the contact area is larger or if the ridge on the seal is shorter, etc. For example, other embodiments may have a path length that is at least 3 times, or at least 4 times, or at least 5 times the horizontal distance between the start and end points of the path. Other metrics for measuring the seal may include measuring the path of the boundary of the seal, starting from the point where the seal diverges from its base or its flat portion along the path of contact between each side of the seal, and returning to a point near the original starting point on the flat portion of the seal. This metric for the winding path may yield a ratio of at least 4, 5, 6, 7, 8, 9, or greater than 10. As shown, if only one protrusion is used as the convex portion of the leak-proof seal, for example, if the seal is implemented with only the upper portion of the christmas tree shape as the convex member, the ratio is calculated as a (0.3+0.5+0.3+1.4) × 2 (for both sides, because it is symmetrical) ═ 5.0, and the ratio divided by the width of the base portion is 1.1 to give a ratio of 4.5. If two horizontal ridges are used to calculate the metric, i.e. with the seal shown, but with any type of side of the seal, or no side at all, the ratio is calculated as above, but with the lower part to be added, i.e. B ═ 4.8 (due to approximate symmetry). Thus, the total length of a + B, i.e., the entire "christmas tree" embodiment of the seal, is equal to 9.8. For calculation purposes, the width of the lower portion of the seal that acts as a base is 1.2, which results in a ratio of about 8, as shown. For a given base, the longer the path, the higher the ratio, and generally the higher the leak resistance of the seal.

In at least one embodiment of the present invention, the first sealing portion 620 and the second sealing portion 621 are at least 1mm thick, or at least 2mm thick, or at least 3mm thick. The average thickness of the first and second seal portions is generally less than the maximum thickness. The maximum thickness is easier to measure, for example with a ruler, than the average thickness calculated by determining the volume and dividing by the width.

Fig. 7 shows a top view of the container before inversion according to one or more embodiments of the present invention, and fig. 8 shows a bottom view of the container before inversion according to one or more embodiments of the present invention.

At least one embodiment of the present invention includes forming the container 200 to have a thickness of 0.6mm, which increases to 1.8mm at opposite sides 204, 205 of the leak-proof seal 203 at opposite ends of the container 203 (e.g., at ends 550 and 560).

One or more embodiments of the present invention include forming the container 200 to have a thickness between 0.3mm and 0.9mm, which increases to 1.2mm to 2.4mm at the opposite sides 204, 205 of the leak-proof seal 203 at the opposite ends of the container 200 (e.g., at ends 550 and 560).

FIG. 9 shows a perspective view of an end of a leak-proof seal before being inverted to engage one another in accordance with one or more embodiments of the invention. FIG. 10 shows a side view of a first side of the leak-proof seal prior to being inverted according to one or more embodiments of the invention, and FIG. 11 shows a side view of a second side of the leak-proof seal prior to being inverted according to one or more embodiments of the invention.

As shown in fig. 9, 10, and 11, the leak-proof seal 203 may include a gap seal 610 on the gap 206 and two gap seals 610 on the second sealing portion 621, thereby forming a three-stage seal, according to one or more embodiments of the present invention. In one or more embodiments, a tertiary seal is formed by each of the three gap seals 610, wherein each gap seal 610 contacts and engages a planar surface of the gap 206 such that a three-way seal is formed via each gap seal 610 stacked vertically above another gap seal 610 along the gap 206. In at least one embodiment of the present invention, the first sealing portion 620 and the second sealing portion 621 include at least one corresponding protrusion or recess 940, 950. Each protrusion or recess shown may be a simple bump and groove, or may comprise a wider geometry than another portion of at least one corresponding protrusion or recess 940, 950. This may include ridges or any other shape where the outer portion of the projection remote from the surface on which the projection is located is larger than the corresponding entrance to the recess. Therefore, the large convex sealing portion 620 and the concave sealing portion 621 can be manufactured with a small scale as the gap sealing member, if necessary.

In one or more embodiments of the invention, the gap 206 includes a gap seal 610 on a flat portion of the gap 206, and the first sealing portion 620 includes a corresponding depression that folds over the gap seal 610 of the gap 206 and fits into the gap seal 610 of the gap 206 when the container 200 is inverted.

In at least one embodiment of the invention, the geometry of at least one protrusion and/or depression may be shaped as a "christmas tree" and/or a double-headed arrow having a different width at each head and/or a protrusion or depression having a plurality of ridges projecting outwardly.

In one or more embodiments of the invention, utilizing the leak-proof seal 203 includes utilizing a protrusion or depression 940, 950 having a height of at least 2mm and utilizing a geometry having a width that is at least 1mm thicker than the protrusion or depression 940, 950.

By way of at least one embodiment, utilizing the leak-proof seal 203 includes utilizing a protrusion or depression 940, 950 having a height of at least 2mm and utilizing a geometry having a width that is at least 2mm thicker than the protrusion or depression 940, 950.

In accordance with one or more embodiments, utilizing the leak-proof seal 203 includes utilizing two or more of the at least one corresponding protrusion 940 and the at least one corresponding recess 950 in the leak-proof seal 203.

FIG. 12 illustrates gap seals on first and second sides of a leak-proof seal prior to being inverted, according to one or more embodiments of the invention. As shown in fig. 12, by at least one embodiment, the gap 206 may not include a gap seal. In one or more embodiments, the side 204 and the second side 205 of the leak-proof seal 203 (e.g., at the first sealing portion 620 and at the second sealing portion 621) can each include at least one gap seal 610, and the second sealing portion 620 includes one gap seal 610 and the first sealing portion 610 includes two gap seals 610. As such, in one or more embodiments, when the container 200 is inverted, the gap seal 610 shown in fig. 12 folds to contact the gap 206 at the center of the first sealing portion 620 and the second sealing portion 621 and thus create a tertiary seal, wherein the gap 206 is thicker than the rest of the exterior of the container 200. By way of at least one embodiment, when the first sealing portion 620 and the second sealing portion 621 are folded to invert the container 200, the thicker portion of the gap 206 having the gap seal 610 in contact therewith provides a greater force and is stronger than the remainder of the gap 206, and provides a force to engage the first side 204 and the second side 205.

According to one or more embodiments of the invention, the container 200 includes a wall edge on either side wall of the container 200 including the wall of the gap 206, wherein the wall of the gap 206 is thicker than the edges on either side of the container 200. In at least one embodiment of the invention, the wall thickness of the wall of the gap 206 is thickened and smoothly tapered on both sides of the container 200 away from the wall of the gap 206 to create container sidewalls such that the sidewalls of the container 200 are thinner than the walls of the gap 206 on the two opposing edges 550, 560 of the container 200. In one or more embodiments of the invention, the thicker portion of the container wall, including the walls of the gap 206, includes an additional thickness of material on the inner surface 211 of the container 200, wherein such additional thickness of material creates a clamping force when the container 200 is inverted, thereby promoting and engaging a tight seal in the leak-proof seal 200.

With at least one embodiment of the present invention, the gap 206 or each end of the first side 204 and the second side 205 of the leak-proof seal 203 comprises at least one gap seal 610, wherein the at least one gap seal 610 is a protrusion from the gap 206 as shown in FIG. 6 or a protrusion from each end of the first side 204 and the second side 205 of the leak-proof seal 203 as shown in FIG. 12. By way of at least one example, each end of the first side 204 and the second side 205 may include a gap seal, or an end of one of the first side 204 and the second side 205 may include a gap seal, or the gap 206 may include a gap seal, or any combination thereof.

According to one or more embodiments of the invention, the gap 206 may be thicker than a portion of the container 200 such that when the container 200 is inverted, a compressive force is generated due to stretching of the material at the ends. This is the material thickness when viewing the figure, i.e. the material thickness in the gap region. When this force is applied, it pulls the first sealing portion 610 and the second sealing portion 620 together at each end and both ends of the sealing portions to provide a leak-proof, liquid-tight barrier for storage and transport, i.e., to prevent liquid leakage when external forces are applied to the container, without requiring any external structure to hold the seals together. Additionally, the width of the gap may be less than the height of element 621, for example, to compress elements 620 and 621 together when inverted. The thickness of the material at the gap and/or the width of the gap can be made thicker and narrower, either individually or in combination, to increase the sealing force at the ends of the leak-proof seal.

In at least one embodiment of the present invention, the ends of the leak-proof seal can be thicker than the middle portion of the leak-proof seal such that the edges of the leak-proof seal 206 are thicker than the remainder of the leak-proof seal 206.

Fig. 16A shows an alternative embodiment of a sealing profile with a gap on the outside of the container, where the outside of the container is on the right side of the figure, so that the container is easier to open from the outside than from the inside. FIG. 16B shows a second alternative embodiment of a sealing profile with a gap, e.g., under one or more ridges when the seal is closed. As shown in both figures, the initial contact point 1620 is where the first sealing portion 1601 (e.g., the female component shown primarily) contacts the second sealing portion 1602 (e.g., the male component shown primarily). As the contact path continues inward toward the center of the seal, a gap 1610 occurs where there is no contact between the first seal portion 1601 and the second seal portion 1602. The path terminates at the termination of contact, i.e., when continuing to traverse the sealing surface in one direction, specifically at 1630. In FIG. 16A, the gap 1610 makes the seal shown easier to open on the right than on the left. In fig. 16B, the seal includes four gaps, which makes the seal generally easier to open. One or more of the gaps shown in fig. 16B are optional, so that the design may have a gap there or even above the highest point of element 1602, i.e., a gap in element 1601 (not shown for simplicity).

In one or more embodiments, the leak-proof seal comprises a path comprising a length along a surface of the first seal portion or the second seal portion that is at least 2 times a horizontal distance between a start of the path and an end of the path at which initial contact and final contact occurs between the first seal portion or the second seal portion, respectively, e.g., between points 1620 and 1630, wherein the path comprises a length of a surface of the first seal portion 1601 or the second seal portion 1602. Thus, the gap is still important in the calculation, since the liquid has to pass through the gap, and thus the path is continuous, since some liquid will pass through the longest boundary surface and some liquid will pass through the shortest boundary surface, typically on the female and male sealing members, respectively. In one or more embodiments, the path (i.e., the surface along either (or even both) of the first or second seal portions) is at least 2.5 times the horizontal distance between the start of path 1620 and the end of path 1630. In one or more embodiments, the path begins at the base of the leak-proof seal, i.e., the point of contact moves vertically at 1640, and wherein the path is at least 4.5 times the horizontal distance between the start of the path and the end of the path, i.e., the path moves vertically downward at 1650 relative to the base width of the leak-proof seal, particularly where the leak-proof seal diverges from the flat portion of the leak-proof seal.

Definition of

Elastomer-a material that can be repeatedly stretched at room temperature to at least twice its original length and will return to its original approximate length when the stress is immediately released.

Boundary-the length of the surface of the first seal portion or the second seal portion between the initial contact point and the final contact point between the first seal portion and the second seal portion when the leak-proof seal is closed. In a seal profile without gaps, the boundaries are the same length, whether measured along the surface of element 1601 or 1602. In a seal profile with a gap, the boundary for the calculation of the path is the length of the surface of the first seal portion or the second seal portion, where the recessed portion will typically have a larger boundary in a seal with a gap, where there is no contact between some portions of the seal. In this case, the length of the path may be shown by a larger number or a smaller number. See also fig. 16A-16B.

Leak-proof seal-a seal that prevents leakage of liquids and solids from a container during storage and transportation without the need for external structures to maintain a seal.

Coupling-in case of a single container, the container can be made in an integrated mould, wherein all parts of the container are formed and thus coupled to each other during the moulding process, wherein the coupling material is the container material itself, i.e. an elastomer or a plastic or thermoplastic elastomer. The single container may also be made of components that are formed prior to coupling the components together to form the single container. In either case, a single container has multiple components that are all coupled together, or the components will break.

Corresponding recesses-if the seal has a gap, for example when closed, the shape of the protrusion and recess may be the same shape without a gap in the seal, or may be different shapes. In addition, the protrusion and the depression may have different shapes such that, when closed, there is at least one contact boundary along the length of the seal. In either case, the corresponding depressions for the ridges may have the same shape or different shapes.

It will be apparent to those skilled in the art that many modifications and variations to the examples and embodiments described are possible in light of the above teachings. The disclosed examples and embodiments are presented for purposes of illustration only. Other alternative embodiments may include some or all of the features disclosed herein. Therefore, it is intended to cover all such modifications and alternative embodiments, which may fall within the true scope of the invention.

Claims (30)

1. A method of manufacturing a container having a leak-proof seal from the inside out, the method comprising:

forming an elastomer or plastic or any combination thereof from the inside out into a container by:

forming an outer portion of the container on an inner surface of the container prior to inverting the container;

forming an inside portion of the container on an outer surface of the container prior to inverting the container;

an integrated leak-proof seal configured to open and close the container on the exterior surface of the container, wherein the leak-proof seal comprises a first sealing portion and a second sealing portion and at least one contact boundary along the leak-proof seal, wherein the first sealing portion is configured to couple the second sealing portion to close the container, and wherein the first sealing portion is configured to decouple from the second sealing portion to open the container;

forming the container such that the outer surface of the container and the leak-proof seal can be inverted from the inner surface of the container such that the inside portion of the container and the leak-proof seal are located within the container and the outside portion of the container is located outside the container;

wherein the leak-proof seal is integrated on the outer surface of the container prior to inverting the container, the leak-proof seal:

providing access to the inside portion of the container after inverting the container when the leak-proof seal is open, and at least retaining liquid inside the container when an external force is applied to the container after inverting the container and engaging opposite sides of the leak-proof seal without using an external structure to keep the leak-proof seal closed, wherein the container is closed when the leak-proof seal is closed; wherein forming an inside portion of the container on an outer surface of the container comprises forming a gap on the outer surface between a first side of the leak-proof seal and a second side of the leak-proof seal that engage each other after inverting the container, and wherein the gap provides an abutment for each end of the first and second sides of the leak-proof seal to contact to prevent the leak-proof seal from leaking when an external force is applied to the container.

2. The method of claim 1, wherein forming the container comprises:

forming the container in an integrated mold; or

Two or more components are bonded together.

3. The method of claim 1, wherein a width of the gap is less than or equal to a thickness of the leak-proof seal, or wherein a material thickness at the gap is greater than a material thickness of at least one wall thickness of the container, or wherein the gap couples each side of the leak-proof seal on each side of the gap together.

4. The method of claim 1, wherein each end of the first and second sides of the gap or the leak-proof seal comprises at least one gap seal, and wherein the at least one gap seal is a protrusion protruding from each end of the first and second sides of the gap or the leak-proof seal.

5. The method of claim 1, wherein the first and second seal portions are at least 1mm thick.

6. The method of claim 5, wherein the first and second seal portions are at least 2mm thick.

7. The method of claim 5, wherein the first and second seal portions are at least 3mm thick.

8. The method of claim 1, wherein the leak-proof seal comprises a path comprising a length along a surface of the first seal portion or the second seal portion that is at least 2 times a horizontal distance between a start of the path and an end of the path at which initial contact and final contact between the first seal portion or the second seal portion, respectively, occurs.

9. The method of claim 8, wherein the path is at least 2.5 times a horizontal distance between the start point of the path and the end point of the path.

10. The method of claim 8, wherein the path begins at a base of the leak-proof seal, and wherein the path is at least 4.5 times a horizontal distance between the start point of the path and the end point of the path relative to a base width of the leak-proof seal, wherein the leak-proof seal diverges from a flat portion of the leak-proof seal.

11. The method of claim 1, wherein the first and second sealing portions comprise at least one corresponding protrusion or depression comprising a wider geometric shape than another portion of the at least one corresponding protrusion or depression, and wherein the protrusions or depressions comprise the same shape or different shapes.

12. The method of claim 11, wherein utilizing the leak-proof seal comprises utilizing the protrusion or the depression having a height of at least 2mm and utilizing the geometry having a width that is at least 1mm thicker than the protrusion or the depression.

13. The method of claim 11, wherein utilizing the leak-proof seal comprises utilizing the protrusion or the depression having a height of at least 2mm and utilizing the geometry having a width that is at least 2mm thicker than the protrusion or the depression.

14. The method of claim 11, wherein utilizing the leak-proof seal comprises utilizing two or more of the at least one corresponding protrusion and the at least one corresponding recess in the leak-proof seal.

15. The method of claim 1, further comprising forming the container with a width of the container proximate the leak-proof seal that is greater than an opposite width of the container away from the leak-proof seal.

16. The method of claim 1, wherein the leak-proof seal comprises a first side and a second side joined to each other, and wherein the first side comprises a different average thickness than the second side, or wherein the first side comprises a different material than the second side, or wherein the first side comprises a different hardness value than the second side.

17. The method of claim 1, wherein the leak-proof seal comprises a different material than a remainder of the container that does not comprise the leak-proof seal, or wherein the leak-proof seal comprises a different hardness value than a remainder of the container that does not comprise the leak-proof seal.

18. The method of claim 1, further comprising forming the elastomer into the container having a hardness between 70 and 80 on the shore a durometer scale.

19. The method of claim 1, further comprising forming the elastomer into the container having a hardness between 40 and 90 on the shore a durometer.

20. The method of claim 1, wherein forming the container comprises forming the leak-proof seal at opposing edges of the container that are at least as thick as the leak-proof seal between the opposing edges.

21. The method of claim 1, wherein forming the elastomer into the container comprises liquid injection molding, plastic injection molding, transfer molding, or compression molding.

22. The method of claim 1, further comprising utilizing an uncured, heat curable elastomer, and wherein forming the elastomer into the container comprises heat curing the container.

23. The method of claim 1, further comprising forming the container in one forming step without attaching any material to the container after the forming.

24. The method of claim 1, wherein integrating the leak-proof seal comprises gluing, bonding, or attaching the leak-proof seal to the container by co-molding the container and the leak-proof seal together or by overmolding the container to the leak-proof seal or by overmolding the leak-proof seal to the container to couple the leak-proof seal.

25. The method of claim 1, further comprising forming the leak-proof seal without bonding or gluing opposite sides of the leak-proof seal at opposite ends of the leak-proof seal.

26. The method of claim 1, further comprising forming a bottom on the container or forming a groove on the container, or both, such that the container is configured to stand upright.

27. The method of claim 1, further comprising forming the container to have a thickness of 0.6mm, the thickness increasing to 1.8mm on opposite sides of the leak-proof seal at opposite ends of the container.

28. The method of claim 1, further comprising forming the container to have a thickness between 0.3mm and 0.9mm, the thickness increasing to 1.2mm to 2.4mm on opposite sides of the leak-proof seal at opposite ends of the container.

29. The method of claim 1, wherein integrating the leak-proof seal comprises integrating a leak-proof seal with the container, wherein the leak-proof seal has a thickness or average thickness of 0.25cm or greater over any portion of the first seal portion and the second seal portion that is in contact when the leak-proof seal is closed.

30. The method of claim 1, wherein integrating the leak-proof seal comprises integrating a leak-proof seal comprising at least one gap between two contact boundaries selected from the at least one contact boundary within the leak-proof seal.