Container with reinforced bottom

Abstract

A method of fabricating a container is provided. The container includes multiple sidewalls extending in a substantially vertical direction and a bottom wall. The bottom wall includes a central portion, a first curved portion and a second curved portion. The first curved portion includes a first radius of curvature with a first center of curvature located on a first side of the bottom wall of the container, while the second curved portion terminates at the sidewalls and include a second radius of curvature with a second center of curvature located on a second side of the bottom wall of the container. The container further includes multiple reinforcing ribs located on the second side, each of the reinforcing ribs having a minimum height proximate the first curved portion and a maximum height proximate the second curved portion.

What is claimed is: 
     
         1 . A method of fabricating a container, comprising:
 providing a mold for the container, the container comprising:
 a plurality of sidewalls extending in a substantially vertical direction, the plurality of sidewalls terminating at a bottom plane; 
 a bottom wall comprising: 
 a central region; 
 a first curved portion having a first radius of curvature with a first center of curvature located on a first side of the bottom wall; and 
 a second curved portion terminating at the plurality of sidewalls, the second curved portion having a second radius of curvature with a second center of curvature located on a second side of the bottom wall opposite the first side; and 
 a plurality of reinforcing ribs located on the second side of the bottom wall, each of the plurality of reinforcing ribs having a minimum height proximate the first curved portion and a maximum height proximate the second curved portion, one of the plurality of reinforcing ribs having a bottom surface that is substantially coplanar with an outer surrounding portion of the central region and separated from the bottom plane; 
   injecting the mold with a molten material; and   upon expiration of a cooling period, removing the container from the mold.   
     
     
         2 . The method of  claim 1 , wherein the molten material is polypropylene resin. 
     
     
         3 . The method of  claim 1 , further comprising:
 inserting an in-mold label into the mold.   
     
     
         4 . The method of  claim 3 , further comprising:
 retaining the in-mold label in the mold using a static charge, a vacuum, or compressed air.   
     
     
         5 . The method of  claim 3 , wherein the in-mold label is fabricated from polypropylene foil. 
     
     
         6 . A method of fabricating a container, comprising:
 providing a mold for the container, the container comprising:
 a plurality of sidewalls extending in a substantially vertical direction, the plurality of sidewalls terminating at a bottom plane; 
 a bottom wall comprising: 
 a substantially flat region; a 
 a sloped region comprising a first curved portion defining an upward slope and a second curved portion defining a downward slope, the second curved portion merging with the plurality of sidewalls such that an intersection of the second curved portion and the plurality of sidewalls is substantially perpendicular; and 
   a plurality of reinforcing ribs disposed beneath the sloped region, one of the plurality of reinforcing ribs having a bottom surface that is substantially coplanar with an outer surrounding portion of the substantially flat region and separated from the bottom plane;
 injecting the mold with a molten material; and 
 upon expiration of a cooling period, removing the container from the mold. 
   
     
     
         7 . The method of  claim 6 , wherein the molten material is polypropylene resin. 
     
     
         8 . The method of  claim 6 , further comprising:
 inserting an in-mold label into the mold.   
     
     
         9 . The method of  claim 8 , further comprising:
 retaining the in-mold label in the mold using a static charge, a vacuum, or compressed air.   
     
     
         10 . The method of  claim 8 , wherein the in-mold label is fabricated from polypropylene foil. 
     
     
         11 . A method of fabricating a container, comprising:
 providing a mold for the container, the container comprising:
 a sidewall extending in a substantially vertical direction, the sidewall terminating at a bottom plane; 
 a bottom wall comprising:
 a first curved portion having a first radius of curvature with a first center of curvature located on a first side of the bottom wall; and 
 a second curved portion terminating at the sidewall, the second curved portion having a second radius of curvature with a second center of curvature located on a second side of the bottom wall opposite the first side; and 
 a reinforcing rib located on the second side of the bottom wall, the reinforcing rib having a bottom surface that is substantially coplanar with an outer surrounding portion of the bottom wall and separated from the bottom plane, 
 
 wherein the first radius of curvature is greater than the second radius of curvature; 
   injecting the mold with a molten material; and   upon expiration of a cooling period, removing the container from the mold.   
     
     
         12 . The method of  claim 11 , wherein the molten material is polypropylene resin. 
     
     
         13 . The method of  claim 11 , further comprising:
 inserting an in-mold label into the mold.   
     
     
         14 . The method of  claim 13 , further comprising:
 retaining the in-mold label in the mold using a static charge, a vacuum, or compressed air.   
     
     
         15 . The method of  claim 13 , wherein the in-mold label is fabricated from polypropylene foil.