Multi-Layer Injection Molded Container

Abstract

A coinjection molded multi-layer container includes an inner layer, an outer layer, and a barrier layer. The inner layer includes a first polymeric material and forms an inside surface of the container. The outer layer includes the first polymeric material and forms an outside surface of the container. The barrier layer is located between the inner layer and the outer layer and includes a second polymeric material less permeable to gas than the first polymeric material. The barrier layer is biased toward the inside surface or the outside surface such that the inner layer and the outer layer have different thicknesses.

What is claimed is: 
     
         1 . A coinjection molded multi-layer container comprising:
 a base;   a side wall extending from the base, the side wall comprising:
 a side wall inner layer comprising a first polymeric material and forming an inside surface of the side wall; 
 a side wall outer layer comprising the first polymeric material and forming an outside surface of the side wall; and 
 a side wall barrier layer located between the side wall inner layer and the side wall outer layer and comprising a second polymeric material less permeable to gas than the first polymeric material; 
   wherein the side wall barrier layer is biased toward the inside surface of the side wall at a first part of the side wall, such that the side wall outer layer is thicker than the side wall inner layer at the first part of the side wall;   wherein the side wall barrier layer is biased toward the outside surface of the side wall at a second part of the side wall, such that the side wall inner layer is thicker than the side wall outer layer at the second part of the side wall; and   wherein the first part of the side wall is located nearer to the base than the second part of the side wall.   
     
     
         2 . The container of  claim 1 , wherein the base further comprises a base inner layer comprising the first polymeric material and forming an inside surface of the base, a base outer layer comprising the first polymeric material and forming an outside surface of the base, and a base barrier layer located between the base inner layer and the base outer layer and comprising the second polymeric material, wherein the base inner layer is integrally formed with the side wall inner layer, wherein the base outer layer is integrally formed with the side wall outer layer, wherein the base barrier layer is integrally formed with the side wall barrier layer, and wherein the base barrier layer is biased toward the inside surface of the base such that the base outer layer is thicker than the base inner layer. 
     
     
         3 . The container of  claim 2 , further comprising a filter comprising a filter base and a filter side wall, the filter side wall welded to the inside surface of the side wall of the container and the filter base spaced apart from the base of the container, such that a gap is defined between the filter base and the base of the container, the gap allowing the base of the container to be punctured when the container is in use without puncturing the filter. 
     
     
         4 . The container of  claim 3 , wherein the base of the container comprises a center point, an inner boundary having a first radius from the center point, an outer boundary having a second radius from the center point, the second radius larger than the first radius, and an annular puncture zone located between the inner boundary and the outer boundary and configured to be punctured when the container is used, wherein the annular puncture zone ensures that the base of the container is punctured at a location within the annular puncture zone regardless of an orientation in which the container is inserted into a machine that punctures the base of the container. 
     
     
         5 . The container of  claim 3 , wherein the inside surface of the side wall of the container further comprises an inwardly protruding energy director ring configured to concentrate a welding force applied to the inside surface of the side wall of the container. 
     
     
         6 . The container of  claim 5 , wherein a portion of the filter side wall is welded to the side wall of the container at a location of the energy director ring. 
     
     
         7 . The container of  claim 1 , further comprising a lower rim coupling the side wall to a perimeter of the base, an upper shoulder coupled to an upper rim of the side wall and extending radially outward from the side wall and away from the base, a flange coupled to the upper shoulder and extending radially outward from the upper shoulder to form a top surface of the container, an outer rim radially offset from the upper shoulder, and a plurality of reinforcing ribs extending radially outward from the upper shoulder to the outer rim along a bottom surface of the flange.