Method of forming a double container and related assembly

Abstract

A double container, structure for use in forming a double container, and related method are disclosed. The double container may be formed by connecting first and second open-ended containers in a generally opposed relationship. In the preferred embodiment, pairs of matching projections extend from the end wall of each container. One or both projections on one container may include a melting area or region that is placed in contact with the corresponding projection on the opposite container. Ultrasonic energy is then supplied to melt the melting area or region as the containers are pressed together. Upon solidification, a bond is thus formed between the projections to create the double container. In a second embodiment, an intermediate structure for receiving a second container is attached to the first container, such as by ultrasonic welding.

In the claims:  
     
         1 . An assembly intended for use in forming a double container, comprising: 
 a first open-ended structure including a first projection extending from an outer surface thereof; and    a second open-ended structure including a second, matching projection having at least one area or region adapted for melting formed on, along or adjacent to an outer surface thereof;    wherein at least a portion of the first projection contacts or engages the melting area or region on the second projection when the first and second structures are positioned with the open ends thereof in a generally opposed relationship such that a bond is formed therebetween when the area or region is at least partially melted and solidified.    
     
     
         2 . The assembly according to  claim 1 , wherein the first and second structures are containers.  
     
     
         3 . The assembly according to  claim 1 , wherein the melting area or region is provided on a vertically extending side surface of the first projection, whereby the bond is in the form of a shear joint formed between the first and second projections.  
     
     
         4 . The assembly according to  claim 1 , wherein the first structure is a first container including a pair of first projections and the second structure is a second container including a pair of second projections, wherein the first and second pairs of projections match and align when the containers are positioned in the generally opposed relationship.  
     
     
         5 . The assembly according to  claim 4 , wherein each pair of projections comprises first and second generally parallel ribs projecting from a surface opposite the open end of the corresponding container.  
     
     
         6 . The assembly according to  claim 5 , wherein the projections extend substantially the same distance from the corresponding surface of each container.  
     
     
         7 . The assembly according to  claim 1 , wherein the first structure includes a first seating surface and the second structure includes a second seating surface, wherein the seating surfaces are adapted for making contact with one another when the bond is formed between the first and second projections.  
     
     
         8 . The assembly according to  claim 7 , wherein the first and second seating surfaces surround the first and second projections.  
     
     
         9 . The assembly according to  claim 1 , wherein the first and second structures are blow-molded containers, each including an opening or receiver defined by a threaded neck for receiving a cap or closure.  
     
     
         10 . The assembly according to  claim 1 , wherein the first structure is a container and the second structure is an intermediate structure including a receiver for receiving a portion of the container.  
     
     
         11 . The assembly according to  claim 10 , wherein the receiver is a threaded opening for at least partially receiving a correspondingly threaded neck of the container.  
     
     
         12 . A method of forming an assembly for intended use in forming a double container, comprising: 
 positioning first and second open-ended structures with the open ends thereof in a generally opposed relationship;    at least partially contacting a first projection on the first structure with a melting area or region on the second structure; and    supplying ultrasonic energy to the first projection such that the melting area or region at least partially melts and upon solidification forms a bond between the structures.    
     
     
         13 . The method according to  claim 12 , wherein the second structure includes a second projection on which the melting area or region is formed and the contacting step includes at least partially contacting the first projection with the melting area or region on the second projection.  
     
     
         14 . The method according to  claim 12 , wherein the supplying step includes: 
 inserting an ultrasonic transmitter into the opening of the first structure and into contact with a surface thereof;    supplying ultrasonic energy to the surface in the range of about 10-40 kHz; and    holding the first projection in at least partial contact with the melting area or region for at least 0.2 seconds.    
     
     
         15 . The method according to  claim 14 , further including the step of using a stable support structure for supporting the second structure prior to contacting the first projection with the melting area or region.  
     
     
         16 . The method according to  claim 14 , wherein the first structure is a container, the second structure is an intermediate structure including a receiver, and the method further includes placing a portion of a second container in the receiver to form a double container.  
     
     
         17 . A structure for use in forming a double container assembly for the intended use of holding a first substance and a second related substance in first and second chambers, comprising: 
 a first open-ended body having a first projection extending from an outer surface thereof in a direction generally opposite the open end, the projection including an area or region adapted for melting formed along a side face thereof;    whereby a portion of a second structure may contact the melting area or region such that a bond may be formed therebetween when the area or region is at least partially melted.    
     
     
         18 . The structure for use in forming a double container according to  claim 17 , wherein a second projection including a melting area or region is provided adjacent to the first projection.  
     
     
         19 . The structure for use in forming a double container according to  claim 18 , wherein the first and second projections are oriented generally parallel to each other.  
     
     
         20 . The structure for use in forming a double container according to  claim 17 , wherein the end wall of the body includes an annular projection defining a seating surface adapted for engaging a corresponding portion of the second structure.  
     
     
         21 . The structure for use in forming a double container according to  claim 17 , wherein the open-ended body is a container or includes a receiver for receiving a portion of a container.