Abstract:
A container including a shoulder portion terminating at an opening and a sidewall portion extending from the shoulder portion to a base portion. The base portion closes off an end of the container. The shoulder portion, the sidewall portion and the base portion cooperate to define a receptacle chamber within the container into which product can be filled. A barrier layer extends continuously along the base portion, the sidewall portion, and the shoulder portion to the opening and is made of a polymer based material.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Application No. 61/467,433, filed on Mar. 25, 2011. The entire disclosure of the above application is incorporated herein by reference. 
    
    
     FIELD 
     This disclosure generally relates to containers for retaining a commodity, such as a solid or liquid commodity. More specifically, this disclosure relates to a heat-set, polyethylene terephthalate (PET) container having a cost-effective barrier system for blow-trim applications capable of providing high reuse levels of in-plant regrind and improved container recyclability. 
     BACKGROUND 
     This section provides background information related to the present disclosure which is not necessarily prior art. 
     As a result of environmental and other concerns, plastic containers, more specifically polyester and even more specifically polyethylene terephthalate (PET) containers are now being used more than ever to package numerous commodities previously supplied in glass containers. Manufacturers and fillers, as well as consumers, have recognized that PET containers are lightweight, inexpensive, recyclable and manufacturable in large quantities. 
     Blow-molded plastic containers have become commonplace in packaging numerous commodities. PET is a crystallizable polymer, meaning that it is available in an amorphous form or a semi-crystalline form. The ability of a PET container to maintain its material integrity relates to the percentage of the PET container in crystalline form, also known as the “crystallinity” of the PET container. The following equation defines the percentage of crystallinity as a volume fraction: 
               %   ⁢           ⁢   Crystallinity     =       (       ρ   -     ρ   a           ρ   c     -     ρ   a         )     ×   100           
where ρ is the density of the PET material; ρ a  is the density of pure amorphous PET material (1.333 g/cc); and ρ c  is the density of pure crystalline material (1.455 g/cc).
 
     Container manufacturers use mechanical processing and thermal processing to increase the PET polymer crystallinity of a container. Mechanical processing involves orienting the amorphous material to achieve strain hardening. This processing commonly involves stretching an injection molded PET preform along a longitudinal axis and expanding the PET preform along a transverse or radial axis to form a PET container. The combination promotes what manufacturers define as biaxial orientation of the molecular structure in the container. Manufacturers of PET containers currently use mechanical processing to produce PET containers having approximately 20% crystallinity in the container&#39;s sidewall. 
     Thermal processing involves heating the material (either amorphous or semi-crystalline) to promote crystal growth. On amorphous material, thermal processing of PET material results in a spherulitic morphology that interferes with the transmission of light. In other words, the resulting crystalline material is opaque, and thus, generally undesirable. Used after mechanical processing, however, thermal processing results in higher crystallinity and excellent clarity for those portions of the container having biaxial molecular orientation. The thermal processing of an oriented PET container, which is known as heat setting, typically includes blow molding a PET preform against a mold heated to a temperature of approximately 250° F.-350° F. (approximately 121° C.-177° C.), and holding the blown container against the heated mold for approximately two (2) to five (5) seconds. Manufacturers of PET juice bottles, which must be hot-filled at approximately 185° F. (85° C.), currently use heat setting to produce PET bottles having an overall crystallinity in the range of approximately 25%-35%. 
     Unfortunately, PET is a poor barrier to oxygen. One of the main factors that limit the shelf life of foods and beverages (herein known as “fills”) in PET containers is the ingress of oxygen through the walls of the container followed by oxidation of the fill. Many strategies have been employed to reduce the amount of oxygen in contact with food in PET containers. Some strategies include using package barrier coatings, such as chemical vapor deposited (CVD) aluminum oxide or silicon oxide. Still further, some strategies include the use of PET barrier additives that create physical barriers to oxygen diffusion through the packaging (e.g., nylon, nanoclays). However, these barrier additives may include a monolayer barrier blend that is incorporated into the entire preform resulting in scrap material, such as from a removed dome or moil portion, having high levels of barrier material. This scrap material having high levels of barrier material is incapable of being reused effectively in the plant to manufacture subsequent containers. That is, the high levels of barrier material in the strap material is generally non-conducive to in-plant recycling, thereby leading to excessive material waste and increased manufacturing costs. 
     In some applications, embedded barrier layers have been incorporated in a multilayer construction of the container to overcome penetration of oxygen into the container. However, such embedded barrier layers can often delaminate if the container is trimmed or otherwise cut improperly. That is, in some cases of container manufacturer, additional portions of the container are created that must be removed prior to final construction along a cut interface. These additional portions may include a dome section and/or moil portion. In some cases, manufacturers have only continued the embedded barrier layer to a position below the intended cut interface, thereby preventing the cut interface from exposing the laminated, multilayer configuration. With this option, it is difficult to control the barrier layer to ensure adequate barrier coverage (that is, that the embedded barrier layer does not stop too short from the finish of the container thereby exposing the contents to oxygen) while also preventing delamination caused by trimming through the multiple layers. In some applications, attempts have been made to heat and curl the finish of the container after trimming to prevent delamination. However, such technique adds additional manufacturing steps and required equipment, thereby increasing costs and time. 
     SUMMARY 
     This section provides a general summary of the disclosure, and is not a comprehensive disclosure of its full scope or all of its features. 
     According to the principles of the present teachings, a container is provided having a shoulder portion terminating at an opening and a sidewall portion extending from the shoulder portion to a base portion. The base portion closes off an end of the container. The shoulder portion, the sidewall portion and the base portion cooperate to define a receptacle chamber within the container into which product can be filled. A barrier layer extends continuously along the base portion, the sidewall portion, and the shoulder portion to the opening and is made of a polymer based material. 
     According to the principles of the present teachings, a preform for forming a container is provided having a tubular member defining an opening. The tubular member includes a proximal moil-forming section and a distal container-forming section. Barrier material is disposed throughout an entirety of the distal container-forming section and further disposed in a portion of the proximal moil-forming section. 
     According to the principles of the present teachings, a container assembly is provided having a moil section and a container section coupled to the moil section and separable therefrom along a trim plane. The container section includes a shoulder portion, a sidewall portion extending from the shoulder portion to a base portion, wherein the base portion closes off an end of the container section. The shoulder portion, the sidewall portion and the base portion cooperate to define a receptacle chamber into which product can be filled. Barrier material extends continuously throughout the container section and into a portion of the moil section and is made of a polymer based material. 
     Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
    
    
     
       DRAWINGS 
       The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. 
         FIG. 1  is a schematic cross-sectional view of a plastic container and moil constructed in accordance with some embodiments of the present disclosure; and 
         FIG. 2  is a schematic cross-sectional view of a preform constructed in accordance with some embodiments of the present disclosure. 
     
    
    
     Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION 
     Example embodiments will now be described more fully with reference to the accompanying drawings. Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. 
     The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed. 
     When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
     Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
     Spatially relative terms, such as “inner,” “outer,” “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     This disclosure provides for a heat-set, polyethylene terephthalate (PET) container having a cost-effective barrier system for blow-trim applications capable of providing improved layer adhesion, improved oxygen scavenging properties, high reuse levels of in-plant regrind and improved container recyclability. 
     The present disclosure will be discussed in connection with the construction of the preform and the resultant container. It should be understood, however, that the present teachings should not be regarded as being limited to any particular preform or container shape. That is, the present teachings provide utility for a wide range of preform and container configurations, including containers having a flexible, collapsible, or otherwise configured base, sidewalls, and/or shoulder regions effectively absorbing the internal vacuum forces resulting from a hot-fill operation. Therefore, it should be recognized that variations can exist in the present embodiments. 
     As illustrated in  FIG. 1 , the present teachings provide a one-piece plastic, e.g. polyethylene terephthalate (PET), container generally indicated at  10 . The container  10  is substantially elongated when viewed from a side. Those of ordinary skill in the art would appreciate that the following teachings of the present disclosure are applicable to other containers, such as rectangular, triangular, pentagonal, hexagonal, octagonal, polygonal, or square shaped containers, which may have different dimensions and volume capacities. It is also contemplated that other modifications can be made depending on the specific application and environmental requirements. 
     As shown in  FIG. 1 , the one-piece plastic container  10  according to the present teachings defines a body  12 , and includes an upper portion  14  having a cylindrical sidewall forming a finish  20 . Integrally formed with the finish  20  and extending downward therefrom is a shoulder portion  22 . The shoulder portion  22  merges into and provides a transition between the finish  20  and a sidewall portion  24 . The sidewall portion  24  extends downward from the shoulder portion  22  to a base portion  28  having a base  30 . In some embodiments, sidewall portion  24  can extend down and nearly abut base  30 , thereby minimizing the overall area of base portion  28  such that there is not a discernable base portion  28  when container  10  is uprightly-placed on a surface. 
     The exemplary container  10  may also have a neck  23 . The neck  23  may have an extremely short height, that is, becoming a short extension from the finish  20 , or an elongated height, extending between the finish  20  and the shoulder portion  22 . The upper portion  14  can define an opening for filling and dispensing of a commodity stored therein. 
     The finish  20  of the plastic container  10  may include a threaded region having threads, a lower sealing ridge, and a support ring. The threaded region provides a means for attachment of a similarly threaded closure or cap (not illustrated). Alternatives may include other suitable devices that engage the finish  20  of the plastic container  10 , such as a press-fit or snap-fit cap for example. Accordingly, the closure or cap (not illustrated) engages the finish  20  to preferably provide a hermetical seal of the plastic container  10 . The closure or cap (not illustrated) is preferably of a plastic or metal material conventional to the closure industry and suitable for subsequent thermal processing. 
     With continued reference to  FIG. 1 , in some embodiments, plastic container  10  can be formed with a moil portion  50  extending above finish  20 . Moil portion  50  can define a portion of the container  10  to be removed following molding of the preform  100  ( FIG. 2 ). 
     The plastic container  10  has been designed to retain a commodity. The commodity may be in any form such as a solid or semi-solid product. In one example, a commodity may be introduced into the container during a thermal process, typically a hot-fill process. For hot-fill bottling applications, bottlers generally fill the container  10  with a product at an elevated temperature between approximately 155° F. to 205° F. (approximately 68° C. to 96° C.) and seal the container  10  with a closure (not illustrated) before cooling. In addition, the plastic container  10  may be suitable for other high-temperature pasteurization or retort filling processes or other thermal processes as well. In another example, the commodity may be introduced into the container under ambient temperatures. 
     The plastic container  10  of the present disclosure is a blow molded, biaxially oriented container with a unitary construction from multi-layer material. A well-known stretch-molding, heat-setting process for making the one-piece plastic container  10  generally involves the manufacture of a preform  100  of a polyester material, such as polyethylene terephthalate (PET), having a shape well known to those skilled in the art similar to a test-tube with a generally cylindrical cross section. An exemplary method of manufacturing the plastic container  10  will be described in greater detail later. 
     As best seen in  FIG. 2 , the preform  100  can comprise a multi-layer construction including a polymer-based barrier layer  110  generally layered between one or more adjacent layers  112 . It should also be recognized that the polymer-based barrier material can also be blended with the PET material to define a container not having discrete layers. However, for the purpose of this present discussion, the polymer-based barrier will be referred to as a layer member, such as polymer-based barrier layer  110 . 
     In some embodiments according to the present teachings, barrier layer  110  can comprise an oxidizable, polyamide-based material, such as Poliprotect. In some embodiments, barrier layer  110  can comprise an oxidizable, polymeric, oxygen-scavenging material, such as OXYCLEAR®, AMOSORB®, and the like. Barrier layer  110  can be blended with PET to improve layer adhesion between two or more of the barrier layer  110  and the adjacent layer(s)  112 . That is, barrier layer  110  can be made of a blend of PET and an oxidizable, polymeric, oxygen-scavenging material. In some embodiments, the blend can include at least 80% PET and less than or equal to 20% of an oxidizable, polymeric, oxygen-scavenging material. In some embodiments, the blend can include at least 99% PET and up to 1% non-PET active scavenger material by weight. This barrier layer can define about 2% to 3% of the thickness of the sidewall portion  24 . 
     The barrier layer  110  can be disposed in preform  100  such that it extends along preform body  111  from a distal tip  114  of preform  100  and continues toward a proximal end  116  of preform  100 . In some embodiments, barrier layer  110  extends along preform body  111  to a predetermined position  118 . Predetermined position  118 , in some embodiments, is defined by a position closer to proximal end  116  than a trim line  120 . Trim line  120  can be a plane through which the intermediate container is trimmed to size. The material trimmed from the intermediate container proximal from trim line  120 , which is also known as a moil  50  ( FIG. 1 ), represents scrap material. Accordingly, as seen in  FIG. 2 , a portion of preform  100  above trim line  120  may be referred to as a moil-forming section  200  and the portion of preform  100  below trim line  120  may be referred to as a container-forming section  210 . Therefore, it should be appreciated that according to some embodiments of the present teachings, a portion of barrier layer  110  will be contained in the scrap material of the moil-forming section  200 , such as less than 0.5% by weight. Moreover, in some embodiments, barrier layer  110  will extend from distal tip  114  of preform  100  and will extend beyond trim line  120  and will be circumferentially complete thereabout, such that barrier layer  110  extends throughout container-forming section  210  and within a portion of moil-forming section  200 , such as the lowermost 20% by height. 
     As described herein, the barrier layer  110  can comprise any one 01 the following materials or any other desired material. It should be understood that polymer-based barrier materials are better for recycling and reuse than polyamide (nylon) based resin systems. By further using these teachings to limit the amount of barrier material required in the container and scrap material results in a final container with improved recyclability and scrap material that can be reused at higher levels within the plant. 
     
       
         
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
               
                   
               
               
                   
                   
                 Avg. 
                   
                   
                   
               
               
                   
                   
                 mils in 
                   
                 % barrier in 
                 % barrier 
               
               
                   
                 Barrier %/matrix 
                 barrier 
                 % barrier in total 
                 finished 
                 in dome 
               
               
                 Layer % 
                 % in layer 
                 layer 
                 container 
                 container 
                 scrap* 
               
               
                   
               
             
             
               
                 3.8% 
                 16.0% OXYCLEAR ® 
                 0.76 
                 0.61% OXYCLEAR ® 
                 0.74% 
                 ~0.014% 
               
               
                   
                 84.0% 2300K 
                   
                 (balance PET) 
                   
                   
               
               
                 6.0% 
                 12.0% OXYCLEAR ® 
                 1.20 
                 0.72% OXYCLEAR ® 
                 0.88% 
                 ~0.016% 
               
               
                   
                 88.0% 2300K 
                   
                 (balance PET) 
                   
                   
               
               
                 8.2% 
                 8.0% OXYCLEAR ® 
                 1.64 
                 0.66% OXYCLEAR ® 
                 0.80% 
                 ~0.015% 
               
               
                   
                 92.0% 2300K 
                   
                 (balance PET) 
                   
                   
               
               
                 3.8% 
                 100% AMOSORB ® 
                 0.76 
                 3.8% AMOSORB ® 
                 0.46% 
                 ~0.009% 
               
               
                   
                 4020 
                   
                 (0.38% 
                   
                   
               
               
                   
                   
                   
                 polybutadiene, 
                   
                   
               
               
                   
                   
                   
                 balance PET) 
                   
                   
               
               
                 8.2% 
                 100% POLIPROTECT ® 
                 1.64 
                 8.2% PPAPB 
                 0.50% 
                 ~0.009% 
               
               
                   
                 APB 
                   
                 (~0.41% nylon, 
                   
                   
               
               
                   
                   
                   
                 balance PET) 
                   
                   
               
               
                 3.8% 
                 100% AEGIS ® HFX 
                 0.76 
                 3.8% AEGIS ® HFX 
                 4.64% 
                 ~0.087% 
               
               
                   
                   
                   
                 (~0.1% 
                   
                   
               
               
                   
                   
                   
                 polybutadiene, 
                   
                   
               
               
                   
                   
                   
                 ~3.7% nylon-6) 
               
               
                   
               
               
                 *Based on 20% of moil (dome) height for layer height. 
               
             
          
         
       
     
     According to the principles of the present teaching, this arrangement provides several benefits not found in the prior art. Specifically, but not limited to, the present arrangement provides improved barrier performance using less barrier material, because the barrier layer extends throughout the entire container  10 . The materials disclosed herein have been found to provide improved adhesion given better inherent adhesion properties of polymer based scavengers to PET. This arrangement and materials thus provide the ability to trim through the barrier layer  110  without significant delamination. Accordingly, this enables one to minimize the amount of barrier material in the scrap material, thus permitting reuse during in-plant manufacturing. The above will result in improved layer adhesion, oxygen barrier performance, better recyclability, and improved use of in-plant regrind. 
     An exemplary method of forming the container  10  will be described. A preform version  100  of container  10  includes a support ring, which may be used to carry or orient the preform through and at various stages of manufacture. For example, the preform may be carried by the support ring, the support ring may be used to aid in positioning the preform in a mold cavity, or the support ring may be used to carry an intermediate container once molded. At the outset, the preform may be placed into the mold cavity such that the support ring is captured at an upper end of the mold cavity. In general, the mold cavity has an interior surface corresponding to a desired outer profile of the blown container. More specifically, the mold cavity according to the present teachings defines a body forming region, a moil forming region and an optional opening forming region. Once the intermediate container, has been formed, any moil  50  created by the moil forming region may be severed along the trim line  120  and discarded and/or reused according to the principles of the present teachings. 
     In one example, a machine (not illustrated) places the preform heated to a temperature between approximately 190° F. to 250° F. (approximately 88° C. to 121° C.) into the mold cavity. The mold cavity may be heated to a temperature between approximately 250° F. to 350° F. (approximately 121° C. to 177° C.). A stretch rod apparatus (not illustrated) stretches or extends the heated preform within the mold cavity to a length approximately that of the intermediate container thereby molecularly orienting the polyester material in an axial direction generally corresponding with the central longitudinal axis of the container  10 . While the stretch rod extends the preform, air having a pressure between 300 PSI to 600 PSI (2.07 MPa to 4.14 MPa) assists in extending the preform in the axial direction and in expanding the preform in a circumferential or hoop direction thereby substantially conforming the polyester material to the shape of the mold cavity and further molecularly orienting the polyester material in a direction generally perpendicular to the axial direction, thus establishing the biaxial molecular orientation of the polyester material in most of the intermediate container. The pressurized air holds the mostly biaxial molecularly oriented polyester material against the mold cavity for a period of approximately two (2) to five (5) seconds before removal of the intermediate container from the mold cavity. This process is known as heat setting and results in a heat-resistant container suitable for filling with a product at high temperatures. 
     Alternatively, other manufacturing methods, such as for example, extrusion blow molding, one step injection stretch blow molding and injection blow molding, using other conventional materials including, for example, high density polyethylene, polypropylene, polyethylene naphthalate (PEN), a PET/PEN blend or copolymer, and various multilayer structures may be suitable for the manufacture of plastic container  10 . Those having ordinary skill in the art will readily know and understand plastic container manufacturing method alternatives. 
     The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the invention, and all such modifications are intended to be included within the scope of the invention.