CONTAINER AND METHOD OF MANUFACTURE

A blow molded container is provided. The container includes a neck including a sealing surface and a neck finish. The sealing surface defines at least one vent. In some embodiments, methods of manufacturing containers are disclosed.

TECHNICAL FIELD

The present disclosure generally relates to blow-molded containers and more particularly to plastic containers capable of high fill temperatures and pasteurization, and methods for making the same for food packaging.

BACKGROUND

Plastic blow-molded containers are commonly used for food packaging products. Many food and beverage products are sold to the consuming public in blow-molded containers. These containers can be made from polyethylene terephythalate or other suitable plastic resins in a range of sizes. The empty blow-molded containers can be filled with food and/or beverage products at a fill site utilizing automated fill equipment.

For example, manufacture of such plastic blow-molded containers can include initially forming plastic resin into a preform, which may be provided by injection molding. Typically, the preform includes a mouth and a generally tubular body that terminates in a closed end. Prior to being formed into containers, preforms are softened and transferred into a mold cavity configured in the shape of a selected container. In the mold cavity, the preforms are blow-molded or stretch blow-molded and expanded into the selected container.

These food packaging containers are adapted to store food packaging products, however, during manufacturing and depending on the type of food being store in the container, the container may need to be breathable. This disclosure describes an improvement over these prior technologies.

SUMMARY

In one embodiment, a blow molded container is provided. The container includes a neck including a sealing surface and a neck finish. The sealing surface defines at least one vent. In some embodiments, container systems and methods of manufacturing containers are disclosed.

In one embodiment, the blow molded container includes a neck including a circumferential lip extending from an opening of the neck and being configured to sealing engage a closure. The neck includes a neck finish having at least one gap. The container includes a body defining a volume and having a base. The lip defines at least one vent aligned with the at least one gap in a configuration for passage of a gas from the volume.

In one embodiment, a method for manufacturing a blow molded container is provided. The method comprising the steps of: blow molding a preform having a selected configuration into an intermediate article having a neck and a dome, the neck including a sealing surface having at least one recess and a neck finish; cutting the sealing surface to define an articulating element including the at least one recess; and trimming the intermediate article to remove the dome and the element in a configuration to form a finished container including the sealing surface having at least one vent.

DETAILED DESCRIPTION

The exemplary embodiments of blow-molded containers and more particularly, polyethylene terephythalate (PET) containers and methods for making the same are discussed in terms of food packaging products. In some embodiments, the present container includes a blown-neck finish closure with a molded sealing surface vent for products that require a breathable container.

In some embodiments, the present container has a recess, including a sealing surface vent configured to facilitate gas release from within a sealed container. In some embodiments, the sealing surface vent is molded and trimmed on a two stage blown finish container. In some embodiments, the container is formed from plastic. In some embodiments, the container is vented at the closure. In some embodiments, during manufacture, the amount of plastic employed for manufacture is reduced relative to standard vented injected finishes without a reduction in performance of the container.

In some embodiments, the present container includes a sealing surface vent. In some embodiments, the container includes one or a plurality of sealing surface vents. In some embodiments, the sealing surface vent can include variously configured shapes and/or sizes. In some embodiments, the variously configured shapes and/or sizes include semi-circular and/or sawtooth. In some embodiments, the container includes tamper evidence features and the sealing surface vent includes a sawtooth shape configuration. In some embodiments, the sealing surface vent includes a selected surface area.

In some embodiments, a method for manufacturing the present container is provided. In some embodiments, the method includes the step of blow molding an intermediate container. In some embodiments, the method incudes the step of transferring the intermediate container into a punch trimmer. In some embodiments, the method includes the step of positioning clamping jaws of the punch trimmer in a closed orientation to secure a neck and/or one threads of the intermediate container. In some embodiments, the method includes the step of inserting pneumatic cylinders to insert punches into the intermediate container to form the sealing surface vent. In some embodiments, the punch trimmer includes the pneumatic cylinders. In some embodiments, the method includes the step of retracting the punches via the pneumatic cylinders from the intermediate container. In some embodiments, the method includes the step of positioning the clamping jaws of the punch trimmer in an open position to release the intermediate container onto a conveyer. In some embodiments, the method includes the step of passing the intermediate container through a trimmer where a punched flap and a dome of the intermediate container is removed to form a finished container.

In some embodiments, the present manufacturing method described above includes a container mold, for example, a bottle mold. In some embodiments, the mold includes a recess or a plurality of recesses in the sealing surface of the mold. In some embodiments, the recess or plurality of recesses are oriented to not impede release of the intermediate container from the mold. In some embodiments, the recess or plurality of recesses are oriented in a T-90 direction perpendicular to a parting line of the mold. In some embodiments, the mold includes a dome disposed above the sealing surface. In some embodiments, the dome includes a relief where a vent or a plurality of vents can be punched and/or cut out above the relief in the sealing surface post mold. In some embodiments, the mold includes a snap ring or bead disposed around the neck of the mold. In some embodiments, the snap ring or bead includes reliefs and/or interruptions such that gas can escape easily from the plurality of sealing surface vents of a finished container. In some embodiments, the mold includes threads configured for engagement with a cap. In some embodiments, the threads include reliefs and/or interruptions. In some embodiments, the interruption includes a gap.

In some embodiments, the present manufacturing method includes a punch trimmer configured to form the sealing surface vent within the intermediate container post-molding. In some embodiments, the punch trimmer is configured to cut the vent in a flush configuration with the sealing surface. In some embodiments, the punch trimmer includes clamping jaws. In some embodiments, the clamping jaws are positioned in an open and/or closed orientation. In some embodiments, the clamping jaws include pneumatic punches. In some embodiments, a pneumatic punch is disposed on an inside of each of the jaws. In some embodiments, the clamping jaws are employed to secure the finish of the neck of the intermediate container while the pneumatic punches are inserted into molded recessed locations. In some embodiments, the pneumatic punches are rapidly inserted into the molded recessed locations to form vents. In some embodiments, the clamping jaws are positioned in the open and closed orientation via a programmable logic controller controlled punching machine. In some embodiments, the programmable logic controller receives inputs from a blow molder programmable logic controller and/or receives inputs from one or more sensor inputs. In some embodiments, the punching process is controlled by the programmable logic controller. In some embodiments, the machine controls pneumatic or servo-driven opening and closing of the clamping jaws. In some embodiments, the machine controls pneumatic insertion and retraction of the pneumatic punches.

In some embodiments, the present manufacturing method includes pneumatic punches that cut vents into the sealing surface. In some embodiments, the pneumatic punches cut the vent vertically into the dome on one or more sides of a relief. In some embodiments, the pneumatic punches are inserted into the intermediate container to produce a U-shaped cut. In some embodiments, a plurality of U-shaped cuts are produced. In some embodiments, a top of a U-shaped cut is left uncut and is creased/hinged inwardly by the pneumatic punches. In some embodiments, after the punching process is complete, the punch trimmer is retracted and the clamping jaws securing the neck finish of the intermediate container are positioned in the open orientation to allow the intermediate container to continue to a trimmer device where the dome is removed along with the top of the U-shaped cut that is hinged. In some embodiments, a finished container includes a sealing surface that is on a single plane and a vent that is disposed on a different plane. In some embodiments, the sealing surface vent is recessed within the sealing surface. In some embodiments, the punching process is configured for use with various types of plastic containers produced with a blown neck finish. In some embodiments, the punching process can be employed to produce various types of vent configurations along the sealing surface of a blown finish container.

In some embodiments, the present manufacturing method includes a punching process performed inside of a mold cavity. In some embodiments, a dome relief is cut inside of the mold while the mold is under pressure. In some embodiments, the punching process is a post-mold punching process. In some embodiments, the post-mold punching process is completed after the dome of an intermediate container is removed. In some embodiments, the dome is removed via a male-female punch set. In some embodiments, operating speeds of the punching process varies depending on the rate of production and operates as quickly as needed to form a clean cut without burrs or rough edges.

In some embodiments, the present manufacturing method includes a sealing surface vent and/or dome relief that can have variously configured shapes and/or sizes. In some embodiments, the variously configured shapes include semi-circular and/or sawtooth. In some embodiments, the container includes tamper evidence features and the sealing surface vent includes a sawtooth shape configuration. In some embodiments, the sealing surface vent includes a surface area.

In some embodiments, the present manufacturing method includes the step of machining a mold and/or insert to form an intermediate container that includes a recess or recesses disposed within the sealing surface, a dome relief or reliefs, a thread or threads disposed at a neck including an interruption, and/or a snap ring/bead that includes an interruption. In some embodiments, the present manufacturing method includes the step of operating the clamping jaws via mounting the clamping jaws to a machine frame sub-assembly that is opened and closed via pneumatics, servo or other mechanical devices. In some embodiments, punches of the clamping jaws are mounted to fixed air cylinders such that the punches can extend into the intermediate container and then fully retract. In some embodiments, a sub-assembly is provided that positions the clamping jaws in an open and closed orientation and is mounted to a base frame that includes a programmable logic controller, one or more valves, manual controls, and/or a safety circuit.

In some embodiments, the present manufacturing method includes the step of operating a blow molder to produce the intermediate container. In some embodiments, the present manufacturing method includes the step of automatically conveying the intermediate container into a punching machine where a fully automatic punching process occurs. In some embodiments, the method incudes the step of inserting the intermediate containers into a trimmer. In some embodiments, the trimmer removes a punched flap and a dome flash of the intermediate container. In some embodiments, the present manufacturing method includes a finished container including a sealing surface vent. In some embodiments, the present manufacturing method includes a finished container including a plurality of sealing surface vents.

In some embodiments, the present manufacturing method includes an operating temperature of the preform at 115 degrees Celsius to about 125 degrees Celsius and a blow mold temperature at 130 degrees Celsius to about 140 degrees Celsius. In some embodiments, a sidewall of the present container includes a PET percent crystallinity of 23% to about 32%. In some embodiments, the present container can maintain an initial shape at an elevated pressure of greater than 3 pounds per square inch (psi) and an elevated vacuum of greater than 3 inches of mercury (In Hg).

In some embodiments, the present manufacturing method fabricates the present container via an injection molded preform, which is subjected to a blow mold and trim process. In some embodiments, the present container can be filled with food, food preparation oils, viscous and/or beverage products. In some embodiments, the container is used for storing food including pretzels and/or cheeseballs. In some embodiments, the present container can be employed as a cold fill container. In some embodiments, the present container can be employed as a hot fill container.

In some embodiments, the present disclosure includes a container that is employed with a method for manufacturing food packaging having the ability to produce food packages made from PET with minimal weight and selectively desirable physical performance features, as described herein.

In some embodiments, the present container is manufactured with selective physical performance features, for example, a reduction in plastic weight, a selected pre-form design, selected bottle processing and/or bottle crystallinity of a circumferential side wall of a blown container of the present container. In some embodiments, the selected physical performance features can include a higher injection molding efficiency and/or cavitation and an increased bi-axial orientation of PET container material. In some embodiments, the present container is manufactured with a smaller diameter preform, which forms a final bottle neck finish through the blowing process that allows for higher injection mold efficiency as well as improved material orientation throughout the container. In some embodiments, the container includes a container with an improved material distribution and crystalline orientation. In some embodiments, the manufacturing method provides a container having improved top load, vacuum resistance and/or permeability. In some embodiments, the manufacturing method provides stretching PET to optimum crystalline orientation levels to improve physical performance in top load, vacuum, gas and vapor permeation through the container side wall.

In some embodiments, the present manufacturing method provides PET enhancements via improved material orientation with selective physical performance features, such as, for example, improved top load performance and/or improved moisture vapor transmission rate (MVTR) performance.

The following discussion includes a description of components of a blow molded container. Alternate embodiments are also disclosed. Reference is made in detail to the exemplary embodiments of the present disclosure, which are illustrated in the accompanying figures. Turning toFIGS.1-6, there are illustrated components of a blow molded container10.

Container10is configured for storing products such as food, food preparation and/or beverages. Container10includes a body12that extends from an end14to an end16, and defines a longitudinal axis AA, as shown inFIG.1. Body12includes a circumferential side wall18that extends between ends14,16. A volume V is defined from body12, as shown inFIG.1. Body12includes a substantially cylindrical configuration. In some embodiments, body12may include various configurations, such as, for example, oval, oblong triangular, square, polygonal, irregular, uniform, non-uniform, offset, staggered, and/or tapered. Body12may be manufactured by blow molding techniques, as described herein. In some embodiments, body12includes one or a plurality of walls.

Sealing surface22defines a recess, for example, a vent30, as shown inFIGS.2-5. Vent30is disposed about circumferential lip26and is configured for passage of a gas, for example, pressurized gas from volume V. The pressurized gas exits through vent30from inside of container10when container10is sealed via a closure, for example, a lid40. In some embodiments, the pressurized gas passes through spaced apart portions, including a gap34in a thread32, described herein, and releases into atmosphere external to container10. In some embodiments, the pressurized gas rotates around thread32and releases into the atmosphere.

Vent30includes a wall that includes a continuous surface extending between a surface of neck20and sealing surface22, as shown inFIG.3. Vent30is continuous and non-interrupted with openings. In some embodiments, vent30may include one or more through openings. Vent30is axially aligned relative to sealing surface22and body12, as shown inFIG.3. In some embodiments, vent30may be disposed at alternate orientations, relative to sealing surface22, for example, parallel, transverse and/or angular orientations such as acute or obtuse, coaxial and/or may be offset or staggered. Vent30includes a recessed, semi-circular configuration, as shown inFIG.3. In some embodiments, vent30includes a saw-tooth configuration to provide tamper evidence. In some embodiments, vent30may include various configurations, such as, for example, oval, oblong triangular, square, polygonal, irregular, uniform, non-uniform, offset, staggered, and/or tapered.

In some embodiments, sealing surface22includes a plurality of vents30. In some embodiments, the plurality of vents30are variously dimensioned and include, but are not limited to a length from about 1 mm to about 10 mm, a height from about 1 mm to about 10 mm and/or a depth from about 1 mm to about 10 mm.

Vent30includes a selected surface area. In some embodiments, the surface area is 1 to 500 mm2. In some embodiments, sealing surface22includes a plurality of vents30having the same or different surface area. In some embodiments, each vent30has the same or different surface area depending on the dimensions of each vent30.

Neck finish24includes a diameter D, as shown inFIG.2and thread32is disposed about diameter D. Thread32is configured for engagement with lid40. In some embodiments, thread32includes at least one thread. In some embodiments, thread32includes a plurality of threads32. In some embodiments, thread32may include various configurations, such as, for example, non-angled, irregular, uniform, non-uniform, offset, staggered, and/or tapered. Thread32includes a discontinuous thread, as shown inFIG.3. As described above, thread32includes gap34, as shown inFIGS.3-5. Vent30is configured for alignment with gap34in a configuration for passage of pressurized gas from volume V, as described herein. In some embodiments, all or a portion of gap34can be aligned with vent30. In some embodiments, thread32includes a plurality of gaps34. In some embodiments, thread32is continuous and does not include gap34, as shown inFIG.6.

In some embodiments, container10includes a snap bead (not shown). The snap bead is configured for snap engagement with lid40. In some embodiments, the snap bead is an interrupted ring. In some embodiments, the snap bead may include various configurations, such as, for example, non-angled, irregular, uniform, non-uniform, offset, staggered, and/or tapered. In some embodiments, lid40is metal and/or plastic.

In some embodiments, container10has a crystallinity from about 23% to about 32%. In some embodiments, a preform of container10can be heated and stretched to produce a container10having a crystallinity between about 10 and about 50%. In some embodiments, the preform of container10includes a molecular weight between about 120,000 g/mol and about 500,000 g/mol.

A finished PET blow-molded, container10is manufactured for use with a selected application, as described herein. In some embodiments, the selected application includes food, food preparation oils, viscous and/or beverage products.

In some embodiments, the present manufacturing method provides PET enhancements via improved material orientation with selective physical performance features, for example, improved top load performance and/or improved MVTR performance.

In some embodiments, a method for manufacturing container10, as shown inFIGS.7-10is provided. During manufacturing100, a container preform is blown/molded in a blow molder in a step102, as shown inFIGS.8and9. The container preform includes a selected configuration and is molded into an intermediate article, for example, an intermediate container50having neck20, sealing surface22, neck finish24, thread32including gap34, and a dome52, as shown inFIG.8. In some embodiments, the method includes an HDPE intermediate container50manufactured via an extruder instead of being molded from a container preform. Intermediate container50is transferred into a punch trimmer200(shown inFIG.10) in a step104.

Punch trimmer200is configured to form vent30within intermediate container50relative to a recess54that is pre-formed into the intermediate article via the mold. Punch trimmer200includes a clamping jaw202and a clamping jaw204. Clamping jaws202,204are configured for engagement with neck20and/or thread32. Clamping jaw202includes pneumatic cylinders206that include a punch208. An inner surface of clamping jaw202defines an opening210. Punch208is configured for disposal and translation within opening210, as described herein. The inner surface of clamping jaw202defines threaded portions212configured for engagement with neck20and/or thread32. Clamping jaw204includes pneumatic cylinders214that include a punch216. Pneumatic cylinders214are diametrically opposed to pneumatic cylinders206. An inner surface of clamping jaw204defines an opening218. Punch216is configured for disposal and translation within opening218, as described herein. The inner surface of clamping jaw204defines threaded portions220configured for engagement with neck20and/or thread32.

Clamping jaws202,204are positioned in a closed orientation to secure neck20and/or thread32in a step106. Pneumatic cylinders206and/or214insert punches208and/or216into intermediate container50in a step108to form vent30. Vent30is disposed in sealing surface22, as described herein. Punches208and/or216are configured to cut vent30in a flush configuration with sealing surface22. Dome52includes a relief or recess56where vent30can be punched and/or cut out below recess56in sealing surface22, as shown inFIG.9. In some embodiments, vent30is disposed in sealing surface22and dome52simultaneously. In some embodiments, punches208and/or216are rapidly inserted into intermediate container50. In some embodiments, punches208and/or216cut vent30vertically into dome52on one or more sides of recess56. Punches208and/or216are inserted into the intermediate container50to produce a U-shaped cut vent30. A top of the U-shaped cut vent30is left uncut and is creased/hinged inwardly (e.g., a punched flap/articulating element) by punches208and/or216. The top of the U-shaped cut vent30translate into dome52.

Punches208,216are retracted via pneumatic cylinders206,214from intermediate container50in a step110. Punch trimmer200is retracted and clamping jaws202,204are positioned in an open orientation to release intermediate container50and to position intermediate container50onto a conveyor (not shown) in a step112. In some embodiments, clamping jaws202,204are positioned in the open and closed orientation via a programmable logic controller (no shown). In some embodiments, the programmable logic controller receives inputs from a blow molder programmable logic controller and/or receives inputs from one or more sensor inputs. In some embodiments, the punching process is controlled by the programmable logic controller.

Intermediate container50travels through a trimmer (not shown) where a top of the U-shaped cut vent30that is hinged (e.g., punched flap/articulating element) and disposed with dome52are removed in a step114. The end product of manufacturing100is the finished container10, shown inFIG.1-5.

In some embodiments, manufacturing100is configured for use with various types of plastic containers produced with a blown neck finish. In some embodiments, manufacturing100can be employed to produce various types of vent30configurations along a sealing surface of a blown finish container.

In some embodiments, a method for manufacturing container10is provided. In some embodiments, during manufacturing, a container preform is blown/molded in a blow molder. In some embodiments, vent30is molded into the preform without the additional step of a punch trimmer200, as described herein. The container preform includes a selected configuration and is molded into an intermediate article (not shown) having neck20, sealing surface22, neck finish24, vent30, thread32including gap34, and a dome52. The intermediate container travels through a trimmer (not shown) where dome52is removed. The end product of manufacturing is the finished container10, shown inFIG.1-5.

In some embodiments, the method includes reusing dome52to produce other containers. In some embodiments, reusing dome52includes grinding, blending, drying and adding dome52and adding the ground, blended and dried material to a melt stream, wherein dome52does not contain additives.

In some embodiments, during manufacture, container10is filled with food and/or beverage products at a fill site utilizing automated fill equipment. In some embodiments, the food and/or beverage products are hot due to high temperatures in the fill and pasteurization of the products. Positive pressure is induced in all directions inside container10when container10is filled with the food and/or beverage products. In some embodiments, container10is capable of maintaining an initial shape at an elevated pressure of greater than 3 pounds per square inch (psi) and withstands a vacuum draw of greater than 3 In Hg during filling of container10with hot food and/or beverage products.