Container with base cup and projection to limit stacking of base cups

According to the preferred embodiment of the present invention, a method and apparatus for forming base cups for plastic bottles is disclosed wherein a hollow body is blow molded and then cut in half to form two base cups. The side wall of the body is molded with a pair of outwardly extending projections such that when stacking a plurality of base cups, the projection of one cup engages the top lip of the adjacent lower cup thereby making denesting of the top easier.

BACKGROUND AND SUMMARY OF THE INVENTION 
Since the widespread acceptance by consumers of blow molded PET containers 
for carbonated beverages, efforts have been made by the bottling industry 
to improve the containers. Many of such containers are composites, 
consisting of a blow molded bottle and a supporting base cup. Many efforts 
have concentrated on improving the bottle but few improvements have 
involved the base cup of the bottle. 
Base cups have generally been made using injection molding techniques which 
implicitly impose some disciplines on the shape of the injection molded 
article. For example, projections and overhangs can not readily be formed 
on the sidewalls of an injection molded article. In addition, the weight 
of the base cup can only be reduced a certain amount because of the flow 
characteristics of the plastic during the injection molding steps. 
It is an object of the present invention, therefore, to provide a base cup 
container consisting of a blow molded bottle and a blow molded base cup. 
A further object of the present invention is to provide an improved method 
and apparatus for manufacturing the base cup container. 
SUMMARY OF THE INVENTION 
The base cup of this invention consists of a blow molded article having a 
irregularly shaped base and an upstanding annular wall which terminates in 
an inwardly directed lip. The lip is intended to engage the side wall of 
the blow molded bottle in a fluid tight relation so as to prevent water or 
other washing fluid used in the bottling process from accumulating inside 
the base cup. The base cup also includes drain openings in the base so 
that in the event any water flows past the lip into the base cup it will 
be automatically drained from the base cup through the drain openings. 
The base cup is formed by first blow molding a hollow body corresponding in 
the shape to the shape of two base cups secured in rim-to-rim engagement 
and then dividing the body along a line midway between the end walls and 
extending diametrically through the body side wall to thereby divide the 
body into two base cups. This procedure also enables the formation of a 
de-nesting projection or projections extending outwardly from the base cup 
side wall. During assembly of the container, a plurality of base cups are 
necessarily stacked and in the absence of a de-nesting ring or projection 
of some type on the base cups, it is difficult to disengage individual 
base cups from the stack. 
In the present invention, de-nesting projections, which can take the form 
of a ring on the base cup side wall or can also take the form of 
embossments such as trademarks or other identifying indicia, are formed on 
the side wall of the base cup. Such projections are readily formed on a 
blow molded base cup, but not an injection molded base cup because of the 
problem of removing the base cup from the mold. 
The blow molded body is readily formed with a groove at a position midway 
between the end walls and this groove can be conveniently slit to divide 
the body into two base cups, each of which has the above described 
inwardly extending lip at the upper end of the side wall. 
The invention includes improved blow molding structure for forming the blow 
molded bodies in large numbers and body handling and slitting assemblies 
for dividing the bodies into two base cups. 
The result is an improved base cup container which can be readily be 
manufactured in large numbers. 
Further objects, features and advantages of the present invention will 
become apparent to one skilled in the art upon reading the following 
specification and by reference to the following drawings and claims.

With reference to the drawing, the base cup container of this invention, 
indicated generally at 10, is illustrated in FIG. 1 as including a 
conventional blow molded bottle 12 for carbonated beverages, formed most 
commonly of a clear PET material and having a threaded neck 14, a 
generally tubular body 16 and a rounded base 18 (FIG. 4). The container 12 
is supported in a base cup 20 which is secured to the bottle base 18, 
usually by a liquid adhesive, and is capable of firmly supporting the 
composite container 10 on a horizontal surface. For this purpose, the base 
cup 20 has a bottom wall 22 which is shaped so that it has a plurality of 
points that are located in the same horizontal plane. 
The base cup 20 has an upwardly extending tubular side wall 23 and 
intermediate the upper and lower ends of the base cup, the side wall 23 is 
formed with an outwardly extending projection 24. In the form of the base 
cup illustrated in FIGS. 1-4A, inclusive, the projection 24 takes the form 
of an annular de-nesting ring 24 which extends continuously around the 
circumference of the upwardly extending tubular wall 23. At its upper end 
or rim, the wall 23 terminates in an upwardly and inwardly inclined 
annular sealing lip 26 which is engaged with the cylindrical side wall 16 
of the bottle 12 (FIG. 14). The purpose of the lip 26 is to fluid seal the 
upper end of the base cup 20 to the bottle 12 to prevent the washing water 
or other fluid that is used to rinse the bottle 12 in the final stages of 
the bottling process from flowing into the base cup 20. The lip 26 
functions to deflect water or other fluid flowing downwardly on the bottle 
wall 16 outwardly and down the outer surface of the base cup 20. In the 
event any of such water does enter the base cup 20, a plurality of 
openings 28 provided in the bottom wall 22 of the base cup 20 will drain 
the fluid out of the interior of the base cup 20 so as to maintain 
sanitary conditions around the composite container 10. 
The de-nesting ring 24 functions, as illustrated in FIG. 4 which shows a 
plurality of base cups 20 in a stack 32, to facilitate one-by-one removal 
of base cups 20 from the stack 32. The base cups 20 are arranged in the 
stack 32 by telescoping the lower end of one base cup 20 into the top end 
of the base cup therebelow. This telescoping proceeds until the de-nesting 
ring 24 engages the lip 26 which functions as the top rim of the base cup 
20. As shown in FIG. 4, the de-nesting ring 24 is of a larger diameter 
than the lip 26 so that it will engage the lip 26 to prevent further 
telescoping movement of the upper base cup into the lower base cup. The 
resulting is a stack 32 in which the base cups 20 can be readily removed 
one at a time from the stack to facilitate assembly of containers 12 and 
base cups 20. 
A modified form of the base cup 20, indicated generally at 20a, is 
illustrated in FIGS. 5 and 6. The base cup 20a is identical to the base 
cup 20 except for the form of the de-nesting projections on the side wall 
23. In the base cup 20a, the projection midway between the upper and lower 
ends of the base cup sidewall 23 consists of embossments 34, illustrated 
diagramatically as the letters "A, B and C" which project outwardly from 
the sidewall 23. The embossments 34 project outwardly from the sidewall 23 
at a plurality of positions around the circumference of the sidewall 23, 
preferably at equally spaced locations such as the three locations 
illustrated in FIG. 6 that are 120.degree. apart. 
The embossments 34, which can conveniently take the form of the trademark 
identifying the contents of the container 10, function like the de-nesting 
ring 24 to enable one-by-one removal of the base cups 20a from the stack 
36 shown in FIG. 5. This is due to the fact that the projections 34 are 
located substantially midway between the upper end lower ends of the 
container sidewall 23 and engage the lip 26a at the upper rim of the base 
cup so as to limit the extent to which the base cups can be telescoped. 
Since the base cups 20 and 20a are substantially identical, only the method 
and apparatus for forming the base cup 20 will be described in detail, it 
being understood that the cup 20a is formed by the same method and 
apparatus. The base cup 20 is made by first blow molding a hollow body 40, 
shown in FIGS. 9 and 12, which corresponds in shape to the shape of two of 
the base cups 20 secured in lip to lip engagement. The body 40 has end 
walls 42 corresponding to the base cup bottom walls 22 and a tubular 
sidewall corresponding to the base cup sidewalls 23. As shown particularly 
in FIG. 12a, the sidewall 44 has in inwardly extending V-shaped groove 48 
midway between its ends. 
The hollow body 40 is blow molded in the blow mold apparatus indicated 
generally at 50 in FIGS. 7, 8 and 9. The apparatus 50 is a multi-part blow 
mold assembly consisting of two halves 52 and 54 each of which has a main 
blow mold portion 56 corresponding to 1/2 the shape of the tubular 
sidewall 44. Each of the halves 52 and 54 also include top and bottom end 
portions 58 and 60, respectively, each of which corresponds to 1/2 of an 
end wall 42 of the body 40. 
The main blow mold portions 56 are mounted on platens 62 which are movable 
toward and away from each other to close and open the blow mold, 
respectively, and the end portions 58 and 60 are mounted on pivot 
assemblies 64 carried by the platens 62. 
In each of the mold half assemblies 52 and 54, the pivot assemblies 64 
include actuating arms 66 which are connected together by an adjustable 
linkage assembly 68. As a result, when one of the arms 66 is rotated in 
one direction, both of the end mold sections 58 and 60 are moved toward 
the main mold section 56 and when the arm 66 is moved in the opposite 
direction the end mold sections 58 and 60 are moved away from the main 
mold section 56. 
Cylinder assemblies 70, mounted on the platens 62, as shown in FIG. 8, are 
operatively connected to the lower arms 66, by means of crank arms 72 that 
are secured to the shafts 74 which are in turn also secured to the arms 
66. Thus, when the cylinder assemblies 70 are retracted, the mold end 
sections 58 and 60 are concurrently moved from their open positions shown 
in FIG. 7 toward their closed positions in FIGS. 8 and 9. When the 
cylinder assemblies 70 are extended, the mold end sections 58 and 60 are 
moved from their closed positions shown in FIGS. 8 and 9 toward their open 
position shown in FIG. 7. 
An extrusion head and blow pin assembly 80, which receives a supply of 
molten plastic material from a conventional plasticator (not shown) is 
operable to extrude a downwardly extending tubular parison 82 (FIG. 8) 
which is located between the mold halves 52 and 54 in the open position of 
the mold assembly illustrated in FIG. 8. The mold halves 52 and 54 then 
move to the closed position illustrated in FIG. 9, the parison 82 is 
expanded into conformity with the mold cavity and the body 40 is formed. 
The mold halves 52 and 54 are then moved toward their open positions shown 
in FIG. 8 and body 40 is removed and transferred to the conveyor 84 (FIG. 
10) which delivers the body 40 to the slitter assembly indicated generally 
at 86. 
The slitter assembly 86 includes a feeder wheel 88 which rotates in a 
clockwise direction was viewed in FIG. 10 and a carrier wheel 90 which 
rotates in a counter clockwise direction as viewed in FIG. 10. 
The slitter assembly 86 also includes a main frame 92 on which a main drive 
motor 94 is mounted. The motor 94 has a drive shaft 96 which drives a 
chain and sprocket assembly 98 which in turn drives the main drive shaft 
100 which drives the carryier wheel 90. The wheel 90 includes a pair of 
side plates 102 on which camp heads 104 are mounted for engaging opposite 
end walls 42 of the blow molded body 40. Actuating cylinders 106 are 
provided for moving the heads 104 away from each other to release a body 
40 and toward each other to clamp a part 40 therebetween as illustrated in 
FIG. 11. 
A drive motor 108 is mounted on the frame 92 for rotating the heads 104. 
The motor 108 drives a shaft 110 which in turn drives pulley and belt 
assemblies 112 which in turn drive pulleys 114 which are driven by belts 
116, only portions of which are shown for purposes of clarity. 
An auxiliary chain and sprocket assembly 118, driven by the main shaft 100, 
drives a shaft 120 which in turn drives the feeder wheel 88. 
A slitter knife 122 is mounted in a fixed position on the upper portion of 
the frame 92 for engagement with the molded bodies 40 that are being 
concurrently rotated about their own axes longitudinal and about the axis 
of the main drive shaft 100. The slitter knife 122 is located in line with 
the grooves 48 in the bodies 40 midway between the ends of the groove, as 
illustrated in FIG. 12a. The result is a clean slitting of each body 40 so 
as to divide it into a pair of base cups 20. As shown in FIG. 11, the 
bodies 40 are slit and divided during their travel past the slitter knife 
122 at the upper end of the frame 92. When the divided bodies 40 reach the 
lower part of their travel, adjacent the lower end of the frame 92, the 
heads 104 are moved apart by the cylinders 106 so as to release the thus 
formed base cups 20. When the heads 104 are horizontally aligned with the 
next body 40 on the feeder wheel 88, they are moved toward each other by 
the cylinder 106 so as to grip the body 40 therebetween as shown in FIG. 
11, and transfer the body from the feeder wheel 88 to the carrier wheel 
90. The holes 28 in the bottom wall of the base cup 20 can be conveniently 
formed while the base cups are on the slitter assembly 86 or can be formed 
after they are removed from the slitter assembly 86. 
The base cups 20 are then arranged in stacks 32 in which the de-nesting 
rings 24 enable easy removal of the base cups 20 in a one by one manner 
from the stack 32. The base cups are then assembled with the bottles 12 as 
shown in FIGS. 1 and 4a and secured by adhesive in the assembled 
positions. In these positions, the sealing lip 26 on the upper rim of each 
base cup 20 engages the bottle side wall 16 so as to prevent fluid from 
entering the upper end of the base cup. In the event fluid does enter the 
base cup, it is readily drained therefrom through the openings 28. 
From the above description it is seen that this invention provides improved 
base cups 20 and 20a along with an improved method and apparatus for 
manufacturing the base cups.