Plastic bottle with linerless closure

Abstract: An integral blow molded bottle (10) has a neck (12), a thread (14) surrounding the neck and a collar (16) at the top of the neck. A circumferential flange (32) is provided on the outside of the top of the collar (16), and a support column (36) is provided on the inside of the collar for limiting threading of a cap (24) down on the neck. A circumferential groove (38) formed in the outside of the collar (16) beneath the flange (32) prevents bottoming of the flange by the cap (24) threaded onto the neck (12).

Description: This invention relates to seals for closing one piece blow molded plastic bottles according to the preamble of claim 1 and to a method of making the bottles. The seal is formed by contact between the top of the bottle neck and a cap threaded onto the neck of the bottle. Blow molded plastic bottles, particularly blow molded bottles with relatively large diameter necks of the type used for liquid contents, are conventionally sealed closed by threading a cap onto the neck and compressing a thin foam liner mounted on the cap against the top of the neck of the bottle. The compressed liner forms a tight liquid seal to prevent the contents of the bottle from leaking. Bottles using a foamed liner seal typically, have a neck diameter of about 76mm (3 inches). Pour spouts are commonly fitted in the interiors of the necks to facilitate pouring of the contents from the bottles. The foam liner adequately seals the contents of the bottle but is costly. The ability to eliminate the foam liner from the cap while retaining an effective seal would save the cost of the liner and associated assembly costs of caps which incorporate the foam liner. This cost savings could be passed on to the purchaser. The aim of the present invention is to provide a blow molded plastic bottle having a linerless closure. A more specific aim is to provide such a bottle having a seal flange integrally formed from the top of the neck of the bottle for forming a resilient seal with a cap threaded onto the neck of the bottle and to a method of making the bottle. The closure is conveniently provided on blow molded bottles with approximately 76mm (3 inches) diameter necks which also accommodate inserted pouring spouts. Bottles of this type are commonly used in the marketing of liquid soaps and detergents. From one aspect the invention consists in a bottle comprising a blow molded hollow plastic body and a plastic neck integral with the body, the neck including an exterior neck thread and a cylindrical collar located at the top of the neck radially inwardly of the thread, characterized in that the neck includes a circumferential cap support column on the interior thereof, a flange collapse groove in the outer surface of the collar below the top of the support column and extending circumferentially around the collar, and an upwardly angled circumferential seal flange on the outside of the top of the collar immediately above the groove, the outer end of the flange being located above the cap support column and forming the top of the bottle, and the inner end of the flange joining the support column. From another aspect, the invention consists in a method of manufacturing a blow molded bottle with an integral sealing flange comprising a. extruding a molten plastic parison between a pair of mold halves; b. closing the mold halves on the parison to confine the parison within a cavity between the mold halves; c. inflating the parison against the walls of the cavity to form an integral blow molded plastic bottle having a body, a threaded neck and a collar at the top of the bottle; and d. opening the mold halves and ejecting the blown bottle from between the mold halves; characterized by the steps of e. forming a groove in and extending around the exterior surface of the collar during step c.; and f. machining the top of the collar to form an upwardly and outwardly extending circumferential seal flange at the top of the collar above the groove having a molded lower surface opening into the groove, a molded end surface, a machined top surface and a circumferential stop column extending around the inside of the collar at a level below the free end of the flange. In a preferred embodiment, the top surface of the seal flange is formed during machining of the neck at the same time as the inner surface of the neck is machined for reception of the spout insert. The groove under the seal flange is a circumferential V-recess which permits resilient flexing of the flange during tightening of the cap down on the neck. The resilience of the flange assures that the flange conforms to the downwardly facing circumferential surface of the cap to provide a tight seal despite inevitable slight variations in the shape of the bottle neck and cap. High torque threading of the cap onto the bottle bottoms the cap on the column while retaining resilient contact with the flange for an assured, reliable seal. The bottle may be formed by parison blow molding using mold halves having a V-shaped circumferential ridge extending around the mold halves, when closed, immediately above the threads on the neck. During blow molding of the parison to form the bottle, the parison is pressed against the ridge to form a circumferential V-recess extending completely around the top of the neck of the bottle above the threads of the bottle and slightly below the finished top of the neck. After blow molding the bottle is ejected from the mold halves and plastic above the neck, including any blow dome, is removed to open the neck. The neck is then machined by extending a reamer into the interior of the neck to form an interior neck surface for reception of an optional pour spout insert and the top surfaces of the column and flange. The reaming operation completes manufacture of the bottle to provide an integral linerless closure flange having an upper machined wall and an outer edge and lower surface defined during blow molding of the bottle. The V-shaped groove below the flange formed in the bottle by the annular ridge in the mold provides space for downward flexing of the flange during tightening of the cap on the bottle. This space has sufficient axial height to prevent bottoming of the flange despite high torque tightening when the cap is first threaded onto the bottle after filling. High torque tightening bottoms the cap on the column. High torque tightening of the cap is done at about 68-81 N (50-60 ft lbs). The consumer opens the bottle by unthreading the cap in order to pour out part of the bottle contents. The cap is then threaded back onto the bottle neck to re-engage the flange and seal the bottle closed. This low torque reclosing of the bottle need not bottom the cap on the column in order to re-engage the flange and reform a reliable seal. The resilient flange assures that the consumer, typically a housewife or homemaker, will be able to close and effectively reseal the bottle manually. Manufacture of the bottle with the disclosed linerless closure is performed during the conventional blow molding and neck reaming operations without the necessity of additional parts or assembly operations inherent in the manufacture of the prior closure with the foam sealing ring previously used to seal closed bottles of this type. Elimination of the seal ring and of the assembly steps necessary to attach the ring to the cap considerably reduces the cost of manufacture of the bottle. In order that the present invention may be more readily understood reference will now be made, by way of example, to the accompanying drawings, in which:- Figure 1 is a diametrical cross section of the upper part of a blow molded bottle embodying the invention; Figure 2 is an enlarged fragmentary cross section of the bottle neck, cap and spout of Figure 1, prior to engagement of the cap on the neck of the bottle; Figures 3 and 4 are similar to Figure 2 and show low torque and high torque closure of the bottle, respectively; and Figure 5 is a fragmentary sectional view taken through blow mold used for forming the bottle of Figure 1 with an integral linerless closure. A one-piece blow molded plastic bottle 10 includes a cylindrical neck 12 with a thread 14 extending around the outside of the neck. Cylindrical collar 16 forms the top of the neck 12. As illustrated in Figure 1, the outer diameter of the collar is slightly less than the diameter of the lower portion of the neck so that thread 14 extends radially outwardly beyond the collar for engagement with the complementary thread on the bottle cap. The neck is integrally joined to the shoulder and body of the bottle which are conventional and are not illustrated in the drawings. A pour spout insert 18 is fitted into the interior of the neck and tightly engages machine surfaces 20 on the inside of the neck. As shown in Figure 1, the insert includes a pour spout 22 located a distance above and adjacent one side of the neck. A drain back opening may be provided in the spout insert, if desired, in order to permit drain back of liquid into the bottle 10. Bottle cap 24 includes an enlarged hollow cylindrical body 26 which normally surrounds the cap insert, a radially outwardly extending ring 28 at the bottom of the cap extending outwardly over the neck collar 16, and a downwardly extending annular lip 29 which is provided with an interior thread 30 complementary with neck thread 14 to facilitate threading the cap onto the neck of the bottle. As shown in Figure 2, the top of the annular collar 16 includes a circumferentially continuous and upwardly extending seal flange 32. The flange has a radial length approximately equal to one-half the radial thickness of the collar and extends outwardly and upwardly from the middle of the collar to an upper end 34 normally defining the top of neck 12. The inner end of the flange 32 integrally joins the upper inner half of the collar 16 which forms a stop column 36 engagable with the lower surface of ring 28 when the cap is tightly threaded onto neck 12. An inwardly extending V-shaped circumferential groove 38 is located between flange 32 and the lower portion of collar 16 to permit resilient collapse of the flange without bottoming during tightening of the cap on the bottle neck. Groove 38 is formed during blow molding of bottle 10. The bottle 10 is closed by placing cap 24 on neck 12 and then rotating the cap to engage threads 14 and 30 and lower the cap down on the neck to bring cap ring 28 into engagement with the sealing flange 32. The cap completely surrounds the spout insert 18 as shown in Figure 1. After the body of the bottle has been filled, a cap applying machine places a cap on the neck and rotates the cap down onto the flange with relatively high torque of 68 to 81 N (50-60 ft lbs) to compress the flange down until the annular ring 28 engages stop column 36 on the inner half of the collar as shown in Figure 4 of the drawings. Flange 32 is compressed downwardly into groove 38 to reduce the height of the groove. However, the groove has a sufficient height along the axis of the neck to prevent bottoming of the flange. In this way, the flange provides a resilient circumferential seal extending completely around the neck and completely closing the bottle when the cap is threaded onto the neck under high torque loading after filling. The high torque closing of the bottle assures that the bottle remains sealed closed for the relatively long interval between closing and initial opening by the customer. When the customer unscrews the bottle cap from the neck the resilient flange 32 flexes up and nearly returns to its initial position of Figure 2 and is in position to form a resilient reliable circumferential seal with the cap 24 when the customer rethreads the cap onto the neck. The torque applied during rethreading of the cap on the neck depends upon the strength of the consumer and is usually less than the high torque used to close the bottle initially. Figure 3 illustrates the position of the cap and flange upon resealing of the bottle by the customer. Slightly greater torque applied to the cap will result in slightly greater downward deformation of the flange, depending upon the torque exerted on the cap. The resilience of the flange assures the seal continues despite production variations in the shape of the neck and cap. These variations may include variations in the geometry and locations of the threads, of the collar 16 and flange 32 and are inherent in manufacture of molded plastic products. Bottle 10 may be manufactured using conventional parison blow molding techniques in which a molten parison of thermoplastic resin is extruded between a pair of mold halves. The mold halves close on the parison to capture the parison within a mold cavity, following which a blow needle punctures a blow dome portion of the parison located above the neck portion of the cavity and a compressed gas is flowed into the parison to inflate the parison against the walls of the cavity and form the bottle. The mold halves are cooled and quickly set the inflated parison to form a bottle having a shape defined by the shape of the mold cavity. Figure 5 is a sectional view taken through a mold and blown parison showing a portion 40 of mold 42 which forms the top of the neck 12 of bottle 10. This portion of the mold is circular in horizontal cross section. Bottle 10 is shown expanded against portion 40. The mold portion 40 includes a cylindrical wall 44 defining the outer surface of neck collar 16. Ridge 46 projects inwardly into the interior of the mold from the top of surface 44 and extends completely around the mold. Mold surface 48 located above ridge 46 diverges outwardly from the ridge. Ridge 46 may be an insert mounted in the mold. Blowing and expansion of the parison forces the plastic in the parison against the walls of the mold cavity. As shown in Figure 5, the expanded parison 50 is forced against surfaces 44 and 48 and the ridge 46 between the surfaces to form the outer wall 52 of collar 16, annular groove 38 and surface 54 located above the groove. The plastic sets in the position shown in Figure 5, following which the mold halves are opened and the blown bottle 10 and blow dome are ejected from between the mold halves. The plastic above the neck portion of the bottle, including the blow dome, is then severed from the bottle. Severing may occur at a line 56 shown in Figure 5. After severing, the bottle is supported by a holder extending into recess 68 and a rotary reaming tool is extended down into the open mouth of the bottle to remove plastic from the top of the bottle. This reaming operation forms a cut upper surface 60 extending at an upward angle radially outwardly along collar 16 forming the top wall 70 of support column 36 and the top wall 66 of the seal flange 32. Surface 60 extends to the upper end 34 of the flange. The reaming operation also forms the surface 20 forming the inner cylindrical edge of the collar 16 and the curved lower portion of surface 20 in order to assure a tight fit with the spout insert 18 mounted in the mouth of bottle 10. The ridge 46 has a lower surface lying in a plane perpendicular to the central axis of neck 12 and an upper surface extending upwardly from the inner end of its lower surface. Surfaces on the mold 42 define the molded surface 52 on the outside of collar 16, molded surface 62 in the collar forming the bottom of the groove, molded surface 64 on the bottom of the flange forming the top of the groove and molded surface 54 on the end of the flange. Reamed surfaces 20 and 60 form the top surface 66 of flange 32, the top surface 70 of column 36 and the surfaces on the inside of the collar assuring a fit with insert 18. Figure 5 illustrates blow molding the bottle using a blow dome and a blow needle to flow air into the parison during molding. Alternatively, bottle 10 may be blown by extruding a parison down and over a blow pin. The molds close on the blow pin so that air flowed through the pin inflates the parison to blow the bottle. The plastic at the blow pin forms the neck of the bottle. The mold halves used to blow the bottle using blow pin blowing include surfaces similar to surfaces 44 and 48 and ridge 46 as previously described. After ejection of the bottle from between the mold halves, a reaming operation as described is performed to form the upper surface of the flange 32 and column 36 and the interior surface of the collar for reception of spout insert 18. The bottle 10 is formed from a suitable thermoplastic resin which, for instance, may be polyethylene. If desired, the bottle may be formed from a co-extruded parison with advantages inherent in a multi-layer construction.

Claims: A bottle (10) comprising a blow molded hollow plastic body and a plastic neck (12) integral with the body, the neck including an exterior neck thread (14) and a cylindrical collar (16) located at the top of the neck radially inwardly of the thread, characterized in that the neck includes a circumferential cap support column (36) on the interior thereof, a flange collapse groove (38) in the outer surface of the collar below the top of the support column and extending circumferentially around the collar, and an upwardly angled circumferential seal flange (32) on the outside of the top of the collar immediately above the groove, the outer end of the flange being located above the cap support column and forming the top of the bottle, and the inner end of the flange joining the support column (36). A bottle according to claim 1, characterized in that the height of the groove (38) is greater than the thickness of the flange (32) to permit resilient flexing of the flange into the groove, by a cap (24) threaded onto the neck (12) of the bottle (10) without engaging the bottom of the groove. A bottle according to claim 1 or 2, characterized in that the collar (16) includes an outer cylindrical blow molded surface, the groove (38) includes upper and lower blow molded surfaces (62,64), such upper groove surface (64) forming the lower surface of the flange, the flange has a blow molded end surface (54) and a reamed upper flange surface (60), and the column (36) has a reamed upper column surface (70), said reamed surfaces being continuous and said blow molded surfaces being continuous. A bottle according to claim 3, characterized by a reamed inner surface (20) on the collar (16) continuous with the reamed upper collar and column surfaces. A bottle according to any preceding claim, characterized in that the groove (38) is V-shaped in transverse cross section. A bottle according to claim 3, 4 or 5, characterized in that said reamed upper surfaces (60,70) normally lie on the surface of a cone. A bottle according to claim 4, 5 or 6, characterized in that a spout insert (18) is fitted within the interior of the neck (12) and engaging the reamed inner surface (20) of the collar (16). A bottle according to any preceding claim, characterized by a cap (24) engageable with the exterior thread (14) of the neck (12) permitting the cap to be threaded downwardly onto the bottle, and having an annular sealing surface located above the collar (16) and engagable with the top surface (66) of the seal flange (32) to flex the flange into the groove (38) and seal the contents of the bottle. A bottle according to any of the preceding claims 1-7, characterized by a cap (24) having an interior thread (30) engagable with the exterior thread (14) to hold the cap on the bottle and a downwardly facing annular surface engaging the top (60) of the support column (36) and the flange (32) for sealing the contents of the bottle. A method of manufacturing a blow molded bottle (10) with an integral sealing flange (32) comprising a. extruding a molten plastic parison between a pair of mold halves; b. closing the mold halves on the parison to confine the parison within a cavity between the mold halves; c. inflating the parison against the walls of the cavity to form an integral blow molded plastic bottle having a body, a threaded neck (14) and a collar (16) at the top of the bottle; and d. opening the mold halves and ejecting the blown bottle from between the mold halves; characterized by the steps of e. forming a groove (38) in and extending around the exterior surface of the collar (16) during step c.; and f. machining the top of the collar (16) to form an upwardly and outwardly extending circumferential seal flange (32) at the top of the collar above the groove (38) having a molded lower surface (64) opening into the groove, a molded end surface (54), a machined top surface (66) and a circumferential stop column (36) extending around the inside of the collar at a level below the free end of the flange.

Inventors: CARGILE DAVID W, CARGILE, DAVID W.
Applicants: GRAHAM PACKAGING CORP, GRAHAM PACKAGING CORPORATION
Application year: 1992
Main classification: B65D1
IPC codes: B65D41, B65D1, B65D47