Abstract:
A one-piece plastic container includes a body defining a longitudinal axis and having an upper portion, a sidewall portion and a base portion. The upper portion has a spout defining an opening into the container and a finish offset radially outwardly from the spout. A trough defines a passage into the body. The trough slopes toward the passage and defines a non-orthogonal angle relative to the longitudinal axis. According to other features, the sidewall portion is integrally formed with and extends from the upper portion to the base portion. The base portion closes off an end of the container. The finish defines at least one thread, for attaching a closure thereon.

Description:
TECHNICAL FIELD 
     This disclosure generally relates to plastic containers for retaining a commodity, such as a solid or liquid commodity. More specifically, this disclosure relates to a one-piece blown container having a pour spout arranged at an angle relative to a longitudinal axis of the container. 
     BACKGROUND 
     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. 
     Typically, an upper portion of the plastic container defines an opening. This upper portion is commonly referred to as a finish and includes some means for engaging a cap or closure to close off the opening. In the traditional injection-stretch blow molding process, the finish remains substantially in its injection molded state while the container body is formed below the finish. The finish may include at least one thread extending radially outwardly around an annular sidewall defining a thread profile. In one application, a closure member or cap may define a complementary thread, or threads, that are adapted to cooperatively mate with the threads of the finish. 
     In some applications, it is desirable to provide a spout at the opening of the container. In one example, a spout may be formed as a secondary component and subsequently connected to a container after the container has been blown. Such independently made pour spouts can improve pouring from heavy or awkward to hold container designs. In some examples, a drip back feature can be incorporated into the pour spout that allows the consumer to pour into and dispense from the corresponding cap yet still ensure all of the cap&#39;s remaining contents drip back inside the container during cap reapplication. 
     In many instances, the spout, once connected to the container, may define an angle relative to a longitudinal axis of the container to facilitate pouring. While a container having an angled spout improves functionality of the container such as during pouring, the two-piece design requires significant material and manufacturing costs. Thus, there is a need for a one-piece container design that has a pourable spout feature incorporated into the finish of the container. 
     SUMMARY 
     Accordingly, the present disclosure provides a one-piece plastic container having a body defining a longitudinal axis and having an upper portion, a sidewall portion, and a base portion. The upper portion has a spout defining an opening into the container and a finish offset radially outwardly from the spout. A trough defines a passage into the body. The trough slopes toward the passage and defines a non-orthogonal angle relative to the longitudinal axis. 
     According to other features, the sidewall portion is integrally formed with and extends from the upper portion to the base portion. The base portion closes off an end of the container. The finish defines a means, such as at least one thread, for attaching a closure thereon. 
     According to yet other features, the spout includes a terminal lip defining a plane that extends generally perpendicularly to the longitudinal axis. The terminal lip is offset entirely above the finish in a direction away from the base. The spout defines a longitudinal slot extending from the terminal lip to the passage. The terminal lip transitions to the longitudinal slot along arcuate surfaces. The trough defines a first angle relative to a transverse line drawn through the container from the longitudinal axis to the passage. The trough defines a second angle relative to the transverse line from the longitudinal axis to a diametrically opposed point relative to the passage. The first angle can be greater than the second angle. The first angle can be about five (5) degrees and the second angle can be about two (2) degrees. 
     Additional benefits and advantages of the present disclosure will become apparent to those skilled in the art to which the present disclosure relates from the subsequent description and the appended claims, taken in conjunction with the accompanying drawings. It will also be appreciated by those skilled in the art to which the present disclosure relates that the container of the present disclosure may be manufactured utilizing alternative blow molding processes to those disclosed above. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a side elevational view of a one-piece plastic container constructed in accordance with the teachings of the present disclosure and shown with an exemplary cap. 
         FIG. 2  is a perspective view of a preform used for construction of the one-piece plastic container of  FIG. 1 . 
         FIG. 3  is a sectional view of the preform taken along line  3 - 3  of  FIG. 2  and shown positioned in an exemplary mold cavity used during formation of the container of  FIG. 1 . 
         FIG. 4  is a detail side view of an upper portion of the one-piece plastic container of  FIG. 1 , the upper portion including a finish and a spout. 
         FIG. 5  is a sectional view of the upper portion taken along line  5 - 5  of  FIG. 2 . 
         FIG. 6  is a sectional view of an upper portion according to additional features; 
         FIG. 7  is a top view of the preform of  FIG. 2 ; and 
         FIG. 8  is a side view of an upper portion of a container constructed in accordance with additional features of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is merely exemplary in nature, and is in no way intended to limit the disclosure or its application or uses. 
       FIGS. 1-3  show one preferred embodiment of the present container. In the figures, reference number  10  designates a one-piece plastic, e.g. polyethylene terephthalate (PET), container. As shown in  FIG. 1 , the plastic container  10  has an overall height H 1  of about 292.68 mm (11.52 inches). The container is shown with an exemplary cap  11 . The plastic container  10  can define a longitudinal axis L and be substantially cylindrical in cross section. In this particular embodiment, the plastic container  10  has a volume capacity of about one (1) liter (1000 cc). 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, hexagonal, octagonal 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 spout  18  and a finish  20 . Integrally formed with the finish  20  and extending downward therefrom is a shoulder region  22 . The shoulder region  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 region  22  to a base portion  28  having a base  30 . 
     A neck  32  may also be included having 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 region  22 . The plastic container  10  has been designed to retain a commodity. The commodity may be in any form such as a solid or liquid product. In one example, a liquid 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 plastic container  10  with a liquid or product at an elevated temperature between approximately 155° F. to 205° F. (approximately 68° C. to 96° C.) and seal the plastic container  10  with the cap or closure  11  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 plastic container  10  under ambient temperatures. 
     The plastic container  10  of the present disclosure is an injection-stretch blow molded, biaxially oriented container with a unitary construction from a single or 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  34  ( FIG. 2 ) 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 and a length typically approximately fifty percent (50%) that of the resultant container height. In one example, the preform  34  can be injection molded. As will be appreciated, the upper portion  14  (i.e. the spout  18  and the finish  20 ), remains substantially unchanged from its preform state while the container body  12  is formed below the finish  20 . For reference purposes, features of the upper portion  14  have been described interchangeably for the plastic container  10  and the preform  34 . An exemplary method of manufacturing the plastic container  10  will be described in greater detail below. 
     Turning now to  FIGS. 2-7 , the preform  34  will be further described. The preform  34  generally includes the upper portion  14 , a neck-forming region  36 , a shoulder-forming region  38 , a sidewall-forming region  40  and a base-forming region  42 . The preform  34  is shown placed into a mold cavity  46  in  FIG. 3 . As mentioned above, the upper portion  14  including the spout  18  and the finish  20 , of the preform  34  remains substantially unchanged during blowing, filling and shipping operations. The container  10  is also shown in phantom in  FIG. 3  after the preform  34  has undergone a blow-molding process. Specifically, the neck-forming region  36 , the shoulder-forming region  38 , the sidewall-forming region  40  and the base-forming region  42  are all expanded in the mold cavity  46  to create the neck  32  ( FIG. 1 ), the shoulder region  22 , the sidewall portion  24 , and the base portion  28  of the resultant plastic container  10 , respectively. As shown in phantom in  FIG. 3 , the container  10  can include a substantially smooth and continuous second transition  71  between the inner surface of the sidewall and the inner surface of the spout  18 . While not shown in its entirety, it is appreciated that the mold  46  defines a mold surface  48  conforming to the shape of the resultant plastic container  10 . 
     The upper portion  14  will now be further described. The spout  18  includes a terminal lip  52  that defines an opening  50  into the preform  34  (and likewise into the resultant plastic container  10 ). The terminal lip  52  can define a plane  54  ( FIG. 3 ) that extends substantially perpendicularly to the longitudinal axis L. In other examples, the spout  18  may define an angle relative to the base  30 . The spout  18  assists in channeling, funneling and/or metering the commodity as it is poured from the plastic container  10  through the opening  50 . The finish  20  of the plastic container  10  includes a threaded region  56  having at least one thread  58  formed on an annular sidewall  60 . The threaded region  56  provides a means for attachment of a similarly threaded closure or cap (i.e. cap  11 ,  FIG. 1 ). The exemplary cap  11  defines at least one thread (not shown) formed around an inner diameter for cooperatively riding along the thread  58  of the finish  20 . Alternatives may include other suitable devices that engage the finish  20  of the plastic container  10 . Accordingly, the closure or cap  11  engages the finish  20  to preferably provide a hermetical seal of the plastic container  10 . The closure or cap  11  is preferably of a plastic or metal material conventional to the closure industry and suitable for subsequent thermal processing, including high temperature pasteurization and retort. 
     A trough  64  is formed radially at a transition between the finish  20  and the spout  18 . The trough  64  defines a generally arcuate surface  65  having a passage  66  into the body  12  of the plastic container  10 . In this way, contents remaining on the cap  11  after pouring may drip through the passage  66  and back into the plastic container  10 , subsequent to cap reapplication. The trough  64  generally defines an angle sloped toward the passage  66 . As a result, such contents can be further directed toward the passage  66  (by gravity) once in the trough  64 . In one example, as shown in  FIG. 3 , the trough  64  can define a first angle  70  from the passage  66  to the longitudinal axis L relative to a transverse line  73  drawn through the plastic container  10 . The trough  64  can define a second angle  72  from the longitudinal axis L to a diametrically opposed point  74  on the trough  64  relative to the transverse line  73 . The first angle  70  can be greater than the second angle  72 . In one example, the first angle  70  can be 5 degrees and the second angle  72  can be 2 degrees. In other examples, the first angle  70  can be less than or equivalent to the second angle  72 . It is appreciated that other angles can be used. 
     A longitudinal slot  80  ( FIG. 4 ) is formed on the spout  18  between the terminal lip  52  to the passage  66 . The terminal lip  52  transitions to the longitudinal slot  80  along arcuate surfaces  82 . The finish  20  may include a support ring  86 . A radial channel  88  may be formed between the support ring  86  and the annular sidewall  60 . The support ring  86  may be used to carry or orient the preform  34  through and at various stages of manufacture. For example, the preform  34  may be carried by the support ring  86 , the support ring  86  may be used to aid in positioning the preform  34  in the mold cavity  46 , or an end consumer may use the support ring  86  to carry the plastic container  10  once manufactured. 
     During use, the plastic container  10  may be tipped generally in a direction away from the longitudinal slot  80  thereby directing the commodity toward the terminal lip  52  when pouring. In this way, the terminal lip  52  of the spout  18  may direct the commodity in a controlled, metered manner when poured from the plastic container  10 . In one example, a handle (not shown) may be provided on the sidewall portion  24  ( FIG. 1 ) opposite the passage  66  to facilitate tipping of the plastic container  10  during pouring. 
     With continued reference now to  FIG. 4 , exemplary dimensions for the upper portion  14  will be described. It is appreciated that other dimensions may be used. A diameter D 1  of the spout  18  may be 32.92 mm (1.30 inch). A diameter D 2  of the finish  20  and the support ring  86  may be 49.68 mm (1.96 inch). A diameter D 3  of the radial channel  88  may be 41.68 mm (1.64 inch). A width W 1  of the trough  64  may be 5.97 mm (0.23 inch). A width W 2  of the longitudinal slot  80  may be 9 mm (0.35 inch). A width W 3  taken at the transition from the terminal lip  52  to the arcuate surfaces  82  may be 25 mm (0.98 inch). A radius R 1  of the arcuate surfaces  82  may be 8 mm (0.32 inch). 
     As best shown in  FIG. 3 , a height H 2  from a top  90  of the finish  20  to the trough  64  at the passage  66  may be 8.8 mm (0.35 inch). A height H 3  from the top  90  of the finish  20  to the trough  64  at the diametrically opposed point  74  may be 6.44 mm (0.25 inch). A height H 4  from the top  90  of the finish  20  to the bottom of the support ring  86  may be 15.9 mm (0.67 inch). An inner diameter D 4  of the opening  50  may be 32.92 mm (1.30 inch). An inner diameter D 5  of the preform  34  may be 32.60 mm (1.28 inch). In general, D 4  is greater than or equal to D 5 , i.e. D 4 ≧D 5 . 
     With reference now to  FIG. 5 , additional exemplary dimensions for the finish  20  will be described. A height H 5  from the top  90  of the finish  20  to the top of the radial channel  88  may be 11.38 mm (0.45 inch). A height H 6  from the top  90  of the finish  20  to the top of the support ring  86  may be 13.41 mm (0.53 inch). A wall thickness T 1  of the finish  20  taken above the thread(s)  58  may be 1.53 mm (0.06 inch). Various radii will now be listed with exemplary dimensions. R 1  may be 0.51 mm (0.02 inch). R 2  may be 0.75 mm (0.03 inch). R 3  may be 0.25 mm (0.01 inch). R 4  may be 2.5 mm (0.10 inch). 
     As shown in  FIG. 6 , a finish  20 ′ is shown according to additional features. The finish  20 ′ includes at least one thread  58 ′ formed on an inner diameter thereof. As can be appreciated, a cap (not shown) can have at least one complementary thread formed on an outer diameter for engaging the thread(s)  58 ′. 
     In one example, a machine (not illustrated) places the preform  34  heated to a temperature between approximately 190° F. to 250° F. (approximately 88° C. to 121° C.) into the mold cavity  46 . The mold cavity  46  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  34  within the mold cavity  46  to a length approximately that of the resultant plastic container  10  thereby molecularly orienting the polyester material in an axial direction generally corresponding with the central longitudinal axis L of the plastic container  10 . Again, during the stretching process, the finish  20  remains unchanged in an injection molded state while the container body  12  is formed below the finish  20 . While the stretch rod extends the preform  34 , air having a pressure between 300 PSI to 600 PSI (2.07 MPa to 4.14 MPa) assists in extending the preform  34  in the axial direction and in expanding the preform  34  in a circumferential or hoop direction thereby substantially conforming the polyester material to the shape of the mold cavity  46  (e.g., the mold surface  48 ) 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 plastic container  10 . The pressurized air holds the mostly biaxial molecularly oriented polyester material against the mold surface  48  of the mold cavity  46  for a period of approximately two (2) to five (5) seconds before removal of the plastic container  10  from the mold cavity  46 . This process is known as heat setting and results in a heat-resistant container suitable for filling with a product at high temperatures. 
     In another example, a machine (not illustrated) places the preform  34  heated to a temperature between approximately 185° F. to 239° F. (approximately 85° C. to 115° C.) into the mold cavity  46 . The mold cavity  46  may be chilled to a temperature between approximately 32° F. to 75° F. (approximately 0° C. to 24° C.). A stretch rod apparatus (not illustrated) stretches or extends the heated preform  34  within the mold cavity  46  to a length approximately that of the resultant plastic container  10  thereby molecularly orienting the polyester material in an axial direction generally corresponding with the central longitudinal axis L of the plastic container  10 . Again, during the stretching process, the finish  20  remains unchanged in an injection molded state while the container body  12  is formed below the finish  20 . While the stretch rod extends the preform  34 , air having a pressure between 300 PSI to 600 PSI (2.07 MPa to 4.14 MPa) assists in extending the preform  34  in the axial direction and in expanding the preform  34  in a circumferential or hoop direction thereby substantially conforming the polyester material to the shape of the mold cavity  46  (e.g., the mold surface  48 ) 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 plastic container  10 . The pressurized air holds the mostly biaxial molecularly oriented polyester material against the mold cavity  46  for a period of approximately two (2) to five (5) seconds before removal of the plastic container  10  from the mold cavity  46 . This process is utilized to produce containers suitable for filling with product under ambient conditions or cold temperatures. 
     Alternatively, other manufacturing methods 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 the plastic container  10 . Those having ordinary skill in the art will readily know and understand plastic container manufacturing method alternatives. 
     With reference now to  FIG. 8 , another one-piece plastic, e.g. PET container  110  according to additional features is shown. The plastic container  110  generally defines a body  112 , and includes an upper portion  114  having a spout  118  and a finish  120 , similar to the spout  18  and the finish  20  as described above. The plastic container  110  can be formed by the injection-stretch blow molding process described above. Accordingly, the spout  118  and the finish  120  remain substantially unchanged from their preform state while the container body  112  is formed below the finish  120 . The plastic container  110  has an overall height H 7  of about 270.74 mm (10.66 inches). The plastic container  110  generally includes a first and a second bulbous portion  122  and  124 , respectively. A diameter D 6  of the plastic container  110  taken at the first bulbous portion  122  may be 61.93 mm (2.44 inches). A diameter D 7  of the plastic container  110  taken at the second bulbous portion  124  may be 121.62 mm (4.79 inches). A diameter D 8  of the plastic container  110  taken at a transition between the first and second bulbous portions  122  and  124  may be 48.5 mm (1.91 inch). A diameter D 9  of the plastic container  110  taken at a base  130  may be 85.32 mm (3.36 inches). A radius R 5  may be 56.03 mm (2.21 inches). A radius R 6  may be 732.54 mm (28.84 inches). A radius R 7  may be 152.67 mm (6.01 inches). A radius R 8  may be 161.58 mm (6.36 inches). 
     While the above description constitutes the present disclosure, it will be appreciated that the disclosure is susceptible to modification, variation and change without departing from the proper scope and fair meaning of the accompanying claims.