Patent Publication Number: US-2011049085-A1

Title: Bottle

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to co-pending U.S. Provisional Patent Application Ser. No. 61/178,824, filed on May 15, 2009, which is incorporated by reference herein in its entirety and made part hereof. 
    
    
     TECHNICAL FIELD 
     The invention relates generally to a bottle suitable for use in steam sterilization processes, and more specifically, to a bottle having structures that can provide sufficient strength to allow a recycled PET bottle to be used in steam sterilization. 
     BACKGROUND 
     Steam rinse sterilization processes are often used on bottles and other containers, including those made of HDPE and other polymers. Such sterilization processes, for example using a WAB peroxide steam rinser, often result in the bottles reaching temperatures of 75-85° C. This temperature coincides with the glass transition temperature of PET, as shown in  FIG. 8 , and the modulus of PET changes rapidly throughout this temperature range, as shown in  FIG. 9 . As a result, the physical stability of PET bottles decreases and becomes unpredictable and inconsistent, resulting in shrinkage and/or deformation of the bottles. Thus, the use of PET bottles in steam sterilization processes can present difficulties. The use of recycled PET (rPET) increases the unpredictability and inconsistency of the physical properties, as the intrinsic viscosities of recycled materials typically exhibit greater variation. Additionally, certain deformation characteristics are more difficult to control in square or other non-cylindrical bottles, and controlling shrinkage of the bottle becomes more important as a result. 
     The present device and method are provided to address the problems discussed above and other problems, and to provide advantages and aspects not provided by prior bottles and other containers of this type. A full discussion of the features and advantages of the present invention is deferred to the following detailed description, which proceeds with reference to the accompanying drawings. 
     BRIEF SUMMARY 
     Aspects of the present invention relate to a bottle that includes a neck portion having an opening configured to permit filling and emptying of the bottle, a shoulder portion connected to a lower end of the neck portion, a sidewall connected to a lower end of the shoulder portion and extending vertically downward from the shoulder portion, and a base connected to a lower end of the sidewall and forming a bottom surface of the bottle. The sidewall has a plurality of annular ribs extending around a periphery of the sidewall. Each of the annular ribs includes a plurality of sequential enlarged portions interconnected by bridges, with each of the enlarged portions having a vertical width that is greater than a vertical width of each of the bridges. 
     According to one aspect, the sidewall further includes recessed lands located between the annular ribs. 
     According to another aspect, a first rib of the plurality of ribs is staggered in relation to at least one adjacent second rib of the plurality of ribs, such that the enlarged portions of the first rib are vertically offset from the enlarged portions of the second rib, and the bridges of the first rib are vertically offset from the bridges of the second rib. In one embodiment, the first and second ribs may be staggered such that the enlarged portions of the first rib are vertically centered in relation to the bridges of the second rib and the enlarged portions of the second rib are vertically centered in relation to the bridges of the first rib. In another embodiment, all of the plurality of ribs may be arranged in an alternating, staggered arrangement, such that the enlarged portions and the bridges of each rib are vertically offset from the enlarged portions and the bridges, respectively, of each adjacent rib, and such that the enlarged portions and the bridges of each rib are vertically centered in relation to the bridges and the enlarged portions, respectively, of each adjacent rib. The plurality of ribs may form a brick-like pattern in this embodiment. 
     According to a further aspect, the enlarged portions of the ribs are generally rectangular in shape. 
     According to yet another aspect, the sidewall of the bottle has a generally square cross-section and is formed by four generally flat panels connected by four rounded corners. The plurality of ribs are staggered, such that each rib of a first group of the ribs has one of the enlarged portions vertically aligned with each of the four corners, and each rib of a second group of the ribs has one of the bridges vertically aligned with each of the four corners. In one embodiment, the first group of ribs and the second group of ribs are arranged in an alternating arrangement. 
     According to a still further aspect, the bottle is manufactured using a blow molding process, from a material that includes at least some recycled PET, and is capable of exhibiting a dimensional stability of less than 1% dimensional change during a WAB steam sterilization process in which the bottle reaches temperatures in the range of 75-85° C. 
     Additional aspects of the invention relate to a bottle that includes a base that forms a lowermost surface of the bottle, an opening proximate a top of the bottle, spaced vertically from the base, configured to permit filling and emptying of the bottle, and a sidewall extending vertically upward at least a portion of a vertical distance from the base to the opening. The sidewall is formed by four generally flat panel sections connected by four rounded corners. The sidewall has a plurality of annular ribs extending around a periphery of the sidewall. Each of the annular ribs includes a plurality of sequential enlarged portions interconnected by bridges, with each of the enlarged portions having a vertical width that is greater than a vertical width of each of the bridges. A first rib of the plurality of ribs is staggered in relation to at least one adjacent second rib of the plurality of ribs, such that the enlarged portions of the first rib are vertically centered in relation to the bridges of the second rib and the enlarged portions of the second rib are vertically centered in relation to the bridges of the first rib, and such that first rib has one of the enlarged portions vertically aligned with each of the four corners and the second rib has one of the bridges vertically aligned with each of the four corners. 
     According to one aspect, the sidewall further includes recessed lands located between the annular ribs. 
     According to another aspect, all of the plurality of ribs are arranged in an alternating, staggered arrangement, such that the enlarged portions and the bridges of each rib are vertically offset from the enlarged portions and the bridges, respectively, of each adjacent rib to form a brick-like pattern. 
     According to a further aspect, the enlarged portions of the ribs are generally rectangular in shape. 
     According to yet another aspect, all of the plurality of ribs are arranged in an alternating, staggered arrangement, such that the enlarged portions and the bridges of each rib are vertically centered in relation to the bridges and the enlarged portions, respectively, of each adjacent rib, and such that the plurality of ribs form an alternating pattern at each of the four corners where the enlarged portions and the bridges of alternating ribs are vertically aligned with each respective corner. 
     According to a still further aspect, the bottle is manufactured using a blow molding process, from a material that includes at least some recycled PET, and is capable of exhibiting a dimensional stability of less than 1% dimensional change during a WAB steam sterilization process where the bottle reaches temperatures in the range of 75-85° C. 
     Further aspects of the invention relate to a bottle that includes a neck portion having an opening configured to permit filling and emptying of the bottle, a shoulder portion connected to a lower end of the neck portion, a sidewall connected to the lower end of the shoulder portion and extending vertically downward from the shoulder portion, and a base connected to a lower end of the sidewall and forming a bottom surface of the bottle. The shoulder portion has a tapered configuration that tapers from a narrower top end with a generally circular cross-sectional shape to a wider bottom end with a generally square cross-sectional shape, and the sidewall has a generally square cross-sectional shape formed by four generally flat panel sections connected by four rounded corners. The sidewall has a plurality of raised, annular ribs extending around a periphery of the sidewall. Each of the annular ribs includes a plurality of sequential, generally rectangular enlarged portions interconnected by bridges, each of the enlarged portions having a vertical width that is greater than a vertical width of each of the bridges. The ribs are further separated by recessed lands located between the ribs. All of the plurality of ribs are arranged in an alternating, staggered arrangement, such that the enlarged portions and the bridges of each rib are vertically centered in relation to the bridges and the enlarged portions, respectively, of each adjacent rib, and such that the plurality of ribs form an alternating pattern at each of the four corners where the enlarged portions and the bridges of alternating ribs are vertically aligned with each respective corner. 
     According to one aspect, the bottle is manufactured using a blow molding process, from a material that includes at least some recycled PET, and is capable of exhibiting a dimensional stability of less than 1% dimensional change during a WAB steam sterilization process where the bottle reaches temperatures in the range of 75-85° C. 
     Still further aspects of the invention relate to a method of blow molding a bottle as described above, and a method of sterilizing a bottle as described above. The method of sterilizing may include conducting a WAB steam sterilization process on the bottle, which process reaches temperatures in the range of 75-85° C. The bottle may exhibit a dimensional stability of less than 1% dimensional change during the WAB steam sterilization process. 
     Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       To allow for a more full understanding of the present invention, it will now be described by way of example, with reference to the accompanying drawings in which: 
         FIG. 1  is a perspective view of a bottle; 
         FIG. 2  is a front view of the bottle of  FIG. 1 ; 
         FIG. 3  is a right view of the bottle of  FIG. 1 ; 
         FIG. 4  is a rear side view of the bottle of  FIG. 1 ; 
         FIG. 5  is a left side view of the bottle of  FIG. 1 ; 
         FIG. 6  is a top view of the bottle of  FIG. 1 ; 
         FIG. 7  is a bottom view of the bottle of  FIG. 1 ; 
         FIG. 8  is a graph illustrating the heatflow of PET and HDPE over a temperature range; and 
         FIG. 9  is a graph illustrating the modulus of PET and HDPE over a temperature range. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description of various example structures according to the invention, reference is made to the accompanying drawings, which form a part hereof, and in which are shown by way of illustration various example devices, systems, and environments in which aspects of the invention may be practiced. It is to be understood that other specific arrangements of parts, example devices, systems, and environments may be utilized and structural and functional modifications may be made without departing from the scope of the present invention. Also, while the terms “top,” “bottom,” “front,” “back,” “side,” “rear,” and the like may be used in this specification to describe various example features and elements of the invention, these terms are used herein as a matter of convenience, e.g., based on the example orientations shown in the figures or the orientation during typical use. Additionally, the term “plurality,” as used herein, indicates any number greater than one, either disjunctively or conjunctively, as necessary, up to an infinite number. Nothing in this specification should be construed as requiring a specific three dimensional orientation of structures in order to fall within the scope of this invention. 
       FIGS. 1-7  illustrate an exemplary embodiment of a bottle  10  according to aspects of the present invention. The bottle  10  includes a neck  12 , a shoulder portion  14 , a sidewall  16 , and a base  18 . The bottle  10  is generally square/rectangular in cross-section, and the sidewall  16  is defined by four generally flat panels  20  connected by rounded corners  22 . 
     The neck  12  has a circular opening  11  for filling and emptying the bottle  10  (see  FIG. 6 ), and is threaded for attachment of a cap (not shown) thereto, as is known in the art. The neck  12  also includes a flange  13  for supporting a cap ring (not shown) as also known in the art. In other embodiments, the features of the bottle  10 , including the structure of the sidewall  16 , can be utilized in bottles that have different types and configurations of openings for filling and emptying, as well as different types and configurations of closures for such openings, including flip-top lids, snap lids, peel-back lids, other types of lids, and/or combinations of such. For example, in one embodiment, the bottle  10  may include a peel-back portion in addition to the threaded cap. As another example, a bottle may have an opening that is not located at the top of the bottle, such as by having an opening in a side surface of the bottle. 
     The shoulder portion  14  expands the diameter of the bottle  10  from the narrower neck  12  to the wider sidewall  16 . The shoulder portion  14  also creates a gradual transition from a round cross-section to the square/rectangular cross-section of the sidewall  16 . The lower end  14 A of the shoulder portion  14  is generally square in cross-section, having four flattened areas  15 , and has at least one greater cross-sectional dimension than the sidewall  16 . Each of the flattened areas  15  of the shoulder portion  14  is located directly above one of the panels  20  of the sidewall  16 , described below. In this embodiment, the lower end  14 A of the shoulder portion  14 , at the flattened areas  15 , has a greater cross-sectional width, a greater cross-sectional perimeter, and a greater cross-sectional area measured perpendicular to the vertical axis of the bottle  10 , relative to the sidewall  16 . In other embodiments, the features of the bottle  10 , including the structure of the sidewall  16 , can be utilized in bottles that have a differently-configured shoulder portion  14 , or that have no identifiable shoulder portion. 
     The base  18  is located at the lower end of the sidewall  16 , and includes a generally vertical, upstanding portion  51  and a bottom surface  50  forming the lowermost surface of the bottle  10 . The base  18  also has a generally square/rectangular cross-section, having four flattened areas  19 , and also has at least one greater cross-sectional dimension than the sidewall  16 . Each of the flattened areas  19  of the base  18  is located directly below one of the panels  20  of the sidewall  16 , described below. In this embodiment, the upstanding portion  51  of the base  18 , at the flattened areas  19 , has a greater cross-sectional width, a greater cross-sectional perimeter, and a greater cross-sectional area measured perpendicular to the vertical axis of the bottle  10 , relative to the sidewall  16 . The base  18  also includes a base shoulder  17  that transitions from the upstanding portion  51  to the bottom surface  50  of the bottle  10 . The bottom surface  50  has a generally circular recess  52  with a curvilinear profile and a plurality of strengthening ribs  54  arranged in a radial formation at the center of the recess  52 . In other embodiments, the features of the bottle  10 , including the structure of the sidewall  16 , can be utilized in bottles that have a differently-configured base, or that have no identifiable base below the sidewall. 
     The sidewall  16  is recessed from the shoulder portion  14  and the base  18 , and has generally smaller cross-sectional dimensions in this embodiment. As described above, the sidewall  16  is generally square/rectangular in cross-section, having four generally flat panels  20  connected by rounded corners  22 . The upper and lower ends of the sidewall  16  each include an annular shelf  24  forming transitions from the shoulder portion  14  and the base  18  to the recessed lands  28  of the sidewall  16 , with each annular shelf  24  having a generally smooth outer surface that follows the contours of the panels  20  and corners  22 . Each annular shelf  24  is separated from the shoulder portion  14  or the base  18 , respectively, by a first annular shoulder  24 A that forms a reduction in cross-sectional area from the shoulder portion  14  or the base  18  to the respective shelf  24 . Further, each annular shelf  24  is separated from the recessed lands  28  of the sidewall  16  by a second annular shoulder  24 B that forms a reduction in cross-sectional area from the respective shelf  24  to the adjacent recessed lands  28  of the sidewall  16 . 
     The sidewall  16  also includes a plurality of annular ribs  26  extending around the perimeter of the bottle  10 , formed as raised or embossed segments of the sidewall  16 . The ribs  26  extend across each of the flat panels  20  and around each of the corners  22 . The ribs  26  are separated by recessed lands  28 , and the ribs  26  are raised with respect to the lands  28 . In the embodiment illustrated in  FIGS. 1-7 , the lands  28  are completely separated from each other by the ribs  26 . Each of the ribs  26  is formed in a brick-like configuration, having a plurality of sequential enlarged portions or brick portions  30  separated by narrower bridges  32 . In the embodiment shown, the enlarged portions  30  are each formed in a generally rectangular configuration. However, in other embodiments, the enlarged portions  30  may have a different shape, including a square, tapered, or rounded shape. Additionally, the bridges  32  may have different configurations in other embodiments, such as a narrower or wider configuration. Alternately, the bridges  32  may be only intermittently present, such that one of the ribs  26  may have complete gaps or separations between two or more adjacent enlarged portions  30 , and in one embodiment, the bridges  32  may be completely absent for one or more of the ribs  26 . In such embodiments, at least some of the lands  28  may not be completely separated from each other. In another embodiment, additional vertical bridges may exist between two or more of the ribs  26  on the sidewall  16 . In a further embodiment, the orientation of the embossed ribs  26  and the recessed lands  28  may be reversed, with the ribs  26  being recessed into the outer surface of the sidewall  16  and the lands  28  being raised above the ribs  26 . 
     In the embodiment shown in  FIGS. 1-7 , the ribs  26  are arranged in an alternating, staggered formation, such that adjacent ribs  26  are offset from each other. In other words, the enlarged portion  30  of a first rib  26 A is offset from the enlarged portions  30  of the upper and/or lower adjacent ribs  26 B,  26 C, as shown in  FIG. 2 . In the embodiment illustrated, the bridges  32  of the first rib  26 A are located in vertical alignment with the approximate midpoints of the enlarged portions  30  of the adjacent ribs  26 B,  26 C. Likewise, the bridges  32  of the adjacent ribs  26 B,  26 C are located in vertical alignment with the approximate midpoints of the enlarged portions  30  of the first rib  26 A. Further, in this embodiment, the midpoints of the enlarged portions  30  and the bridges  32  of alternating ribs  26  are centered at the midpoints of each of the rounded corners  22 , as best seen in  FIG. 1 . It is understood that the bottle  10  is shown as a thin-wall, blow molded bottle  10 , and that the internal surfaces of the bottle  10  are generally mirror-images of the external surfaces. It is also understood that features of the bottle  10  may be useful in other types of bottles, such as bottles having thicker walls. 
     Viewed another way, the sidewall  16  may be described as having an arrangement of staggered ribs  26 , such that the ribs  26  form an alternating pattern at each of the four corners  22  where the enlarged portions  30  and the bridges  32  of alternating ribs  26  are vertically aligned with each respective corner  22 . In one embodiment, the enlarged portions  30  of a first group of the ribs  26  (e.g.  26 A) are vertically aligned with each of the four corners  22 , and the bridges  32  of a second group of the ribs  26  (e.g.  26 B,  26 C) are vertically aligned with each of the four corners  22 . The first and second groups of ribs  26  may be arranged in an alternating pattern, as described above. Such an alternating pattern may be described as an A-B-A-B repeating pattern, with “A” signifying said first group of ribs  26  (e.g.  26 A) and “B” signifying said second group of ribs  26  (e.g.  26 B,  26 C). In another embodiment, the ribs  26  may be arranged in an alternating pattern, but each rib  26  may not have only bridges  32  or enlarged portions  30  aligned with the corners  22 . For example, each rib  26  may have two bridges  32  aligned with two of the corners  22  and two enlarged portions  30  aligned with the other two corners  22 , in alternating arrangement. In this embodiment, each corner  22  will still have an alternating bridge  32 /enlarged portion  30  pattern progressing vertically down the corner  22 , with opposite corners  22  having identical alternating patterns and adjacent corners  22  having opposite alternating patterns  22 . 
     The degree of offset or staggering of the ribs  26  can be different in other embodiments. For example, in one embodiment, the sidewall  16  may include three or four different staggered rib configurations, such that the ribs  26  alternate in an A-B-C-A-B-C pattern or an A-B-C-D-A-B-C-D pattern, among other embodiments. In a further embodiment, the ribs  26  may not be staggered or offset from each other, or may be randomly staggered on the sidewall  16 . 
     The sidewall  16  is also configured to have a label (not shown) attached thereto. The large, flat surface area provided by the plurality of enlarged portions  30  of the ribs  26  and the surfaces of the annular shelves  24  provide sufficient area for attachment of such a label, for example by using an adhesive. 
     The bottle  10  is suitable for manufacture by blow molding processes, including stretch blow molding processes, but can also be manufactured using other processes. Additionally, the bottle  10  is suitable for use with PET and/or rPET materials, but can provide beneficial effects when manufactured from other materials, including HDPE and other polymer materials. Further, the bottle  10  is suitable for use for steam sterilization processes, including processes utilizing a WAB peroxide steam rinser, but can provide benefits in other applications as well. Still further, the bottle  10  is suitable for use in cold-fill applications, but may also be useful in hot-fill applications, as well as other applications. 
     The structural features of the bottle  10  shown in  FIGS. 1-7 , including at least the structure of the ribs  26  and/or other structures of the sidewall  16 , provide sufficient strength and stability to the bottle  10  to enable the bottle  10  to be used in a steam sterilization process without unacceptable deformation of the bottle  10 . In particular, the structure enables a bottle  10  made of PET (including rPET) be used in steam sterilization processes where the bottle  10  reaches temperatures in the range of 75-85° C. Prototypes of one embodiment of the bottle  10  made using at least some rPET have exhibited dimensional stability of less than 1% dimensional change during a steam sterilization process. Additionally, steam sterilization processes carried out on prototypes of the bottle  10  have shown superior bacteria kill rates during steam sterilization processes. It is thought that the internal geometry of the bottle  10  may cause increased turbulence of the sterilizing medium within the bottle  10 , which may produce a greater kill rate than in other bottles. 
     While the invention has been described with respect to specific examples including presently preferred modes of carrying out the invention, those skilled in the art will appreciate that there are numerous variations and permutations of the above described systems and methods. Thus, the spirit and scope of the invention should be construed broadly as set forth in the appended claims.