Patent Description:
Blow molded articles made of thermoplastic materials are popular in various industries, including the consumer goods and food industries. For example, containers such as bottles for liquid products are often made via blow molding. During the blow molding process, a preform is expanded in a mold, generally with air or another gas under high pressure, to form the resulting article. For certain articles, stretch blow molding is used where the preform is softened and/or stretched while in the mold prior to being expanded into the final article.

Although blow molding has been found to be an effective and efficient process for manufacturing articles such as containers and the like, the requirements of the process can make it difficult to provide articles with certain aesthetic, functional, and/or tactile qualities or characteristics. For example, it may be desirable to provide an article with a textured outer surface, an appearance of a textured outer surface with a smooth outer surface (e.g. to ensure a label can be easily applied thereto), and/or different colors, indicia, decoration and/or text visible when looking at the outer surface. However, the blow molding process often limits the available options for the appearance of the outer surface of the article because of how preforms are formed, the high cost of the molds for the blow molding process and the processing requirements needed to blow the preform into the final article.

Thus, it would be desirable to provide improved aesthetic, functional, and/or tactile features on blow molded articles. It would also be beneficial to provide an improved process for manufacturing blow molded articles to allow for a greater range of aesthetic, functional, and/or tactile features. It would also be desirable to provide an improved method of forming preforms for blow molded articles that allows the resulting blow molded articles to have a greater range of aesthetic, functional, and/or tactile features and/or to allow the tactile, functional, and/or aesthetic features to be changed quickly and cost effectively. Further still, it would be desirable to provide improved aesthetic, functional, and/or tactile features on blow molded articles while keeping the process simple, cost-effective and scalable to mass manufacture and allowing for the resulting articles to have portions or all of the outer surface smooth so as to allow for easy attachment of a label.

<CIT> discusses an injection molded preform to which thermal energy such as radiant heat, convective heat, or ultraviolet energy is applied to form a desired pattern by altering the molecular morphology and optionally imprinting of the surface or subsurface of the portion to be patterned. The preform is used to blow mold a container. The thermal energy changes the molecular morphology by crystallization, chain scission, degradation or melting. The thermal energy may be supplied by a heater, branding iron or laser. In the wording of claim <NUM> <CIT> discloses a blow molded article formed from a preform etched in a predetermined pattern, having one inner layer and one outer layer induced by the etching, the article comprising: a neck forming an opening; a body portion extending from the neck to a base, the body portion including one or more walls surrounding an interior space in fluid communication with the opening, the one or more walls having an article inner surface, an article outer surface, and a thickness; a predetermined feature, preferably an aesthetic or textural feature, incorporated into at least a portion of the one or more walls, wherein the predetermined feature is provided by variations in the thickness of the one or more walls corresponding to the predetermined pattern. <CIT> discusses a process for producing a hollow plastic preform for blow molding a plastic container comprising a visible designed pattern on its surface. The process is said to allow different aesthetic effects on the finished container and may additionally impart those containers with anti-slippery properties and/or pleasant tactile sensation.

<CIT> discusses a preform of a thermoplastic material. A part of the surface is provided with texturing enlarging the surface, which has a low profile depth relative to the wall thickness of the preform. The texturing is said to reduced the time required to heat the preform.

<CIT> discusses a method for producing a marked container including the steps: a first step of heating, beyond a glass transition temperature, at least one shape-changing portion of the thermoplastic material wall of a preform; and a second step of forming the container by injecting a pressurized fluid into the body of the preform such as to change the shape of the heated portion of the wall by stretching it; and a step for marking the preform, during which a mark is provided on the shape-changing portion of the wall such that the mark is stretched at the same time as the wall, during step after forming.

<CIT> discusses how to obtain a vessel having an embossed pattern by a method in which a label is held at a position where the embossed pattern of the label and an engraved pattern of a mold coincide with each other. The parison is introduced into the mold, the mold is clamped down, air is blown into the mold and the label is pasted to the surface of a bottle.

The present invention, defined by the features of the independent claims, provides a solution for one or more of the deficiencies of the prior art as well as other benefits. The specification, claims and drawings describe various features and embodiments of the invention, including a multi-layer blow molded article formed from a preform etched in a predetermined pattern. The article comprises a neck forming an opening; a body portion extending from the neck to a base, the body portion including one or more walls surrounding an interior space in fluid communication with the opening, the one or more walls having an article inner surface, an article outer surface, and a thickness; a predetermined feature incorporated into at least a portion of the one or more walls, wherein the predetermined feature is provided by variations in the thickness of the one or more walls corresponding to the predetermined pattern.

Also disclosed is a multi-layer preform for blow molding formed from a thermoplastic material, the preform comprising a body having one or more walls and an opening, wherein at least a portion of the body includes an etched portion having at least some of the thermoplastic material removed in a predetermined pattern.

"Article", as used herein refers to an individual blow molded hollow object for consumer usage, e.g. a container suitable for containing materials or compositions. The article may be a container, non-limiting examples of which include bottles, tubes, drums, jars, cups, and the like. The compositions contained in such a container may be any of a variety of compositions including, but not limited to, detergents (e.g., laundry detergent, fabric softener, dish care, skin and hair care), beverages, powders, paper (e.g., tissues, wipes), beauty care compositions (e.g., cosmetics, lotions), medicinal, oral care (e.g., tooth paste, mouth wash), and the like. Containers may be used to store, transport, and/or dispense the materials and/or compositions contained therein.

"Blow molding" refers to a manufacturing process by which hollow cavity-containing articles are formed. In general, there are three main types of blow molding: extrusion blow molding (EBM), injection blow molding (IBM), and injection stretch blow molding (ISBM). The blow molded articles of the present invention can be made via IBM and ISBM or any other known or developed blow molding method, all of which are referred to herein simply as blow molding. The blow molding process typically begins with forming a precursor structure or "preform" that is ultimately expanded into the final article. The preform, as used herein, can be any shape or configuration, but is often in the general shape of a tube with at least one open end, or two open ends. Examples of preforms include, but are not limited to, parisons (the name often given to precursor structures used in extrusion blow molding), preforms, and other precursor structures used in different blow molding techniques. Preforms, as used herein, can be formed by extrusion, injection, compression molding, 3D printing and other know or developed methods. Injection molding of the preform can be simple injection molding of a single material, co-injection of two or more materials in a single step and/or over-molding preformed in two or more steps. The injection step can be closely coupled to a blowing step, as in IBM, <NUM>-step ISBM or <NUM>-step ISBM, or can be decoupled in a secondary operation such as <NUM>-step ISBM. During blow molding, a perform or other precursor structure is typically clamped into a mold and a fluid, often compressed air, is directed into the preform through the opening to expand the preform to the shape of the mold. Sometimes the preform is mechanically stretched prior to or at the same time the fluid is introduced (known as "stretch blow-molding"). Also, the perform may be heated or cooled before the fluid is introduced. The pressure created by the fluid pushes the thermoplastic out to conform to or partially conform to the shape of the mold containing it. Once the plastic has cooled and stiffened, the mold is opened and the formed article is ejected.

The term "etch" as used herein as a noun, refers to the cavity formed when material is removed from a surface. As a verb, the terms "etch" and "etching" refers to the act of removing material from a surface. Etching can be performed mechanically, chemically and thermally (e.g. laser). Although there is no specific limitation on the maximum or minimum depth of an etch, etching depths are typically in the range of about <NUM> to about <NUM>, including any depth within the range, such as for example, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> and others.

The term "layer" in the context of the present invention means a thickness of material that is generally continuous and typically homogeneous in terms of its chemical makeup. However, it is contemplated that any particular layer may have discontinuities and/or non-homogeneous materials or regions in certain configurations.

The term "translucent" as used herein means the material, layer, article, or portion of the article being measured has total luminous transmittance of greater than <NUM>% and less than or equal to <NUM>%. The term "transparent" as used herein means the material, layer, article, or portion of the article being measured has total luminous transmittance of <NUM>% or more. The term "opaque" as used herein means the material, layer, article, or portion of the article being measured has total luminous transmittance of <NUM>%. The total luminous transmittance is measured in accordance with ASTM D1003.

As noted above, preforms are commonly used in blow molding processes. An exemplary preform <NUM> is shown in <FIG>. The preform <NUM> has a body <NUM>, and at least one open end <NUM> having an opening <NUM>. The preform <NUM> may also include a neck or finish <NUM>, and a closed end <NUM> disposed opposite of the open end <NUM>. The finish <NUM> of the preform <NUM> may include one or more threads <NUM> or other structures that can be used in the resulting article to engage with a cap or other closure device. The neck <NUM> can also include a transfer ring <NUM> or other structure that can aid in the manufacturing process.

The preform <NUM> can be used in a blow molding process to provide a preliminary structure that can be transformed into a final article, such as a bottle, by means of directing a pressurized fluid into the open end <NUM> of the preform <NUM> while the preform <NUM> is disposed in a mold in the shape of the final article (or an interim article). Typically, the preform <NUM> may be heated or otherwise manipulated mechanically or chemically to soften the material of the preform <NUM> prior to introduction of the pressurized fluid to allow the preform <NUM> to expand into the shape of the mold without shattering or cracking. More details relating to exemplary blow molding processes in accordance with the present invention are described below.

Generally, the preform <NUM> is formed separately from the blow molding step. The preform <NUM> can be formed by any suitable method, including but not limited to molding, extrusion, 3D printing, or other known or developed processes. The preform <NUM> may be formed from a single material or may include layers or regions of different materials. <FIG> is an enlarged cross-section of the preform <NUM> shown in <FIG> taken through section line <NUM>-<NUM>. As shown, the preform <NUM> includes one or more preform walls <NUM>, closed end <NUM> and interior space <NUM>. The preform walls <NUM> have an inner surface <NUM> adjacent the interior space <NUM> and an outer surface <NUM> forming the exterior of the preform <NUM>. Typically, but not necessarily, the preform walls <NUM> are between about <NUM> and about <NUM> thick. The preform walls <NUM> are shown as having three layers, outer layer <NUM>, intermediate layer <NUM> adjacent to, but inward from outer layer <NUM>, and inner layer <NUM>. Although three layers are shown, any number of layers can be used, including a single layer, two or more layers, three or more layers or any other number of layers. Also, although the layers are shown to extend throughout the entire length of the preform <NUM>, any one or more layers may extend only part way through the preform <NUM>. Further, the layers <NUM>, <NUM> and <NUM> may each have a thickness, T1, T2 and T3. The thickness T1, T2, and T3 of each layer <NUM>, <NUM> and <NUM> may be the same or may be different from one or more of the other thicknesses. The layers <NUM>, <NUM> and <NUM> may be made of the same material or different materials. They may also be the same or different colors or have the same or different luminous transmittance. For example, the outer layer <NUM> may be transparent and the inner layer <NUM> or intermediate layer <NUM> may have a color or be translucent or opaque, although any other combinations of layers with the same or different luminous transmittance are contemplated. By including layers with different colors and/or different luminous transmittance, the article formed from the preform <NUM> can have interesting and/or unique aesthetic characteristics.

A preform or article according to the present invention may be formed of a single thermoplastic material or resin or from two or more materials that are different from each other in one or more aspects. Where the preform <NUM> has different layers, the materials making up each of the layers can be the same or different from any other layer. For example, the preform or article may comprise one or more layers of a thermoplastic resin, selected from the group consisting of polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), polystyrene (PS), polycarbonate (PC), polyvinylchloride (PVC), polyethylene naphthalate (PEN), polycyclohexylenedimethylene terephthalate (PCT), glycol-modified PCT copolymer (PCTG), copolyester of cyclohexanedimethanol and terephthalic acid (PCTA), polybutylene terephthalate (PBCT), acrylonitrile styrene (AS), styrene butadiene copolymer (SBC), or a polyolefin, for example one of low-density polyethylene (LDPE), linear low-density polyethylene (LLPDE), high-density polyethylene (HDPE), propylene (PP) and a combination thereof.

Recycled thermoplastic materials may also be used, e.g., post-consumer recycled ("PCR") materials, post-industrial recycled ("PIR") materials and regrind materials, such as, for example polyethylene terephthalate (PCRPET), high density polyethylene (PCRHDPE), low density polyethylene (PCRLDPE), polyethylene terephthalate (PIRPET) high density polyethylene (PIRHDPE), low density polyethylene (PIRLDPE) and others. The thermoplastic materials may include a combination of monomers derived from renewable resources and monomers derived from non-renewable (e.g., petroleum) resources. For example, the thermoplastic resin may comprise polymers made from bio-derived monomers in whole, or comprise polymers partly made from bio-derived monomers and partly made from petroleum-derived monomers.

The thermoplastic resin can have a relatively narrow weight distribution, e.g., metallocene PE polymerized by using metallocene catalysts. These materials can improve glossiness, and thus in the metallocene thermoplastic execution, the formed article has further improved glossiness. Metallocene thermoplastic materials can, however, be more expensive than commodity materials.

One benefit of the present invention is that it allows aesthetic, functional and/or textural features to be added to injection blow molded (IBM) articles and injection stretch blow molded (ISBM) articles that could not otherwise be achieved. This is important because such IBM and ISBM can be made from PET, which is often preferred over other materials because PET is more universally recycled than other clear and glossy thermoplastic materials. The present invention allows for IBM and ISBM articles to be made that have smooth outer surfaces and textured inner surfaces which can provide unique and aesthetically pleasing designs. Although EBM articles can be provided with certain textured surfaces, due to the nature of the extrusion blow molding process (typically using PETG), the range of textures is limited, and the resulting products tend to be less easily recycled than IBM and ISBM articles containing only PET. The "G" in PETG refers to glycol modified PET copolymer in which some of the ethylene glycol is replaced with a second glycol, cyclohexane dimethanol (CHDM) and it is generally considered a contaminant in recycling streams and can negatively impact the performance and processability of PET. Thus, improvements in the aesthetic, textural and/or functional features of IBM and ISBM articles is highly desirable.

The preform <NUM> can be formed by any known or developed method. For example, the preform <NUM> can be formed by injection, co-injection and/or over-molding as well as less conventional techniques like compression molding, 3D printing or the like. The preform <NUM> may be formed such that at least a portion of the preform walls <NUM> includes some texture, e.g. lines, dots, a pattern, and/or indicia, or they may be formed to be smooth. If the preform <NUM> is formed in a mold and a surface includes texture, it important to ensure the texture does not interfere with removal of the preform <NUM> from the mold. This can be done by limiting the height, fineness or density of any texture and/or selecting a texture with peaks and valleys that generally run parallel to the direction in which the preform <NUM> is removed from the mold. For example, it may be required to limit the depth of any texture that creates an undercut perpendicular to the direction of demolding to less than about <NUM> microns. This is especially true for PET materials which tend to have higher stiffness compared to PP or HDPE materials and thus, may sheer rather deform and rebound during the demolding process. Some of the limitations related to texturing the preform <NUM> by means of the preform mold can be avoided by the method described herein and/or by 3D printing of the preform.

In accordance with one aspect of the present invention, the outer surface <NUM> of the preform <NUM> may be modified after it is formed to change the topology of the outer surface <NUM>. Methods for modifying the outer surface <NUM> of the preform <NUM> include, but are not limited to laser-etching, water jets, cold pressing, hot pressing, milling, etc. The outer surface <NUM> may be modified to form lines, dots, patters, and/or indicia in or on the outer surface <NUM>. <FIG> shows an exemplary embodiment of a preform <NUM> that is being laser-etched by the beam <NUM> of laser <NUM>, although any other suitable technique may be employed. The laser beam <NUM> removes a portion of the material forming the outer surface <NUM> of the preform resulting in a texture on the outer surface <NUM>. It is also contemplated, though, that material may be added to the outer surface <NUM> to provide the texture, such as predetermined pattern <NUM>. The predetermined pattern <NUM> may take on any desired shape, including repeating and/or random pattern, lines, dots, curves, letters, numbers or any other desired indicia. Since the modification of the outer surface <NUM> of the preform <NUM> takes place after the preform <NUM> is removed from the mold in which it is formed, there are few, if any, limitations on the particular texture or pattern <NUM> that can be used. This also allows for different preforms <NUM> from the same mold to have different textures which can significantly reduce the cost of producing articles with different aesthetic, functional and/or textural qualities which, in turn, can make production of small numbers of articles and even customized articles economically feasible.

<FIG> is cross-sectional view of the preform of <FIG> taken through section line 3A-3A of <FIG>. The exemplary embodiment shown in <FIG> has three layers in the preform wall <NUM>. Layer <NUM> is the outer layer, layer <NUM> is the intermediate layer and layer <NUM> is the inner layer. As can be seen, the laser-etching removes material from the preform <NUM>. Specifically, in the embodiment shown in <FIG>, the laser-etching removed portions of the outer layer <NUM>. However, the laser <NUM> can be used to remove portions of other layers in addition to or instead of the outer layer <NUM>.

<FIG> is an enlarged view of a portion <NUM> of the preform <NUM> shown in <FIG>. As shown, the laser-etching can remove all or a portion of one or more of the layers <NUM>, <NUM> and <NUM>. The depth D of the laser etching can be the same as or different than the thickness of any layer. For example, the depth D of the laser-etching can be the same as the pre-etching thickness T1 of the outer layer <NUM> or can be greater than or less than the pre-etching thickness the outer layer <NUM> and/or any other layer (e.g. pre-etching thickness T3 of inner layer <NUM> or T2 of intermediate layer <NUM>). The depth D of the etching may be less than the pre-etching thickness T1 of the outer layer <NUM> if it is desired that the outer layer <NUM> form the outer surface <NUM> of the preform <NUM>. Alternatively, the depth D of the etching may be greater than the pre-etching thickness T1 of the outer layer <NUM> if it is desired for one or more layers other than the outer layer <NUM> to form a portion of the outer surface <NUM> of the preform <NUM>. Different depths D of etching can provide different aesthetic, functional, and/or textural features on the resulting blow molded article as can different sizes and shapes of the laser beam <NUM>.

Typically, the depth of the etching is between about <NUM> to about <NUM>, but any suitable depth of etching can be used. For example, any etching or portion thereof can be up to about <NUM>% of the thickness of the preform wall <NUM>. In addition to the depth of the etch, the kerf (the slit or notch made by etching), can take any desired shape. For example, the shape of the kerf may follow a gaussian curve, where the kerf is wider at the top and narrower at the bottom. A kerf can also be in the shape of a non-tapered slit with generally vertical walls. Still further, the shape of a kerf can follow other geometries like a reverse taper or barrel shaped taper. The depth of the etch can vary throughout the kerf and/or can be different in different portions of the texture or predetermined pattern <NUM>.

As stated above, one method to create predetermined pattern <NUM> on the preform <NUM> is laser-etching. Any suitable laser can be used to etch the surface of the preform <NUM>. One example of a laser <NUM> useful for etching/ablating a preform <NUM> in accordance with the present invention is a sealed carbon dioxide type laser, having power in the range of <NUM> W to <NUM>. 5kW, and a laser wavelength of <NUM> microns to <NUM> microns, or from <NUM> microns to <NUM> microns. Such lasers are available from various suppliers, including an LPM1000 module, available in <NUM> LASERSHARP systems from LasX Industries, Inc. of White Bear Lake, MN, United States. Other makes and types of lasers are also possible and different power ranges and settings may be used. The laser <NUM> can include optics that can be used to change the energy density and/or spot size of the laser beam, as desired.

Blow molded articles in accordance with the present invention may be provided with unique and beneficial characteristics. The characteristics are the result of unique features relating to the structure of the article itself, characteristics of the preform <NUM>, and the method of making the preform and/or blow molded article. <FIG> show examples of blow molded articles <NUM> in accordance with the present invention. As noted above, the present invention can provide aesthetic, functional, and textural features to blow molded articles <NUM> that were heretofore not attainable and/or not attainable with currently available mass production equipment and technology. For example, as shown in <FIG>, blow molded articles <NUM> of the present invention may include one or more article walls <NUM> surrounding an interior space <NUM> (shown in <FIG>), a neck <NUM> with an opening <NUM> in fluid communication with the interior space <NUM>, a base <NUM>, an article inner surface <NUM>, and an article outer surface <NUM>. The article <NUM> may include a texture <NUM> on the article inner surface <NUM> or article outer surface <NUM> of the blow molded article <NUM>. As shown in <FIG>, blow molded articles <NUM> may include one or more predetermined features <NUM>, such as aesthetic features <NUM>. Examples of aesthetic features include, but are not limited to patterns, indicia, one or more colors, shading, gradation, appearance of depth, as well as other aesthetic features and combinations thereof. Generally, the aesthetic feature(s) <NUM> of the article <NUM> are visible by users under ordinary use conditions. However, embodiments are contemplated wherein the aesthetic feature(s) <NUM> or portions of the aesthetic feature(s) <NUM> are visible only under certain circumstances, such as when the article <NUM> is filled with a product or material, partially filled or when the article <NUM> is empty or partially empty. Functional features include, but are not limited to, features such as increase or decrease of strength, increase or decrease of flexibility, increase or decrease of coefficient of friction, structure that creates ribs, ramps, protuberances, valleys, or other structures that provide some function to the article <NUM>. The blow molded articles <NUM> of the present invention are multilayer articles <NUM>. In multilayer articles <NUM>, there may be two or more layers. For example, as shown in <FIG>, article <NUM> may have a first layer <NUM> forming the article outside surface <NUM> of the article <NUM>, a third layer <NUM> forming an inside surface <NUM> of the article <NUM>, and a second layer <NUM> sandwiched between the first layer <NUM> and the third layer <NUM>, wherein the layers together make up the entire wall <NUM> of the article <NUM> in that region. Generally, the multilayer region (i.e. the region comprising more than one layer) makes up a major portion or the entirety of the article <NUM> wall <NUM> surface, but embodiments are contemplated wherein at least a portion of the article <NUM> includes fewer than all of the layers disposed in at least another region of the article <NUM>. For example, one or more of the layers may not extend the entire distance from the neck <NUM> to the base <NUM> of the article <NUM>.

The walls <NUM> of the article <NUM> can be any suitable thickness. For example, the wall thickness TW (shown in <FIG>) may range from about <NUM> to about <NUM>, although other thicknesses are possible depending on the particular process used and the desired end result. Also, the relative thickness of the layers, if any, can be different from each other and can vary throughout the particular layer. That is each of the layers may have a thickness that is different from the other layers or some or all may have thicknesses that are approximately the same. Generally, each layer is somewhere between <NUM>% and <NUM>%, <NUM>% and <NUM>%, <NUM>% and <NUM>%, or <NUM>% and <NUM>% of the total thickness of the article wall. And, as noted above, different portions of the walls <NUM> and/or layers may have different thicknesses, as desired.

One or more of the layers or portions of any layer in the blow molded article <NUM> may be transparent, translucent or opaque. Likewise, one or more of the layers or portions thereof may include one or more pigments or other color-producing material. In such instances, one or more of the layers may be visible through one or more of the other layers. The presence of a smooth transparent outside layer can help allow for pigments in other layers to be visible from outside of the article <NUM> and can at the same time provide the article <NUM> with gloss. Without being bound by theory, it is believed that the presence of a glossy surface at a distance from a translucent or opaque layer that includes pigments can create an effect of "depth" which can contribute to a premium appearance of the article itself. It can also give the appearance that the article <NUM> is made from glass or a material other than a thermoplastic material.

One especially advantageous and unique aspect of the present invention is that it allows for blow molded articles <NUM> to be formed with a visual impression of texture on the article outer surface <NUM> of the article <NUM>, even where the article outer surface <NUM> or portions thereof are smooth relative to the texture or visual impression of texture. As shown in <FIG>, a relatively smooth article outer surface <NUM> with visually-apparent texture may be, for example, achieved when the texture <NUM> is formed on the inner surface <NUM> of the article <NUM>, and at least a portion of the one or more layers of the wall <NUM> of the article <NUM> is/are transparent or translucent. A smooth article outer surface <NUM> can be advantageous, for example, when applying a label <NUM> to a portion of the article outer surface <NUM> of the article <NUM>, especially when the label <NUM> is intended to adhere to the article outer surface <NUM>, such as, for example, pressure sensitive labels, shrink labels, direct object printing, wrap around labels, screen printing, in-mold labels, transfer labels, pad printing and any other labels, printing or materials placed on or adjacent the outer surface <NUM>. A smooth article outer surface <NUM> can also be desirable when the article outer surface <NUM> is to be printed, when a shrink label is used, and/or for other reasons, including "feel", processing, look, etc..

As shown in <FIG>, the article <NUM> may have a predetermined feature <NUM>, such as texture <NUM> disposed on a portion <NUM> of the article <NUM>. The texture <NUM> may create all or a portion of an aesthetic feature <NUM>, as set forth herein. In the example shown, the texture <NUM> is disposed on the inner surface <NUM> of the article, but embodiments are contemplated wherein the texture <NUM> is disposed on the article outer surface <NUM> and or both the article inner surface <NUM> and the article outer surface <NUM>. The texture <NUM> is shown as being created by variations in the thickness T6 of the inner layer <NUM> of the article. The predetermined feature <NUM> can also provide a functional feature such as a rib, rifling or other structure. The texture <NUM> is the result of the etching done to the preform <NUM> that was used to form the article <NUM> and the blow molding process itself.

The predetermined feature <NUM> results from the preform <NUM> from which the article <NUM> is made being manipulated prior to expanding the article <NUM> to its final shape. The predetermined feature <NUM> may include etched regions <NUM> and non-etched regions <NUM>. The etched regions <NUM> correspond to the areas of the article <NUM> that were etched when the article was a preform <NUM> and not yet expanded to its final shape. The non-etched regions <NUM> are regions or the article <NUM> that correspond to regions of the preform <NUM> that were not etched prior to being expanded into the final article <NUM>. The etched regions <NUM> may be flush with or extend inwardly or outwardly from the non-etched regions <NUM> of the outer surface <NUM> of the article <NUM>. It may be desirable that if the etched regions <NUM> extend inwardly or outwardly from the non-etched regions <NUM>, they do so no more than a pre-determined amount to provide the outer surface <NUM> with a particular topography. For example, limiting the inward or outward extension of the etched regions <NUM> can help provide an outer surface <NUM> that is smooth to the touch and/or can readily accept printing and/or a label, or other form of decoration.

As shown in <FIG>, the article <NUM> may have a first layer <NUM> having a first thickness T4, a second layer <NUM> having a second thickness T5, and a third layer <NUM> having a third thickness T6. The first layer <NUM> is disposed outwardly of the third layer <NUM>. The first layer <NUM> includes thinned regions <NUM> that are thinner than the thickness T4 of the first layer <NUM> outside of the thinned regions <NUM>. The thinned region <NUM> of the first thickness T4 may be less thick than at least a portion of the second thickness T5 and/or third thickness T6 overlying the thinned regions T4. Thus, the predetermined feature <NUM> may be created by variations in the thickness of one or more of the layers of the article <NUM> in a predetermined pattern <NUM>. As shown in <FIG>, the first thickness T4 of the article <NUM> may vary more than the second thickness T5 of the second layer <NUM> and/or the third thickness T6 of the third layer <NUM> through at least a portion of the predetermined feature <NUM>.

<FIG> show different examples of how the wall <NUM> of an article <NUM> may look due to different etching depths made to the preform <NUM>. <FIG> shows the wall <NUM> of a preform <NUM> wherein the depth D of the etching is less than the thickness T1 of the outer layer <NUM>. <FIG> shows how the wall <NUM> of an article formed from the preform <NUM> of <FIG> might look after the article <NUM> is formed. As shown, the portion of the wall <NUM> shown includes three layers, a first layer <NUM>, a second layer <NUM> disposed inwardly of the first layer <NUM> and a third layer <NUM> that is disposed inwardly of the second layer <NUM>. The first layer <NUM> has a portion corresponding to the etching of the preform <NUM> that is thinner than the non-etched portion of the wall <NUM>. <FIG> shows the wall <NUM> of a preform <NUM> wherein the depth D of the etching is equal to the thickness T1 of the outer layer <NUM>. <FIG> shows how the wall <NUM> of an article formed from the preform <NUM> of <FIG> might look after the article <NUM> is formed. As shown, the wall <NUM> shown includes three layers, but the first layer <NUM> has a portion missing corresponding to the etching of the preform <NUM>. Thus, at least a portion of the outer surface <NUM> of the article <NUM> is formed by the second layer <NUM>. <FIG> shows the wall <NUM> of a preform <NUM> wherein the depth D of the etching is greater than the thickness T1 of the outer layer <NUM>. <FIG> shows how the wall <NUM> of an article formed from the preform <NUM> of <FIG> might look after the article <NUM> is formed. As shown, the wall <NUM> includes three layers, but the article outer surface <NUM> has a portion corresponding to the etching of the preform <NUM> that is made up of the third layer <NUM>. An article <NUM> can be formed from any number of layers and can include any number of textural, functional and/or aesthetic features <NUM> that have characteristics, e.g. different layers visible and/or forming the outer surface <NUM> of the article <NUM>.

<FIG> are examples of bottles. <FIG> shows an article <NUM>, a bottle, with an aesthetic feature <NUM> visible on the article outer surface <NUM>. The article has three layers of material forming the wall <NUM> of the article <NUM>. The outer layer of the article <NUM> is a different color than the middle layer. The unique aesthetic feature <NUM> can be attributed to the fact that a portion of an inner layer of the article <NUM> is visible through the outer layer. The aesthetic pattern <NUM> is formed by laser-etching the preform used to make the article <NUM>. Specifically, the outer layer of the preform is laser-etched in a predetermined pattern <NUM> and at a predetermined depth to allow the color of the middle layer of the article <NUM> to be visible through the outer layer. In the embodiment shown, the first layer <NUM> includes a material that provides a gloss surface. The article outer surface <NUM> is generally smooth despite the visual impression of texture provided by the aesthetic feature <NUM>.

The extent to which a particular surface is smooth can be expressed in terms of various different surface topography measurements. Two measurements that have been found to be particularly helpful in characterizing the surface topography of preforms and articles in accordance with the present invention are Maximum Peak/Pit Height (Sz) and Root Mean Square Roughness (Sq) as described below in the Measurement Methods section of this specification. For example, it may be desirable to limit the Maximum Peak/Pit Height across some or all of the article outer surface <NUM> and/or the Root Mean Surface Roughness the to provide a surface that is desirable for printing, and/or labeling, or for other tactile, aesthetic or functional reasons. For example, it may be desirable for the Sz of some or all of the article outer surface <NUM> to be less than or equal to <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns. Additionally, or alternatively, it may be desirable for some or all of the etched regions <NUM> to have an Sq of a certain value or below. For example, it may be desirable for some or all of the etched regions <NUM> to have an Sq of less than or equal to <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns. As a result of the process used to form the predetermined feature <NUM>, such as predetermined pattern <NUM>, the inner surface <NUM> may have certain topological characteristics as well. For example, some or all of the etched regions <NUM> of the inner surface <NUM> may have an Sq of greater than or equal to about <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns and the Sz of some or all of the article inner surface <NUM> may be greater than or equal to <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns.

<FIG> shows an article <NUM>, a bottle, with an aesthetic feature <NUM> visible on the article outer surface <NUM>. The article has three layers of material forming the wall <NUM> of the article <NUM>. The outer layer of the article <NUM> is a different color than the middle layer. The unique aesthetic feature <NUM> can be attributed to the fact that a portion of an inner layer of the article <NUM> is visible through the outer layer. The aesthetic pattern <NUM> is formed by laser-etching the preform used to make the article <NUM>. Specifically, the outer layer of the preform is laser-etched in a predetermined pattern <NUM> and at a predetermined depth to allow the color of the middle layer of the article <NUM> to be visible through the outer layer. In the embodiment shown, the first layer <NUM> includes a material that provides a gloss surface. The article outer surface <NUM> is smooth relative to the visual impression of texture provided by the aesthetic feature <NUM>. Specifically, the article outer surface <NUM> or portion thereof that is smooth, for example, may have an Sq of less than or equal to about <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns. Additionally, or alternatively, the article outer surface <NUM> may have a topography created by the predetermined feature <NUM> having an Sz that is less than or equal to <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns. As a result of the process used to form the predetermined feature <NUM>, such as predetermined pattern <NUM>, the inner surface <NUM> may have certain topological characteristics as well. For example, some or all of the etched regions <NUM> of the inner surface <NUM> may have an Sq of greater than or equal to about <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns and the Sz of some or all of the article inner surface <NUM> may be greater than or equal to <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns.

For any multi-layer article <NUM>, the article outer surface <NUM> may be formed solely by the third layer <NUM> or may be formed partially by the third layer <NUM> and at least partially by any other layer. For example, the article <NUM> may have a wall <NUM> that has an article outer surface <NUM> formed mostly by the third layer <NUM> and partially by another layer. This can be the case when the outer layer <NUM> of the preform is etched to a depth that an underlying layer is exposed in the final article <NUM>. This can provide the article <NUM> with unique visual and tactile features as the layers may have different characteristics, such as gloss, translucency, color, feel, etc..

Although the above examples are of a multi-layer article, mono-layer blow molded articles are also contemplated. For example, as shown in <FIG>, a mono-layered article <NUM> may be formed from a preform having a thermally-etched predetermined pattern <NUM>. An aesthetic, functional, and/or texture feature may be incorporated into the wall <NUM> of the article <NUM> such that it is visible from the exterior of the article <NUM>. The predetermined feature <NUM> may be formed from variations in the thickness of the wall <NUM> corresponding to the predetermined pattern <NUM>. The predetermined pattern <NUM> may include regions or patterns that were ablated from the outer surface <NUM> or inner surface <NUM> of the preform <NUM> (an example of which is shown in <FIG>) used to create the article <NUM>, such as, for example, by laser-etching. The mono-layer, laser-etched, blow molded article <NUM> may have an article outer surface <NUM> or portion thereof that is smooth, for example, having an Sq of less than or equal to about <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns. Additionally, or alternatively, the article outer surface <NUM> may have a topography created by the predetermined feature <NUM> having an Sz that is less than or equal to <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns. As a result of the process used to form the predetermined feature <NUM>, such as predetermined pattern <NUM>, the inner surface <NUM> may have certain topological characteristics as well. For example, some or all of the etched regions <NUM> of the inner surface <NUM> may have an Sq of greater than or equal to about <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns and the Sz of some or all of the article inner surface <NUM> may be greater than or equal to <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, <NUM> microns, or <NUM> microns.

The article <NUM> may be a container such as bottle <NUM> shown in <FIG>. The bottle <NUM> may be filled with a composition <NUM> such as a personal care or home care composition. The bottle <NUM> may include aesthetic features <NUM> that are enhanced or mitigated by the presence of the composition <NUM> in the bottle <NUM>. For example, a composition <NUM> in a clear bottle <NUM> with a texture <NUM> on the article inner surface <NUM> may result in the texture <NUM> being more, less or even non-apparent where the composition <NUM> is disposed adjacent the texture <NUM> than where it is not. In one example, a white composition <NUM> in a clear bottle <NUM> with texture <NUM> on the inner surface may obscure the pattern of the texture <NUM> where the composition <NUM> is disposed adjacent the texture <NUM>. However, the texture <NUM> may be clearly visible in regions where the composition <NUM> is not present, for example, the top portion of the bottle <NUM> when the bottle <NUM> is less than half-full of the composition <NUM>. Similarly, other forms of color-matching between the bottle-color and the composition-color (e.g. a blue composition in a blue bottle) may result in the aesthetic feature <NUM> being more or less-apparent during the time the product is sold or used. Alternately, the aesthetic features <NUM> of the bottle <NUM> may be enhanced by the composition <NUM> therein. For example, choosing different colors for the composition <NUM> and the bottle <NUM> may result in the texture or aesthetic features <NUM> being visually enhanced when the composition <NUM> is in the bottle <NUM>. Often, colors are described in terms of color-saturation (e.g. L in the L, a, b-scale) and hue, but other color characteristics may also affect the aesthetics of the bottle-composition combination.

Another advantage of the present invention is that it can provide for predetermined features <NUM> to be disposed on the inner surface <NUM> of the article <NUM> without the need to alter the inner surface <NUM> of the preform <NUM>. Such predetermined features <NUM> may be simple in nature (e.g. straight, parallel lines) or complex (e.g. curved lines, non-parallel lines, dots, shapes, letters, indicia, and combinations thereof). As noted above, by texturing the inner surface <NUM> of the article <NUM> as opposed to the article outer surface <NUM>, the article outer surface <NUM> can present a smooth surface that may be desired for its "feel" or to allow for more efficient and/or effective printing or labeling of the surface. Further, however, the predetermined feature <NUM> can still provide the article <NUM> with unique visual, tactile or functional characteristics. For example, if at least a portion of the wall <NUM> of the article <NUM> is transparent or translucent, a texture <NUM> or aesthetic feature <NUM> can be provided on the inner surface <NUM> of the article <NUM> and is visible through the wall <NUM> of the article. If a colored or opaque composition <NUM> is included in the article <NUM>, it is possible to have the texture <NUM> or aesthetic feature <NUM> appear visually to the user only after some of the composition <NUM> has been dispensed from the article <NUM>. Also, providing a texture <NUM> on the inner surface <NUM> of an article <NUM> can be used to enhance or otherwise modify a texture <NUM> or other aesthetic feature <NUM> that is disposed on the article outer surface of the article or vice-versa.

Beyond purely aesthetic benefits, the predetermined feature <NUM> may provide the article <NUM> with one or more functional aspects alone or in addition to any aesthetic or textural feature or benefit. For example, the bottle <NUM> with a certain aesthetic feature <NUM> or texture <NUM> can be paired with a composition <NUM> such that the aesthetic feature <NUM> or texture <NUM> is more of less visible after a certain amount of the composition <NUM> has been dispensed from the bottle <NUM>. Thus, the manufacturer can incorporate a repurchase reminder or other information into the bottle <NUM> in ways that were heretofore not available. As such, consumers may find the product to be interesting and/or sophisticated which may drive purchase intent and increase sales. Further, the predetermined feature <NUM> may, for example, provide ribs or other structural features on the article inner surface <NUM> or article outer surface <NUM> to provide for improved strength and/or flexibility to all or parts of the article <NUM>.

The predetermined feature <NUM> can be registered with any label <NUM>, pigment, texture, graphic, or any other textural or aesthetic feature of the article <NUM>. For example, it may be desirable to provide the article <NUM> with a region of visual depth, or a texture <NUM> in a particular location to help enhance another feature of the article <NUM>. To do so, the texture <NUM> and/or other aesthetic feature <NUM> can be registered or provided in a pre-determined location such that the texture <NUM> and/or aesthetic feature <NUM> is located in the desired location on the final article <NUM>. Additionally, the present invention can provide the additional benefit of not having to register labels and/or printing with certain areas on the article <NUM> because the predetermined feature <NUM> can be provided while still allowing for a generally smooth outer surface <NUM>. Thus, it may provide a more cost efficient and effective to present articles <NUM> for labeling or further decoration, etc. than similar articles with rough or uneven outer surfaces.

The pattern <NUM> etched onto the preform <NUM> can be designed so as to provide the predetermined feature <NUM> on the article <NUM> after any distortion that may result from the blowing of the preform <NUM> into the finished article <NUM>. For example, some or all of the features, patterns, indicia and the like comprising a predetermined pattern <NUM> on the article <NUM> may be etched on the preform <NUM> in a pattern that is distorted relative to its desired finished appearance, so that the features, patterns, indicia and the like acquire their desired finished appearance upon being formed into the three-dimensional article <NUM>. Such pre-distortion printing may be useful for indicia such as logos, diagrams, bar-codes, and other images that require precision in order to perform their intended function.

Preforms <NUM> and articles <NUM> according to the invention can comprise layers and/or materials in layers with various functionalities. For example, an article <NUM> may have a barrier material layer or a recycled material layer between an outer thermoplastic layer and an inner thermoplastic layer. The article <NUM> may comprise, for example, additives typically in an amount of from <NUM>%, <NUM>% or <NUM> % to about <NUM>%, <NUM>% or <NUM>%, by weight of the article. Non-limiting examples of functional materials include, but are not limited, to titanium dioxide, filler, cure agent, anti-statics, lubricant, UV stabilizer, anti-oxidant, anti-block agent, catalyst stabilizer, colorants, pigments, nucleating agent, and a combination thereof.

As noted above, the article <NUM> of the present invention can be made by any known blow molding method, including IBM and ISBM. In such methods, the article <NUM> is formed from a preform <NUM>, such as the one shown in <FIG>. The preform <NUM> can be made by any known method, including injection, 3D printing or any other suitable method. <FIG> shows an example of a preform <NUM> in an injection preform mold <NUM> after the material making up the preform <NUM> has been injected into the preform mold cavity <NUM> of the preform mold <NUM> and the preform <NUM> has been formed into the desired shape. The material making up the preform <NUM> is injected into the mold through orifice <NUM>. After the material is cooled or otherwise modified such that the preform <NUM> can maintain its shape, the preform <NUM> is removed from the mold <NUM>. The preform <NUM> may be subjected to any number of post-molding techniques, including, but not limited to chemical treatments, heating, cooling, light, mechanical manipulation, such as, for example, cutting, etching, scraping, bending, coating, etc. These techniques can help provide the preform <NUM> and/or final article <NUM> formed from the preform <NUM> desired properties.

In accordance with the present invention, the outer surface <NUM> of the preform <NUM> may be provided with a preform texture, such as, for example, in a pattern such as predetermined pattern <NUM>. Although the preform texture could be provided by the preform mold <NUM>, as noted above, such processes are very limited in the preform textures that they can create due to the requirement that the preform <NUM> be removed from the mold <NUM>. As such, it is preferred that the preform <NUM> be provided with the preform texture after it is removed from the mold <NUM>. As shown in <FIG>, the preform <NUM> may be laser-etched by one or more lasers <NUM>. The laser(s) <NUM> can direct one or more laser beams <NUM> to modify or remove a portion of the outer surface <NUM> of the preform <NUM>. The material ablated or removed can create a pattern and/or a preform texture on the outer surface <NUM> of the preform <NUM>. The predetermined pattern <NUM> or preform texture can include any number of lines, shapes, dots, curves, indicia, letters or combinations thereof. Any portion of the outer surface <NUM> of the preform may be laser-etched or otherwise modified and the modification process can take place at one time or in multiple different steps. The preform <NUM> may be rotated about its longitudinal axis L during etching to allow the etching device to etch the outer surface <NUM> about the circumference of the preform <NUM> or the etching device may be rotated about the preform <NUM>, or both can be rotated.

Once the desired preform texture or pattern is applied to the preform <NUM>, the preform may be moved to a blow molding step to form the final article <NUM> or may be stored or otherwise treated for different properties. Generally, just prior to the blow molding step, the preform <NUM> is heated or otherwise treated to soften it from a hardened state. This allows the preform <NUM> to be more easily blown into the shape of the final article <NUM>. Often, the preform is heated by lamps, hot air, radiation or convection, but other methods of heating the preform <NUM> can be used. When the preform <NUM> is ready to be "blown" or expanded into the shape of the final article <NUM>, it is placed into a blow mold, such as for example, the one shown in <FIG>. The blow mold <NUM> has a cavity <NUM> formed by walls <NUM>. The cavity <NUM> is the shape of the final article <NUM>. The walls <NUM> may be smooth or may have some texture. The preform <NUM> in the mold <NUM> is expanded such that the walls <NUM> of the preform <NUM> contact the walls <NUM> of the blow mold <NUM> and take the shape of the cavity <NUM>. Generally, the preform <NUM> is expanded by forcing air or another fluid into the opening <NUM> of the preform through the open end <NUM> of the preform. If desired, a vacuum created in the cavity <NUM> can assist the expansion of the preform <NUM>. Once the preform <NUM> is expanded into the shape of the mold <NUM> and thus, the final article <NUM>, the article <NUM> can be cooled and the blow mold <NUM> can be removed. The article <NUM> can be subjected to additional processing steps, including but not limited to inspection, removal of imperfections, cleaning, filling, labeling, printing, and sealing.

It is possible to configure the blowing process such that some or all of the preform texture creates a texture <NUM> of the article <NUM>. Surprisingly, the blow molding process can be configured to create the texture <NUM> on the inner surface <NUM> of the article <NUM>, the opposite surface of the wall <NUM> where it was originally etched or otherwise created. This is especially surprising for thermal etching on the external surface of the preform <NUM>. In order to reach temperatures sufficient for thermal ablation and material vaporization, typically a zone of melted or heat affected material is generated. This melted or heat affected zone can create thermally induced crystallization on the external surface. Crystallized material resists stretching and reforming to the surface of the blow cavity and tends to rebound from the surface of the blow mold. In order to create a smooth outer surface <NUM>, the amount of thermal crystallization on the external surface should be controlled (via efficient ablation on the external surface), the blowing parameters need to be optimized to <NUM>) minimize additional thermal and strain induced crystallization on the external surface and <NUM>) Set the material in the mold to avoid concave or convex surfaces in the transition from thick to thin surfaces (see chart that describes blow molding parameters that enable this).

For example, if the preform <NUM> was laser-etched on the outer surface <NUM>, the final blow molded article <NUM> can have a texture <NUM> corresponding to the laser-etching pattern on its inner surface <NUM>. This transfer of the preform texture to the inner surface <NUM> of the article <NUM> can allow the article <NUM> to have unique and aesthetically pleasing features compared to previously known blow molded articles <NUM>. One example, as described in more detail above, is a bottle having a smooth article outer surface and an aesthetic feature <NUM> that gives the appearance of thickness, depth and/or texture to the bottle. Such aesthetic features can make the bottle more attractive and more consumer preferred. Additionally, because the article <NUM> can be provided with a smooth article outer surface <NUM>, it can be more easily labeled and/or have printing applied thereto. Further still, because the method provides a way to add a texture, pattern or functional feature to the preform <NUM> after it is out of the preform mold <NUM>, it can significantly simplify the process for making complex features on the end article <NUM>. This also allows for the functional, textural and/or aesthetic features of the end article <NUM> to be changed despite the preform <NUM> being from the same preform mold <NUM> and allows for much quicker and more efficient changes to the overall aesthetics, texture or functional features of the article <NUM> because new preform molds <NUM> are not needed if it is desired to change the resulting article <NUM>. Thus, small productions batches and even customized articles become economically feasible.

Wall thickness, layer thickness, maximum peak/pit height (Sz), and root mean square roughness (Sq), as used herein, are measured as set forth below.

Wall Thickness is measured with a digital micrometer, such as a Shinwa <NUM> Digital Micrometer having an accuracy of +/- <NUM>, at two or more locations in the region of the article where the wall thickness is to be measured.

Layer thickness is measured with an industrial microscope, such as Olympus BX Series Optical Microscope having an accuracy of <NUM>, at two or more locations in the region of the article where the layer thickness is measured.

Sz, the Maximum Peak/Pit Height, is measured using a 3D Laser Scanning Confocal Microscope such as a Keyence VK-X200 series microscope available from KEYENCE CORPORATION OF AMERICA) which includes a VK-X200K controller and a VK-X210 Measuring Unit. The instrument manufacturer's software, VK Viewer version <NUM>. <NUM>, is used for data collection and the manufacturer's software, Multifile Analyzer version <NUM>. <NUM> and VK Analyzer version <NUM>. <NUM>, are used for data analysis. If needed, the manufacturer's image stitching software, VK Image Stitching version <NUM>. <NUM>, can be used. The manufacturer's analysis software is compliant with ISO <NUM>. The light source used is a semiconductor laser with a wavelength of <NUM> and having a power of about <NUM> mW.

The sample to be analyzed is obtained by cutting a piece of the article out of the article that includes the region to be analyzed in a size that can fit the microscope for proper analysis. To measure Sz of an article with etched and non-etched regions <NUM>, a sample should be obtained that includes both the etched and non-etched regions <NUM>. The analysis should take place over both the etched and non-etched regions <NUM>. If the etched region has one axis that is longer than another, the long axis of the etched region to be measured should be oriented approximately perpendicular to the long axis of the image region. If the sample is not flat, but flexible, the sample may be flattened and held down on the microscope stage with tape or other means. If, due to the shape, flexibility or other characteristic of the sample, measurements will be more accurate when the sample is not flattened, corrections may be used, as explained hereinbelow.

Sz is obtained by acquiring and stitching together several contiguous images of the sample in the region of interest (e.g. a region including both etched and non-etched areas). The images are collected using 10X objective lens suitable for non-contact profilometry such as a 10X Nikon CF IC Epi Plan DI Interferometry Objective with a numerical aperture of <NUM>, giving an image area of approximately <NUM> X <NUM> micrometers per image. The images are automatically stitched using the manufacturer's "VK Image Stitching" software. Data is acquired from the images using the acquisition software's "Expert Mode" wherein the following parameters are set as described herein: <NUM>) Height Scan Range is set to encompass the height range of the sample (this can vary from sample to sample depending on the surface topography of each); <NUM>) Z-direction step size is set to <NUM> micrometers; <NUM>) Real Peak Detection mode is set to "On"; and <NUM>) Laser Intensity and Detector Gain are optimized for each sample using the autogain feature of the instrument control software.

Prior to analysis, the data is subjected to the following corrections using the manufacturer's Multifile Analyzer software: <NUM>) 3x3 median smoothing in which the center pixel of a 3x3 pixel array is replaced by the median value of that array; <NUM>) noise removal using strong height cut (following built in algorithm in the analysis software), and <NUM>) shape correction using the simplest method (plane, second order curve or waveform removal) sufficient to remove the shape of the surface. Regions including foreign materials, artifacts of the sample harvesting process or any other obvious abnormalities should be excluded from analysis and alternative samples should be used any sample can't be accurately measured. The shape of the surface is removed using the Waveform Removal method of the Surface Shape Correction tool. The cutoff wavelength is specified to be approximately five times the size of the largest structure to be preserved. The Reference Plane is specified using the Set Area method and selecting the same area as is used for the shape removal. The resulting value is the Sz for the measured portion of the article.

Root Mean Square Roughness, Sq, is measured using a 3D Laser Scanning Confocal Microscope such as a Keyence VK-X200 series microscope available from KEYENCE CORPORATION OF AMERICA) which includes a VK-X200K controller and a VK-X210 Measuring Unit. The instrument manufacturer's software, VK Viewer version <NUM>. <NUM>, is used for data collection and the manufacturer's software, Multifile Analyzer version <NUM>. <NUM> and VK Analyzer version <NUM>. <NUM>, are used for data analysis. If needed, the manufacturer's image stitching software, VK Image Stitching version <NUM>. <NUM>, can be used. The manufacturer's analysis software is compliant with ISO <NUM>. The light source used is a semiconductor laser with a wavelength of <NUM> and having a power of about <NUM> mW.

The sample to be analyzed is obtained by cutting a piece of the article out of the article that includes the region to be analyzed in a size that can fit the microscope for proper analysis. To measure Sq of an etched portion of an article, a sample should be obtained that includes an etched region and the analysis should take place only over the portion of the sample that is etched. If the sample is not flat, but is flexible, the sample may be held down on the microscope stage with tape or other means. If, due to the shape, flexibility or other characteristic of the sample, measurements will be more accurate when the sample is not flattened, corrections may be sued, as explained hereinbelow.

The measurement data from the sample is obtained using a 20X objective lens suitable for non-contact profilometry, such as a 20X Nikon CF IC Epi Plan DI Interferometry Objective with a numerical aperture of <NUM>. The data is acquired using the acquisition software's "Expert Mode", with the following parameters set as described he: <NUM>) Height Scan Range is set to encompass the height range of the sample (this can vary from sample to sample depending on the surface topography of each); <NUM>) Z-direction Step Size is set to <NUM> micrometers; <NUM>) Real Peak Detection mode is set to "On"; and <NUM>) Laser Intensity and Detector Gain are optimized for each sample using the autogain feature of the instrument control software.

Prior to analysis, the data is subjected to the following corrections using the manufacturer's Multifile Analyzer software: <NUM>) 3x3 median smoothing in which the center pixel of a 3x3 pixel array is replaced by the median value of that array; <NUM>) noise removal using weak height cut (following built in algorithm in the analysis software), and <NUM>) shape correction using waveform removal (<NUM> cutoff). The Reference Plane is specified using the Set Area method and selecting the same area as is used for the shape removal. Regions including foreign materials, artifacts of the sample harvesting process or any other obvious abnormalities should be excluded from analysis and alternative samples should be used any sample can't be accurately measured. The resulting value is the Root Mean Square Roughness, Sq, for the measured portion of the sample.

All percentages are weight percentages based on the weight of the composition, unless otherwise specified. All ratios are weight ratios, unless specifically stated otherwise. All numeric ranges are inclusive of narrower ranges; delineated upper and lower range limits are interchangeable to create further ranges not explicitly delineated. The number of significant digits conveys neither limitation on the indicated amounts nor on the accuracy of the measurements. All measurements are understood to be made at about <NUM> and at ambient conditions, where "ambient conditions" means conditions under about one atmosphere pressure and at about <NUM>% relative humidity.

Claim 1:
A multi-layer blow molded article (<NUM>) formed from a preform (<NUM>) etched in a predetermined pattern (<NUM>), the article (<NUM>) comprising:
a neck (<NUM>) forming an opening;
a body portion extending from the neck (<NUM>) to a base, the body portion including one or more walls surrounding an interior space (<NUM>) in fluid communication with the opening, the one or more walls having an article inner surface (<NUM>), an article outer surface (<NUM>), and a thickness;
a predetermined feature (<NUM>), preferably an aesthetic or textural feature (<NUM>), incorporated into at least a portion of the one or more walls, wherein the predetermined feature is provided by variations in the thickness of the one or more walls corresponding to the predetermined pattern (<NUM>), wherein the article (<NUM>) has a first layer having a first thickness and a second layer having a second thickness, the first layer being disposed outwardly of the second layer, and wherein the predetermined feature (<NUM>) includes a thinned region of the first layer that is less thick than at least a portion of the first layer outside of the thinned region.