Patent ID: 12221263

DETAILED DESCRIPTION

The exemplary embodiments of blow-molded containers and more particularly, wide mouth polyethylene terephythalate (PET) containers and methods for making the same are discussed in terms of food packaging products. In some embodiments, the present container system includes a container that can be used as a replacement for glass containers. In some embodiments, the present container system includes a container having a 30 or 32 ounce container made from polyethylene terephthalate that can withstand fill and pasteurization temperatures greater than 185° F. In some embodiments, the present container system can be employed with a method of manufacture including pasteurization that can be performed for selected periods of time, for example, 10 minutes under selected temperatures. In some embodiments, the present container system includes a container weighing 42 grams and employed with a method of manufacture including blow molding and trim steps.

In some embodiments, the present container system includes a container defining a flexing base that facilitates movement of the base in an outward orientation when pressure is built up inside of the container immediately after fill and pasteurization. In some embodiments, the flexing base of the container moves in an inward orientation during cooling of the container when a vacuum is created from a food and/or beverage product cooling within the container. In some embodiments, the present container system includes a container defining a push up at a base of the container that does not distort and retains its shape after inward and outward movement of the base. In some embodiments, the present container system includes a container that is capable of withstanding a vacuum pressure configured to pull a safety button on a metal lug cap that is attached to a top of the container. In some embodiments, the present container system includes a container defining a vacuum compensating base with a shaped base geometry. In some embodiments, the present container system includes a container defining a neck with a neck finish configuration that is different than existing containers in the marketplace.

In some embodiments, during manufacture, the present container system can be run on a machine capable of a base-over stroke system. The base-over stroke system can be set at 15 millimeters (mm) to about 25 mm. In some embodiments, the operating temperature of the preform is 115 degrees Celsius to about 125 degrees Celsius and the blow mold temperature is 130 degrees Celsius to about 140 degrees Celsius. In some embodiments, a sidewall of a container of the present container system includes a PET percent crystallinity of 23% to about 32%. In some embodiments, the present container system includes a container that can maintain an initial shape at an elevated pressure of greater than 3 pounds per square inch (psi) and an elevated vacuum of greater than 3 inches of mercury (In Hg).

In some embodiments, the present container system includes a container that is manufactured via an injection molded preform, which is subjected to a blow mold and trim process. In some embodiments, the present container system includes a container that can be filled with food, food preparation oils, viscous and/or beverage products. In some embodiments, the present container system includes a container that can be employed as a cold fill container. In some embodiments, the present container system includes a container that can be employed as a hot fill container. In some embodiments, the present container system includes a container that is employed as a light weight, high strength and barrier food packaging product.

In some embodiments, the present disclosure includes a container system that is employed with a method for manufacturing food packaging having the ability to produce food packages made from PET with minimal weight and selectively desirable physical performance features, as described herein.

In some embodiments, the present container system is manufactured with selective physical performance features, such as, for example, a reduction in plastic weight, a selected pre-form design, selected bottle processing and/or bottle crystallinity of a circumferential side wall of a blown container of the present container system. In some embodiments, the selected physical performance features can include a higher injection molding efficiency and/or cavitation and an increased bi-axial orientation of PET container material. In some embodiments, the present container system includes a container that is manufactured with a smaller diameter preform, which forms a final bottle neck finish through the blowing process that allows for higher injection mold efficiency as well as improved material orientation throughout the container. In some embodiments, the container system includes a container with an improved material distribution and crystalline orientation. In some embodiments, this manufacturing method provides a container system including a container having improved top load, vacuum resistance and/or permeability. In some embodiments, this manufacturing method provides stretching PET to optimum crystalline orientation levels to improve physical performance in top load, vacuum, gas and vapor permeation through the container side wall.

In some embodiments, the present manufacturing method provides PET enhancements via improved material orientation with selective physical performance features, such as, for example, improved top load performance, improved vacuum resistance performance and/or hoop strength, improved oxygen (O2) performance, and improved moisture vapor transmission rate (MVTR) performance.

In some embodiments, the present manufacturing method includes the steps of employing a single stage blow molding process and providing a preform that produces containers having a dome. In some embodiments, the method includes the step of testing the one or more preforms to ensure the one or more preforms include a selected weight and selected neck finish dimension. In some embodiments, the method includes the step of employing the one or more preforms with a four cavity production mold. In some embodiments, the method includes the step of blow molding the one or more preforms, which may comprise a container. In some embodiments, the method includes the step of trimming the one or more blow-molded preforms. In some embodiments, the step of trimming includes a spin trim operation to remove a dome from the one or more blow-molded preforms. In some embodiments, the method includes a two-stage blow molding process such that the one or more preforms are injection molded and stored before blowing the one or more preforms to produce a container.

The present disclosure may be understood more readily by reference to the following detailed description of the embodiments taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this application is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting. In some embodiments, as used in the specification and including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It is also understood that all spatial references, such as, for example, horizontal, vertical, top, upper, lower, bottom, left and right, are for illustrative purposes only and can be varied within the scope of the disclosure. For example, the references “upper” and “lower” are relative and used only in the context to the other, and are not necessarily “superior” and “inferior”.

The following discussion includes a description of components of a plastic, hot-fillable container system. Alternate embodiments are also disclosed. Reference is made in detail to the exemplary embodiments of the present disclosure, which are illustrated in the accompanying figures. Turning toFIGS.1-10, there are illustrated components of a plastic, hot-fillable container20.

Container20is configured for storing products such as food, food preparation and/or beverages. Container20has a length L1from about 5 to about 7 inches. In some embodiments, length L1is about 5.864 inches. Container20includes a body22that defines a longitudinal axis AA, as shown inFIG.1. Body22includes a circumferential side wall44that extends between a top end24and a bottom end46. Body22includes a substantially cylindrical configuration. In some embodiments, body22may include various configurations, such as, for example, oval, oblong triangular, square, polygonal, irregular, uniform, non-uniform, offset, staggered, and/or tapered. Body22may be manufactured by blow molding techniques, as described herein.

End24includes a surface26. Surface26defines a centrally disposed cylindrical neck28that includes an outer diameter having threading30. In some embodiments, a blow mold for threading30includes a surface31defining at least one cavity, such as, for example, a vent33. Vents33are oriented perpendicular to a top of a surface S of threading30, as shown inFIG.10. In some embodiments, vent33may be disposed at alternate orientations, relative to surface S, such as, for example, parallel, transverse and/or angular orientations such as acute or obtuse, coaxial and/or may be offset or staggered. Vents33are configured to evacuate air trapped between the blow and the plastic as it is being blown.

Neck28is configured for engagement with a metal closure, such as a lid32, as described herein. Neck28defines an opening34configured for facilitating filling of container20. In some embodiments, neck28includes a circumferential ring128, as shown inFIG.2. Ring128is configured to resist and/or prevent neck28from distorting and ovalizing as pressure is added to side wall44of container20. For example, if neck28becomes distorted, the seal between a gasket of lid32and container20may be broken. In some embodiments, ring128includes a radius of curvature of 0.064. In some embodiment, ring128includes a height of 0.106 inches.

Lid32includes a surface36that defines a centrally disposed tamper resistant element, such as a button38, as shown inFIG.2. Button38is configured to be deflected in an upward orientation relative to surface36to visually indicate that lid32has been removed from container20and that container20has been opened. Deflection of button38is caused by a pressure release from within container20when lid32is disengaged from neck28. For example, when lid32is rotated relative to neck28, a seal created by neck28and lid32is released causing a decrease in the pressure within container20.

Surface36of lid32defines a circumferential wall40that defines a plurality of flanges42that are disposed on an inner diameter of lid32. In some embodiments, lid32includes 5 flanges42. Flanges42are disposed transverse relative to wall40and are configured for engagement with threading30of neck28. For example, when lid32engages with neck28and is twisted in a direction, flanges42engage with portions of threading30to fix lid32with neck28. In some embodiments, flanges42are alternatively threading, a ledge, and/or grooves. In some embodiments, surface36of lid32and/or flanges42can be smooth, rough, textured, porous, semi-porous, dimpled, knurled, toothed, raised, grooved and/or polished.

Body22includes a circumferential shoulder43defined from surface26of end24. Shoulder43contacts with wall44such that wall44extends from end24at shoulder43to end46, as shown inFIGS.1and2. Wall44is monolithic and is configured to resist deformation during filling of container20and/or during pasteurization of food, food preparation and/or beverages disposed within an interior chamber48. Wall44is able to withstand a vacuum draw of greater than 3 In Hg and is also able to withstand an amount of elevated pressure of greater than 3 psi. In some embodiments, wall44may include various configurations, such as, for example, oval, oblong triangular, square, polygonal, irregular, uniform, non-uniform, offset, staggered, and/or tapered. Wall44has a diameter D1from about 3 to about 5 inches, as shown inFIG.2. In some embodiments, diameter D1is about 3.337 inches. In some embodiments, body22includes one or a plurality of walls.

Side wall44includes a plurality of circumferential grooves50that are disposed perpendicular relative to longitudinal axis AA. Grooves50are separated by circumferential segments52that are defined from side wall44. Grooves50are configured to provide flexibility to side wall44. In some embodiments, grooves50may include various configurations, such as, for example, parallel, irregular, uniform, non-uniform, offset, staggered, and/or tapered.

End46has a diameter D2from about 3 to about 5 inches, as shown inFIG.2. In some embodiments, D2is about 3.435 inches. End46defines a base54, as shown inFIGS.4and5. Base54is configured to compensate for a change in volume inside of interior chamber48when interior chamber48is filled with food, food preparation and/or beverages or when said food, food preparation and/or beverages are pasteurized after container20is filled. Base54moves relative to wall44in response to pressure changes within interior chamber48to decrease and/or increase the volume as needed. For example, base54is movable in an outward and/or inward direction relative to wall44during pressure and/or vacuum application to prevent container20from deforming. For example, during manufacture and/or when a standard container is filled with hot products, a standard container can undesirably deform during pressure and/or vacuum application, distorting the base of the container. In some embodiments, a distorted base hinders the container's ability to stand upright on a shelf.

Base54includes a surface56that defines a circumferential wall58and a shelf60that is in direct communication with wall58. Both wall58and shelf60extend axially inwardly into interior chamber48, as shown inFIG.5. Wall58has a maximum height H1from about 0.1 to about 3.0 inches. In some embodiments, H1is about 0.414 inches. A gap64separates wall58from an interior surface66of interior chamber48. Gap64distance dd1is from about 0.1 to about 3.0 inches. In some embodiments, dd1is about 0.219 inches. Gap64prevents wall58from rubbing against surface66during inward and outer movement of base54.

Shelf60is angled having an arc BB extending from an edge62to a centrally disposed circular panel68, as described below. Shelf60has a dimeter D3of about 3.0 to about 3.5 inches.

Shelf60of base54defines panel68. Panel68moves outwardly and inwardly relative to wall44through shelf60during pressure and/or vacuum application. Panel68has a diameter D4from about 0.1 to about 3.0 inches. In some embodiments, D4is about 1.860 inches. Diameter D4is less than D3.

Panel68includes a circular center portion70and a plurality of spaced apart radial segments72, as shown inFIGS.3-5. Portion70resists deformation when moving inwardly and outwardly on panel68relative to container20during pressure and/or vacuum application.

A surface71of portion70is concave, as shown inFIG.5. Surface71has a diameter D5from about 0.1 to about 3.0 inches. In some embodiments, D5is about 0.219 inches. Diameter D5is less than both D3and D4. Portion70includes a wall74that directly communicates with segments72to facilitate pressure relief in interior chamber48. Wall74includes a plurality of longitudinal lines or indents75disposed between segments72, as shown inFIGS.6-8. Lines75are configured to impart flexibility to wall74. Wall74has a height H2.

Segments72are disposed circumferentially about and directly communicate with portion70. At least a portion of each segment72is tapered from an outer side76to an inner side78, as shown inFIG.4. A top side80of each segment72slopes in a downward direction at an angle α1from inner side78to outer side76, as shown inFIG.5. The slope causes each segment72to have a maximum height H3at inner side78and a minimum height H4at outer side76. In some embodiments, base54includes one or a plurality of segments72.

As shown inFIGS.6-8, prior to filling of container20, base54is in its originally shaped configuration, as shown inFIG.6. After container20is filled with hot products such as food, food preparation and/or beverages or pasteurized products, positive pressure P, which is pressure that is greater than that of the atmosphere, is induced in all directions inside interior chamber48of container20, as shown inFIG.7. To compensate for pressure change in interior chamber48, base54will move in an outward orientation, as shown by arrow KK inFIG.7, relative to wall44. In particular, shelf60, panel68, center portion70and segments72will move in the outward direction, and base54will not move beyond end46of container20. After the product is cooled within interior chamber48, vacuum V is applied in all directions of interior chamber48and base54will move in an inward direction, as shown by arrow LL inFIG.8, relative to wall44. The position of shelf60, panel68, center portion70and segments72will be greater than the configuration of originally shaped base54, as shown inFIGS.6and8. For example, base54and its components will be disposed further within interior chamber48than the originally shaped configuration of base54is disposed.

FIG.9is a graphical representation of performance of the container system. Results show that container20can withstand high fill and pasteurization temperatures. For example, a 30-ounce (oz) heat set design of container20was filled at an average high temperature of 183.3 degrees Fahrenheit when the fill target was 175 degrees Fahrenheit. In some embodiments, container20can withstand fill and pasteurization temperatures greater than 185 degrees Fahrenheit. In some embodiments, container20can withstand fill and pasteurization temperatures greater than 185 degrees Fahrenheit to about 220 degrees Fahrenheit.

Container20is made from PET. In some embodiments, container20may be fabricated from plastic and formed using injection and compression molding processes. In some embodiments, container20may be fabricated from polyester (PES), polyethylene (PE), high-density polyethylene (HDPE), polyvinyl chloride (PVC), polyvinylidene chloride (PVDC) (Saran), low-density polyethylene (LDPE), polypropylene (PP), polystyrene (PS), high impact polystyrene (HIPS), polyamides (PA) (Nylons), acrylonitrile butadiene styrene (ABS), polyethylene/acrylonitrile butadiene styrene (PE/ABS), polycarbonate (PC), polycarbonate/acrylonitrile butadiene styrene (PC/ABS), and/or polyurethanes (PU). In some embodiments, container20, as described herein, can be fabricated from materials suitable for food packaging products. In some embodiments, such materials include synthetic polymers such as thermoplastics, semi-rigid and rigid materials, elastomers, fabric and/or their composites.

Container20has a crystallinity from about 23% to about 32%. In some embodiments, a preform of container20can be heated and stretched to produce a container20having a crystallinity between about 10 and about 50%. In some embodiments, the preform of container20includes a molecular weight between about 120,000 g/mol and about 500,000 g/mol.

A finished PET blow-molded, container20is constructed for use with a selected application, as described herein. In some embodiments, the selected application includes food, food preparation oils, viscous and/or beverage products.

In some embodiments, the present manufacturing method provides PET enhancements via improved material orientation with selective physical performance features, such as, for example, improved top load performance, improved vacuum resistance performance and/or hoop strength, improved O2performance and improved MVTR performance.

In some embodiments, the present container system is employed with a method for manufacturing container20. The method includes the steps of employing a single stage blow molding process and providing a preform that produces containers having base54including shelf60, panel68, center portion70and segments72. In some embodiments, the method includes injection molding the preform using a two-phase injection system, wherein one phase of the two-phase injection system (e.g., a first phase) comprises injecting material into the preform and another phase of the two-phase injection system (e.g., a second phase) comprises injecting material into the preform to form a layer or multiple layers. The material used in the first phase does not include any additives. In some embodiments, the material used in the first phase is virgin PET without additives and the material used in the second phase is PET and additives. This allows the material that is used in the first phase to be reground as virgin PET so as to avoid regrinding issues discussed above.

In some embodiments, the method further comprises running container20on a machine capable of a base-over stroke system. The base-over stroke system is set at 15 mm to about 25 mm. In some embodiments, the operating temperature of the preform is 115 degrees Celsius to about 125 degrees Celsius and the blow mold temperature is 130 degrees Celsius to about 140 degrees Celsius.

In some embodiments, the method includes the step of testing the one or more preforms to ensure the one or more preforms include a selected weight and selected neck finish dimension. In some embodiments, the method includes the step of employing the one or more preforms with a base54production mold. In some embodiments, the method includes the step of blow molding the one or more preforms, which may comprise a container. In some embodiments, the method includes the step of trimming the one or more blow-molded preforms. In some embodiments, the step of trimming includes a spin trim operation to remove a dome from the one or more blow-molded preforms. In some embodiments, the method includes a two-stage blow molding process such that the one or more preforms are injection molded and stored before blowing the one or more preforms to produce a container. In some embodiments, the method includes reusing the dome to produce other containers, such as, for example other wide mouth containers. In some embodiments, reusing the dome includes grinding, blending, drying and adding the dome and adding the ground, blended and dried material to a melt stream, wherein the done does not contain additives.

In some embodiments, shelf60, panel68, and center portion70are blow molded with segments72. In some embodiments, segments72are manufactured and separately attached, applied and/or adhered to panel68of base54.

In some embodiments, during manufacture, container20is filled with food and/or beverage products at a fill site utilizing automated fill equipment. In some embodiments, the food and/or beverage products are hot due to high temperatures in the fill and pasteurization of the products. Positive pressure is induced in all directions inside interior chamber48of container20when container20is filled with the food and/or beverage products. In some embodiments, container20is capable of maintaining an initial shape at an elevated pressure of greater than 3 pounds per square inch (psi) and withstands a vacuum draw of greater than 3 In Hg during filling of container20with hot food and/or beverage products. During filling of container20, base54is movable in an outward and/or inward direction relative to wall44during pressure and/or vacuum application to prevent container20from deforming.

It will be understood that various modifications may be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but merely as exemplification of the various embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.