Patent Grant
11136159
The presently disclosed subject matter relates generally to plastic containers, for example a blow-molded bottle with ribs.
Plastic containers are often used due to their durability and lightweight nature. A wide variety of suitable plastics are commercialized for various uses. For example, polyethylene terephthalate (PET) is often used to form containers, which are lightweight, inexpensive, recyclable and manufacturable in large quantities.
Plastic containers can be used for a variety of products, such as perishable beverages and nonperishable liquids. Often these beverages, such as juices and isotonics, are filled into the containers while the liquid is at an elevated temperature. Subsequently the container is sealed and allowed to cool. This process is known as hot-filling. The containers that are designed to withstand the process are known as hot-fill containers.
The use of blow molded plastic containers for packaging hot-fill beverages is well known. However, a plastic container that is used in the hot-fill process is subject to stresses on the container that can result in the container deforming or failing due to the pressure differential (i.e. vacuum) created by the cooled liquid. Furthermore, the deformation of the container, if not controlled, can detrimentally impact the strength of the container, e.g. hoop strength about the circumference and/or axial load strength.
A variety of techniques and features have been developed to minimize or control deformation resulting from the hot-fill process. Such techniques include incorporation of vacuum panels into the sidewall of the container and/or a diaphragm-like feature or construction in the base of the container. However, there continues to be a need for improved techniques or features to address the pressure-differentials resulting from the hot-fill process in blow-molded plastic containers without compromising the aesthetics or strength of the container.
The purpose and advantages of the disclosed subject matter will be set forth in and apparent from the description that follows, as well as will be learned by practice of the disclosed subject matter. Additional advantages of the disclosed subject matter will be realized and attained by the methods and systems particularly pointed out in the written description and claims hereof, as well as from the appended drawings.
To achieve these and other advantages, and in accordance with the purpose of the disclosed subject matter, as embodied and broadly described, the disclosed subject matter includes a container having a body portion with a sidewall defining an outer perimeter and a hollow interior. The container further includes a bottom portion extending from a lower end of the body portion, the bottom portion defining a horizontal support surface. The container further includes a top portion extending from an upper end of the body portion opposite the bottom portion. The top portion includes a finish portion. The body portion of the container includes a plurality of continuous ribs extending about the outer perimeter of the sidewall, each continuous rib having alternating horizontal segments and branched segments. Each branched segment includes a top branch and a bottom branch joined at either end to define a bounded area therebetween. The plurality of continuous ribs includes at least a first continuous rib and a second continuous rib, the second continuous rib spaced vertically from the first continuous rib. A midpoint of each branched segment of the first continuous rib is aligned along a vertical axis with a midpoint of a corresponding horizontal segment of the second continuous rib, and a midpoint of each horizontal segment of the first continuous rib is aligned along a vertical axis with a midpoint of a corresponding branched segment of the second continuous rib.
Additionally, and as embodied herein, for purpose of illustration and not limitation, a top edge of each top branch of the first continuous rib can define a first horizontal plane, and a bottom edge of each bottom branch of the second continuous rib can define a second horizontal plane. The second horizontal plane can be spaced vertically from the first horizontal plane. For example, the second horizontal plane can be above the first horizontal plane. Furthermore, the body portion can include a continuous groove extending about the outer perimeter of the sidewall between the first horizontal plane and the second horizontal plane. The distance between the first horizontal plane and the second horizontal plane can be approximately 0.040 inches to approximately 0.090 inches.
Furthermore, and as embodied herein, the first continuous rib and second continuous rib can be configured such that a first vertical distance between a midpoint of each top branch of the first continuous rib and a midpoint of a corresponding horizontal segment of the second continuous rib is substantially equal to a second vertical distance between a midpoint of each horizontal segment of the first continuous rib and a midpoint of a corresponding bottom branch of the second continuous rib. The first vertical distance can be approximately 0.280 inches to approximately 0.420 inches.
Additionally, and as embodied herein, the container can include a third continuous rib such that a first vertical distance between a midpoint of each horizontal segment of the second continuous rib and a midpoint of a corresponding top branch of the first continuous rib can be substantially equal to a second vertical distance between the midpoint of each horizontal segment of the second continuous rib and a midpoint of a corresponding bottom branch of the third continuous rib. Although not limited, the body portion of the container can include between 3 and 12 continuous ribs.
Further in accordance with the disclosed subject matter, each bounded area can have any of a variety of suitable shapes, such as a circular shape, oval shape, eye-like shape, rectangular shape, square shape, hexagonal shape, octagonal shape or any other suitable shape. As embodied herein, each branched segment can include at least one linear section aligned parallel to each horizontal segment. The length of each linear section can be substantially equal to a length of each horizontal segment. Although not limited, each continuous rib can have between 4 and 12 branched segments and a corresponding number of horizontal segments.
As further embodied herein, and in accordance with the disclosed subject matter, each continuous rib defines a concave channel in side cross-section relative to an exterior of the perimeter. Each channel can have a nadir having a first depth relative to the sidewall. For example, the first depth can be between 0.020 inches and 0.080 inches. Furthermore, and as embodied herein, each nadir can have a second depth relative to the bounded area. The second depth can be substantially equal to the first depth or can differ from the first depth.
Further in accordance with the disclosed subject matter, the container is a blow molded container. As embodied herein, the container can have a wall thickness of approximately 0.008 inches to approximately 0.017 inches. Additionally, or alternatively, the container can have a total weight of approximately 24 grams to approximately 35 grams. Containers in accordance with the disclosed subject matter can be made from any suitable material, such as low and high-density polyethylene, polyethylene terephthalate, polyethylene naphthalate (“PEN”), PEN blends, polyvinyl chloride, polypropylene, polystyrene, fluorine treated high density polyethylene, post-consumer resin, K-resin, bioplastic, catalytic scavengers, including monolayer-blended scavengers, multi-layer structures, or a mixture, blend, or copolymer thereof. Furthermore, and as embodied herein, the bottom portion of the container can include a vacuum base.
The disclosed subject matter also includes a method of making a container having some or all of the features described herein, as well as a method of using such a container. As recognized in the art, the container disclosed herein can include some or all of the features described herein, or any suitable combination thereof.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and are intended to provide further explanation of the disclosed subject matter claimed.
The accompanying drawings, which are incorporated in and constitute part of this specification, are included to illustrate and provide a further understanding of the containers and methods of the disclosed subject matter. Together with the description, the drawings serve to explain the principles of the disclosed subject matter.
Reference will now be made in detail to the various exemplary embodiments of the disclosed subject matter, exemplary embodiments of which are illustrated in the accompanying drawings. The structure and corresponding method of operation of the disclosed subject matter will be described in conjunction with the detailed description of the system.
The apparatus and methods presented herein can be used for the packaging, transport, storage, commercialization, and consumption of a wide variety of perishable or nonperishable liquids and other products. The disclosed subject matter is particularly suited for blow-molded plastic containers subject to hot-fill processes or the like.
In accordance with the disclosed subject matter herein, the container generally includes a body portion with a sidewall defining an outer perimeter and a hollow interior. The container further includes a bottom portion extending from a lower end of the body portion, the bottom portion defining a horizontal support surface. The container further includes a top portion extending from an upper end of the body portion opposite the bottom portion. The top portion includes a finish portion. The body portion of the container includes a plurality of continuous ribs extending about the outer perimeter of the sidewall, each continuous rib having alternating horizontal segments and branched segments. Each branched segment includes a top branch and a bottom branch joined at either end to define a bounded area therebetween. The plurality of continuous ribs includes at least a first continuous rib and a second continuous rib, the second continuous rib spaced vertically from the first continuous rib. A midpoint of each branched segment of the first continuous rib is aligned along a vertical axis with a midpoint of a corresponding horizontal segment of the second continuous rib, and a midpoint of each horizontal segment of the first continuous rib is aligned along a vertical axis with a midpoint of a corresponding branched segment of the second continuous rib.
The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the disclosed subject matter. For purpose of explanation and illustration, and not limitation, exemplary embodiments of the container in accordance with the disclosed subject matter are shown in
For purpose of illustration, and not limitation, reference is made to the exemplary embodiment of a container 100 shown in
Body portion 102 can extend from top portion 101 directly or indirectly and include sidewall 111. In accordance with the disclosed subject matter, and as embodied herein, body portion 102 can include a plurality of continuous ribs 201, each extending continuously about the outer perimeter of the sidewall 111. Each continuous rib 201 includes branched segments 204 which define the bounded areas 205 of body portion 102, as further discussed herein.
Body portion 102 can have any of a variety of suitable shapes. For example, and without limitation, body portion 102 can have a generally polygonal shape in plan view, such as a rectangular, square or octagonal shape, or an elliptical shape, or as embodied herein, body portion 102 of container 100 can have a substantially circular shape in plan view. Such shapes can be readily manufactured using blow-molding techniques and compatible for use with certain equipment used for sterilization and/or pasteurization, such as a high-pressure processing (or high-pressure preservation or HPP) food processing apparatus.
As previously noted and as embodied herein, body portion 102 can include a plurality of continuous ribs 201 which can strengthen the container while controlling or inhibiting distortion and/or deflection of the body portion 102, for example due to negative pressure in the container, such as for gripping, lifting or manipulating of the container. Container 100 can include any suitable number of continuous ribs. As embodied herein, continuous ribs 201 can extend horizontally about the outer perimeter of the sidewall 111 of the body portion 102. Each continuous rib can include alternating horizontal segments 203 and branched segments 204. In accordance with the disclosed subject matter, each continuous rib 201 can include any suitable number of branched segments 204 and a corresponding number of horizontal segments 203. The number of branched segments 204 and corresponding number of horizontal segments 203 in each continuous rib 201 can depend on the size and shape of the container, as well as on the size and shape of the branched segments 204 and horizontal segments 203 respectively. For example, and without limitation, for a container with a capacity of 20 fluid ounces or a diameter of approximately 2.9 inches, each continuous rib 201 can have between 5 and 9 branched segments 204 and a corresponding number of horizontal segments. In accordance with one aspect of the disclosed subject matter, the container can have 6 branched segments 204 and a corresponding number of horizontal segments 203.
With reference to
Alternatively, and in accordance with the disclosed subject matter, the bounded area 205 can be defined by a top branch 504 and a bottom branch 505 so as to have any of a variety of other suitable shapes. For example, and without limitation, bounded area 205 can have a generally oval shape, or a substantially rectangular shape, a triangular shape, an eye-like shape, a circular shape, a square shape, an octagonal shape, or any other suitable shape. For purpose of example and not limitation, an exemplary embodiment of a container in accordance with the disclosed subject matter with bounded areas 205 having an eye-like shape is depicted in
Additionally, or alternatively, and as further embodied herein, containers in accordance with the disclosed subject matter can include bounded areas 205 of different shapes and sizes. For purposes of example, and not limitation, a first continuous rib can have branched segments 204 defining bounded areas with a generally hexagonal shape, and a second continuous rib can have branched segments 204 defining bounded areas 205 having a generally oval shape. For purposes of example and not limitation,
Further referencing
Alternatively, depending on the desired use of the container 100, the second horizontal plane 507 can be spaced vertically from the first horizontal plane 506 such that the second horizontal plane 507 is below the first horizontal plane 506. That is, the second horizontal plane 507 can be disposed closer to the bottom portion 103 of the container 100 than the first horizontal plane 506, such that second continuous rib 502 can be closer to first continuous rib 501 along a vertical axis. For purpose of example, and not limitation, an alternative exemplary embodiment of a container in accordance with the disclosed subject matter having such a configuration is depicted in
Depending on the desired performance and intended use of the container, the second horizontal plane 507 and the first horizontal plane 506 can be co-planer along a vertical axis such that a top edge of the top branch 504 of a first continuous rib 501 can be aligned with a bottom edge of a corresponding bottom branch 505 of a second continuous rib 502. For example, and with reference to the exemplary embodiment of
Further referencing
Additionally, and as further embodied herein, the container 100 can include a third continuous rib 503. The third continuous rib 503 can be vertically spaced from the second continuous rib 502 such that the vertical spacing between the third continuous rib 503 and the second continuous rib 502 can be substantially equal to the vertical spacing between the first continuous rib 501 and the second continuous rib 502. As such, a first vertical distance can be measured between a midpoint 509 of each horizontal segment 203 of the second continuous rib 502 and midpoint 510 of each corresponding top branch 504 of the first continuous rib 501, and further wherein a second vertical distance can be measured between a midpoint 509 of each horizontal segment 203 of the second continuous rib 502 and midpoint 513 of each corresponding bottom branch 505 of the third continuous 503. As embodied herein, the first vertical distance between midpoints 509 and 510 can be substantially the same as the second vertical distance between midpoints 509 and 513. Alternatively, the vertical spacing between the second and third continuous ribs can be different than the vertical spacing between the first and second continuous ribs.
As further depicted in the exemplary embodiment of
With reference to
For purpose of illustration and not limitation, reference is now made to
As further depicted in
Further in accordance with the disclosed subject matter, each pair of top branch 504 and bottom branch 505 of the branched segments 204 of the continuous ribs 201 defines bounded areas 205 therebetween. For purpose of illustration, and as depicted in
While the above discussion refers to continuous ribs 201 as recessed within the sidewall 111 and bounded areas 205, containers in accordance with the disclosed subject matter can include continuous ribs 201 raised or extending outwardly relative the adjacent sidewall 111 and bounded areas 205. In such embodiments the continuous ribs 201 can have similarly suitable shapes, as described above, so as to have heights measured from the sidewall 111 and bounded areas, respectively.
As further embodied herein, sidewall 111 of container 100 can have a thickness 721. As will be recognized by those skilled in the art, the sidewall thickness 721 of containers according to the disclosed subject matter can be generally uniform, or can be varied across different portions of the sidewall depending on the properties of the material used to make the container and the method of manufacture used. For example, and as embodied herein, a blow molded plastic container 100 can have an average sidewall thickness of between approximately 0.008 inches to approximately 0.017 inches for a container with a capacity of 20 fluid ounces. As further embodied herein, container 100 can have a weight of between approximately 24 grams to approximately 35 grams for a container with a capacity of 20 fluid ounces depending on the properties of the material used to make the container and the method of manufacture used. As will be understood by those in the art, the average sidewall thickness and the weight of container 100 can vary with the size of the container, such that a container with a greater capacity can have increased average sidewall thickness and increased weight.
As further embodied herein, container 100 includes a bottom portion 103 disposed below body portion 102 opposite top portion 101 and extending from a lower end of the body portion 102.
In accordance with another aspect of the disclosed subject matter, a method of making and of using a container 100 of the disclosed subject matter is provided. That is, it will be understood that the container having the various features as disclosed can be made using any suitable technique, including blow molding, extrusion blow molding, single stage polyethylene terephthalate, two stage polyethylene terephthalate, etc. For example, and without limitation, the disclosed containers can be made by the methods disclosed in U.S. Pat. Nos. 8,636,944, 8,585,392, 8,632,867, 8,535,599, 8,544,663, and 8,556,621, each of which is incorporated by reference herein in its entirety. The container can be made from any suitable polymeric materials, including but not limited to low and high-density polyethylene, polyethylene terephthalate, polyethylene naphthalate (“PEN”), PEN blends, polyvinyl chloride, polypropylene, polystyrene, fluorine treated high density polyethylene, post-consumer resin, K-resin, bioplastic, catalytic scavengers, including monolayer-blended scavengers, multi-layer structures, or a mixture, blend, or copolymer thereof. Likewise, the containers disclosed herein can be hot-filled, sealed, and cooled using a suitable process. For purpose of example and not limitation, containers in accordance with the disclosed subject matter can be hot-filled with liquids at temperatures between 68° C.-101° C. (155° F.-214° F.) and usually about 85° C. (185° F.).
The containers of the disclosed subject matter have demonstrated desired performance characteristics not achieved by conventional hoop-ring containers or the like. For purpose of understanding and not limitation, data is provided to demonstrate various operational characteristics achieved by the containers disclosed herein. For purpose of illustration and comparison, computer simulation using a finite element analysis software was performed to compare the characteristics of an exemplary container in accordance with the disclosed subject matter to the characteristics of a container of similar size and construction, but with a traditional hoop-ring design. With reference to
When subjected to internal vacuum forces, the conventional hoop-style container 750 was observed to deform in the vertical direction. For example, stresses can concentrate in hoops 751 when the container 750 is subjected to vacuum forces, and the stress concentrations cause hoops 751 to deform or compress vertically such that the overall height of the hoop-style container 750 decreases. Additionally, such stresses under vacuum conditions are observed to be unevenly distributed in the traditional hoop-style container 750 such that the container deforms vertically more in certain areas of the sidewall than others. This uneven distortion can cause the container to bend or lean under vacuum such that the container sidewall moves or bends transverse to a vertical axis of the container. Such negative pressures in the hoop-style container therefore can result in undesired deformation of the container which can lead to an aesthetically unacceptable container, and/or compromised performance, including reduced strength, e.g. hoop strength and axial load, as well as instability. Furthermore, containers with decreased wall thickness can be desirable for material and weight savings, but the likelihood and/or the amount of deformation can increase as the average wall thickness of the container is decreased.
To model the behavior characteristics of an exemplary embodiment of a hoop-style container 750, a vacuum pressure was simulated within the hoop-style container 750, as depicted in
For purpose of understanding and not limitation,
Accordingly, containers according to the disclosed subject matter can exhibit reduced undesirable or uncontrolled deformation compared to traditional containers having the same sidewall thickness and material weight without compromising performance.
In addition to the specific embodiments claimed below, the disclosed subject matter is also directed to other embodiments having any other possible combination of the dependent features claimed below and those disclosed above. As such, the particular features presented in the dependent claims and disclosed above can be combined with each other in other manners within the scope of the disclosed subject matter such that the disclosed subject matter should be recognized as also specifically directed to other embodiments having any other possible combinations. Thus, the foregoing description of specific embodiments of the disclosed subject matter has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosed subject matter to those embodiments disclosed.
It will be apparent to those skilled in the art that various modifications and variations can be made in the method and system of the disclosed subject matter without departing from the spirit or scope of the disclosed subject matter. Thus, it is intended that the disclosed subject matter include modifications and variations that are within the scope of the appended claims and their equivalents.
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