Technical Field
The presently disclosed subject matter relates generally to plastic containers, and more particularly to hot-fillable containers having discrete surface indentations configured to prevent permanent deformation.
Description of Related Art
Throughout the process of filling a plastic container, such as conventional hot-filled bottling techniques, the container is inherently subject external forces and to positive and negative pressures within the container. These forces and pressures can result in permanent deformation of the plastic material of the container, especially shortly after hot-filling the container, when the temperature of the plastic material is close to or above the glass transition temperature of the plastic material.
Various container configurations are known to permit temporary deformation at predefined locations on the container to compensate for negative pressure generated within the container due to cooling of the hot-filled contents after capping and sealing without permanent deformation of the container. For example, U.S. Pat. Nos. 5,303,834 and 7,334,695, each of which is hereby incorporated by reference herein in its entirety, disclose containers having recessed panels defined on the sidewalls of the containers. The recessed panels are configured to temporarily flex inwardly in response to negative container pressure, thereby reducing the volume of the container and eliminate a portion of the vacuum in the container. U.S. Pat. No. 7,334,695 discloses improvements in recessed panel design which permit vacuum compensation while also preventing permanent container bulging due to positive pressure during the filling process. Additionally or alternatively, and as disclosed in, for example, U.S. Pat. Nos. 6,662,960 and 7,481,375, each of which is hereby incorporated by reference herein in its entirety, one or more reinforcing ribs or grooves, such as horizontal ribs or grooves, may be defined in the container sidewall. Such ribs and grooves provide regions of increased radial stiffness to resist deformation of the container material beyond its plastic limit when subject to internal pressures and external loads.
However, consumer demand for packaged products is heavily influenced by aesthetic considerations of the packaging itself. Container design is therefore circumscribed by a need to provide containers having certain surfaces generally unencumbered by functional geometric features. Presently available plastic containers having pleasing surface aesthetics remain susceptible to permanent deformation during hot fill processing, handling and/or conveyance. Accordingly, there remains a continued need for improved, deformation-resistant plastic containers.
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 plastic containers having one or more indentations defined in the surface thereof, the indentations located and configured to temporarily deform in response to an external load exerted on the surface of the container.
In accordance with the disclosed subject matter, a hot-fillable plastic container is provided including a container body having an outer surface and defining a longitudinal axis. At least one recessed panel is defined in the container body. The at least one recessed panel has an outer perimeter and is recessed relative to the outer surface of the container body, wherein the outer perimeter includes opposing longitudinal sides and transverse ends. A transition region is defined along the perimeter of the recessed panel, the transition region extending between the recessed panel and the outer surface. At least one indentation is formed in the transition region proximate at least one transverse end of the outer perimeter, the indentation having a height, a width, and a depth, the height of the indentation extending beyond the transition region.
As embodied herein, the indentation can be tapered such that the height, width, and depth of the indentation increase with increasing distance from the recessed panel to a maximum width and a maximum depth at the outer surface of the container body. The indentation is configured to temporarily deform when the plastic container is subject to an external load. Furthermore, the indentation can be located at or proximate to the midpoint of a transverse end of the outer perimeter. Furthermore, the indentation can be located the transition region proximate a longitudinal side of the outer perimeter. Methods of forming and filling such hot-fillable plastic containers are also disclosed herein.
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 method and system 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. Methods of forming and filling or using the container of the disclosed subject matter will be described in conjunction with the detailed description of the container.
In accordance with the disclosed subject matter, a hot-fillable plastic container comprising a container body having an outer surface and defining a longitudinal axis, at least one recessed panel defined in the container body, the at least recessed one panel having an outer perimeter and recessed relative to the outer surface of the container body, the perimeter including opposing longitudinal sides and transverse ends, a transition region defined along the perimeter of the recessed panel, the transition region extending between the recessed panel and the outer surface, and at least one indentation formed in the transition region proximate at least one transverse end of the outer perimeter, the indentation having a height, a width, and a depth, the height of the indentation extending beyond the transition region is provided,
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. Hence, features depicted in the accompanying figures support corresponding features and combinations thereof of the claimed subject matter.
Referring now to an exemplary embodiment of
Container body 110 has an outer surface 112 and a plurality of recessed panels 114 defined therein. A plurality of posts 113 are defined on the outer surface 112 between adjacent recessed panels 114. Each recessed panel 114 contains a raised island 120 located substantially centrally on the recessed panel 114. In the embodiment depicted, each raised island 120 has an upper portion 122, middle portion 124, and lower portion 126, wherein middle portion 124 is formed as a generally horizontal rib. Upper portion 122 and lower portion 126 are substantially co-planar with outer surface 112 of container body 110 to help support a label mounted on the outer surface 112 of container body 110 if desired.
Recessed panels 114 are configured to flex inwardly in response to negative pressure within container 100 associated with cooling and contraction of the volume of the hot-filled liquid contents therein. Raised islands 120 increase the circumferential profile of the recessed panels 114, and can thereby limit outward expansion of the recessed panels 114 during pressurization of container 100 to prevent to prevent permanent outward deformation or barreling of the recessed panels. The raised islands and various alternative embodiments thereof are described in more detail in U.S. Pat. No. 7,334,695.
As depicted in the exemplary embodiment of
In the depicted embodiment, the recessed panels 114 are generally rectangular in side view. Hence, the perimeter of each recessed panel 114 has longitudinal sides 130 defined vertically along the longitudinal axis of the upright container and upper transverse end 132 and lower transverse end 134 defined horizontally along the transverse axis of the upright container.
In accordance with the disclosed subject matter, and as previously noted, at least one indentation is formed in the transition region, for example proximate at least one transverse end of the outer perimeter. Accordingly, in one aspect of the disclosed subject matter, at least one indentation 150 is defined in a surface of a container 100 extending radially between the outer surface 112 of the container 100 and a surface of the container 100 that is recessed relative thereto. The at least one indentation 150 has a height, a width, and a depth, and is oriented substantially vertically and substantially perpendicular to or tangential to the radially extending surface. The indentation 150 provides a region of greater flexibility and reduced rigidity relative to the radially extending surface to absorb stress exerted on the container by an external force. For example, and not by limitation, the exemplary embodiment of
An exemplary indentation 150 is depicted in
Conventional container configurations generally have surface regions with high rigidity to provide, for example, grippable surfaces, top load strength, and limited sidewall buckling. However, contact between laterally adjacent containers at these regions of high rigidity, and particularly extended contact between multiple containers squeezed against each other during the hot-fill process, can cause commercially unacceptable localized deformation or warping of the outer surface of the container at these regions of contact. The indentations of the disclosed subject matter are configured to absorb container stress exerted by external forces such as adjacent containers and contact with the side rails of container filling lines. The indentations thus can reduce localized container stress between the transition regions and adjacent outer surface. Stress can be distributed to a greater extent, lowering peak stress at regions of contact with adjacent containers. For example, the curved surface of the indentations extending beyond the transition region can be configured to resist permanent outward deformation, and thus bias the indentation to return to its initial configuration when pressure in the container is reduced.
It is to be recognized that the overall shape and dimensions of the indentation, as well as the relative proportions of the container will vary according to the size and intended use of the container. For example, while a generally cylindrical container is illustrated herein, one of ordinary skill will recognize that the size and shape of container can be modified and the disclosed subject matter is not so limited.
For purpose of illustration only, the dimensions of the indentations and the corresponding container volume and diameter of the exemplary embodiments of container 100 as depicted in
The dimensions above are provided for illustration only, and not limitation. Generally, the depth of the indentations can be between about 0.025 inches and about 0.350 inches, or between about 0.1 inches and about 0.3 inches; the height of the indentations can be between about 0.05 inches and about 0.5 inches, or about 0.15 inches and about 0.4 inches; and the width of the indentations can be between about 0.05 inches and about 0.5 inches, or between about 0.15 inches and about 0.4 inches. In embodiments when the indentations are substantially tapered, such as depicted in
One consideration in determining a dimension of an indentation in accordance with the disclosed subject matter is a corresponding dimension of container as a whole. In certain embodiments, the ratio of the maximum depth of the indentation to the maximum radius of the container is between about 0.075 and about 0.15; the ratio of the maximum height of the indentation to the height of the container is between about 0.05 and about 0.15; and the ratio of the maximum width of the indentation to the maximum radius of the container body is between about 0.10 to about 0.20.
In certain embodiments, however, a relevant consideration for determining a dimension of an indentation in accordance with the disclosed subject matter is a corresponding dimension of a particular portion of the container 100, such as the container body 110 or a panel recessed thereto (e.g., recessed panel 114). Thus, the ratio of the maximum width of an indentation 150 to the maximum width of a recessed panel 114 can be between about 0.1 and about 0.5, or between about 0.2 and about 0.4; and the ratio of the maximum depth of an indentation 150 to the depth between the outer surface 112 of the container body 110 and a recessed panel 114 therein can be between about 0.3 and about 1.0, or between about 0.5 and about 0.95. The ratio of the radius of curvature of indentation groove 152 to the radius of the container body can be between about 0.02 to about 0.06, or between about 0.025 to about 0.04.
In embodiments of the disclosed subject matter in which the container body 110 is separated from additional portions of the container, such as a base portion 108 or an upper dome 104 by a geometric feature, such as a circumferential groove 107, 109, the indentation 150 can extend over substantially the entire distance between the transition portion and the surface geometry feature, or can extend over a portion of said length.
In the exemplary embodiment depicted in
Additionally or alternatively, the indentation can be configured to temporarily flex or deform to relieve stress above a threshold load. For example, indentations can be configured to partially or completely fold in response to external pressure on the container after filling and sealing. For example, an indentation can deform by narrowing (e.g., folding) or by flattening (e.g., widening) depending on the direction of the local stress exerted relative thereto. By way of example, and without limitation to theory, a filled and sealed container squeezed between adjacent containers against a side rail of a container filling line would be subject to local container stress at the points of contact with the adjacent containers and the side rail. In response, the container will flex inwardly, increasing the pressure within the container. When the sum of internal and external pressures exceeds the elastic limit of the polymeric container material at a region of the container, the container material can crease. One or more indentations proximate to the adjacent containers can narrow or fold in response to the local external stress, while the remaining indentations if provided can flatten to alleviate a portion of the pressure in the container. Narrowing or folding of the indentation can result in a temporary decreased in the width of the indentation at the transition region. When the external load is removed, each indentation can return to its as-formed condition. Hence, in contrast to the deformation of the smooth sidewall observed in prior art containers, residual creasing, if any, of the indentations is either unnoticeable or commercially acceptable. Accordingly, as embodied herein, the indentation can be configured to fold inwardly in response to an external force on the outer surface of the container, and to reform substantially to its as-formed shape when the external force is removed. The indentation can therefore advantageously reduce or prevent permanent container creasing or deformation caused by external forces on the container. In particular, the indentation can reduce the susceptibility of the container to permanent deformation relative to an identical or substantially identical container that does not include an indentation as disclosed.
As embodied herein, for purpose of illustration, the transition portion proximate the transverse end 132, 134 of the perimeter is provided with a single indentation 150 at about the midpoint between longitudinal sides. It will be recognized, however, that alternative arrangements of transverse ends 132 and 134, can be provided—with and without indentations 150. For purpose of example and not limitation, only one of transverse end 132 or transverse end 134 can have an indentation 150; or, when more than one recessed panel 114 is provided, only alternating transverse ends 132 and 134 of adjacent panels can have an indentation 150. Likewise, although as depicted only one indentation 150 is provided in each transverse end 132, 134, two or more indentations 150 can be provided in one or both transverse ends 132, 134. Moreover, and as described below, one or more, or two or more, indentations 150 can additionally or alternatively be provided in one or both of the longitudinal sides 130 of one or more panels.
Although the various embodiments depicted herein are all substantially cylindrical containers, container can have any desired shape, provided that the container is susceptible to local deformation of the outer surface of the container body due to pressure exerted by adjacent containers during hot-fill processing and handling.
Although only generally rectangular recessed panels and corresponding transition regions are depicted herein, recessed panel can have any suitable shape, such as square, oval, circular, or polygonal. When the recessed panel and corresponding transition region is round, the indentations can be provided at the bottom and/or top of the transition region.
The cross-sectional side view of the base 108 of the exemplary container embodiments of
The base 108 of the exemplary embodiment of container 100 illustrated in
The containers described herein can be formed from materials including, but not limited to, polyethylene terephthalate (PET), polyethylene naphthalate (PEN) and PEN-blends, polypropylene (PP), high-density polyethylene (HDPE), among others and combinations thereof. Furthermore, various additives or surfactants can be used, such as monolayer blended scavengers or other catalytic scavengers as well as multi-layer structures including discrete layers of a barrier material, such as nylon or ethylene vinyl alcohol (EVOH) or other oxygen scavengers.
In the exemplary embodiments of container 100 depicted herein, for illustration and not limitation, raised islands 120 are defined within the recessed panels 114. In the embodiments depicted in
Based upon the above containers in accordance with the disclosed subject matter herein can be provided with improved load performance relative to containers of similar configuration but without indentations of the disclosed subject matter. For purpose of comparison, fifty samples each of a conventional container and container 100 as illustrated in
The testing was performed on an Instron® top load machine programmed to provide panel extension of 0.250 inches at a speed of 2 inches per minute. Side load testing of a container 100 above and below a raised island 120 (“island side loading”) is depicted in
The load exerted during each testing run was recorded, as was the resulting distance of extension of the recessed panels from their as-formed location on the container. Each sample container was inspected visually for visible container failure (i.e., permanent deformation). It was observed that 5 out of 25 (20% of) control containers and just 1 out of 25 (4% of) containers 100 subject to island side load exhibited visible container failure. 20 out of 25 (80% of) control containers subject to post side load exhibited visible container failure, while 10 of the 25 (40% of) containers 100 subject to post side load exhibited visible container failure. These results demonstrate that the indentations as disclosed and as generally embodied herein can significantly reduce container failure due to side load.
To demonstrate if filled containers having indentations as described herein would not exhibit impaired top-load strength, finite element analysis (FEA) simulations were conducted with a control container and with container 100 as depicted in
To confirm that filled containers having indentations as disclosed properly compensate for internal vacuum after hot-filling, sealing, and cooling, FEA fluid-filled simulation was conducted using a container having indentations formed in the transition region proximate to the upper and lower transverse ends of the perimeter. The simulated container and FEA results are provided in
As previously noted, the disclosed subject matter contemplates various configurations or arrangements of the disclosed indentations. For example, another embodiment of a container in accordance with the disclosed subject matter is provided in
Further in accordance with the disclosed subject matter, at least one such indentation can be formed in the transition region proximate at least one longitudinal side of the outer perimeter of the recessed panels. Indentations formed proximate a longitudinal side of the recessed panel can extend perpendicular to a longitudinal axis defined by the container (e.g., horizontally when the container is in its upright orientation).
As further depicted, in the exemplary embodiment depicted in
Indentations 170 can be disposed symmetrically on opposing longitudinal sides 130a, 130b of recessed panels 114 or in an asymmetric arrangement. In the exemplary embodiment depicted in
Furthermore, the arrangement of indentations 170 can be varied between respective recessed panels 114. For example, one or more indentations 170 can be defined at corresponding locations in each longitudinal side 130a, 130b of a first recessed panel or series of recessed panels, and defined at a second corresponding location in each longitudinal side 130a, 130b of a second recessed panel or series of recessed panels. Accordingly, in certain embodiments, a first arrangement of respective locations of indentations 170 is provided in a first series of recessed panels, and a second arrangement of respective locations of indentations 170 is provided in a second series of recessed panels, such that the first series of recessed panels alternates in succession with the second series of recessed panels around the circumference of the container.
In accordance with another aspect, indentations in the longitudinal sides of a panel 170 can have a height a width, and/or a depth that are proportionately smaller than the height, width, and depth of indentations in the transverse ends of the panel 150 as disclosed above, and/or a radius of curvature proportionately greater than the radius of curvature of indentations 150 as disclosed above.
To demonstrate filled containers having indentations in the longitudinal sides 130a, 130b of the recessed panels 114 as disclosed would properly compensate for internal vacuum after hot-filling, sealing, and cooling, FEA fluid-filled simulation was conducted using a container having indentations formed in the transition region proximate to the upper and lower transverse ends of the perimeter as well as in the longitudinal sides of the panels. The simulated container and FEA results are presented in
Side load testing, similar to that described above was also performed on the containers having indentations in the longitudinal sides of the recessed panels. An illustration of the simulated side loads on the container for finite element analysis (“FEA”) of sidewall displacement and stress of containers in accordance with the disclosed subject matter is shown in
In accordance with another aspect of the disclosed subject matter, a method of forming a hot-fillable container having one or more indentations as described herein is provided. The method includes providing a mold having a surface impression or projection corresponding to the at least one indentation and expanding a parison into the mold to form the container. The mold contains a surface impression to define the indentation. The container can include any features or modifications as described above or otherwise known. It will be understood that the container can be made using any suitable technique, including blow molding, thermoforming, etc. By way of example, and not 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, incorporated herein by reference.
Container embodiments in accordance with the disclosed subject matter are suitable for the manufacture of containers such as, bottles, jars and the like. Such containers can be used with a wide variety of perishable and nonperishable goods. For purpose of understanding, and not limitation, the containers disclosed herein can be filled with liquid or semi-liquid beverages and food products such as sodas, juices, sports drinks, energy drinks, teas, coffees, sauces, dips, jams and the like, and can be suitable for and configured to be filled and re-filled with a hot liquid or non-contact (i.e., direct drop) filler, such as a non-pressurized filler. Containers of the disclosed subject matter can be used for transporting, serving, storing, and/or re-using such products while maintaining a desired shape despite exposure to internal pressure and external loads. The container can have a base configuration and/or side wall features to provide improved sensitivity and controlled deformation from applied forces, for example resulting from pressurized filling, sterilization or pasteurization and resulting thermal expansion due to hot liquid contents and/or vacuum deformation due to cooling of a liquid product filled therein. Examples of such features, which can be incorporated in the container of the disclosed subject matter, are disclosed in International Patent Application No. PCT/US14/011433, hereby incorporated by reference herein in its entirety, as well as U.S. Pat. No. 7,334,695, also incorporated by reference herein in its entirety. For purpose of illustration, and not limitation, reference is made herein to a container that is intended to be hot-filled, and may be re-filled, with a liquid product, such as a carbonated soft drink, tea, sports drink, energy drink or other similar liquid product. The apparatus and methods presented herein can be used for a variety of polymeric containers, having various shapes, sizes and intended uses, such as polymeric containers for liquids, and particularly beverages.
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 disclosed herein 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.
The present application claims priority to U.S. Provisional Application No. 62/095,580, filed on Dec. 22, 2014, the entire contents of which is incorporated herein by reference.
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Number | Date | Country | |
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