1. Field of the Invention
The present invention is directed to bottles having handles. More particularly, the present invention is directed to large capacity bottles having handles and being suitable for use in liquid dispensers, such as water coolers.
2. Description of the Related Art
BPA-based polycarbonates have long been used to produce various types of food and beverage containers However, due to some reports that BPA-based polycarbonates may have negative health effects, an emphasis has recently been placed on producing containers that are “BPA-free.” In particular, the container industry has focused on the production of beverage bottles, where leaching of BPA into the beverage has been a concern due to the prolonged exposure of the beverage to the BPA-based polycarbonate. However, most of the bottle industry's BPA-free focus has been on smaller bottles with a capacity of less than one liter. “BPA” is the designation herein for bisphenol A.
Despite the desire to produce beverage bottles that are BPA-free, many materials that could potentially replace BPA-based polycarbonates exhibit deficiencies in one or more important characteristics, such as strength, toughness, chemical resistance, clarity, heat resistance, and/or processability. Currently, there are no BPA-free bottles having a large capacity (e.g., at least 2.5 gallons) that are sufficiently designed to exhibit the desired characteristics (e.g., strength, toughness, chemical resistance, heat resistance, and/or clarity) sought in large capacity bottles.
Accordingly, there is a need for a large capacity bottle that can be formed of a BPA-free material, yet still exhibit the desired characteristics.
One embodiment of this invention is directed to a bottle comprising an outlet at a first end of the bottle, a base at a second end of the bottle, and a main body located between the outlet and base. A central longitudinal axis extends in a longitudinal direction between the first and second ends of the bottle. The main body of the bottle comprises a well panel and an integrally-formed handle. The well panel at least partly defines a recessed well and the handle spans at least a portion of the recessed well. The outer surface of the well panel defines a concave longitudinal panel curve along a longitudinal reference plane, which contains the longitudinal axis and extends through the centroid of the well panel. The outer surface of the well panel defines a convex transverse panel curve along a transverse reference plane that extends through the centroid of the well panel and is oriented such that the longitudinal axis is normal to the transverse reference plane.
Another embodiment of the invention is directed to a substantially BPA-free bottle comprising an outlet at a first end of the bottle, a base at a second end of the bottle, and a main body located between the outlet and base. The bottle defines a central longitudinal axis extending in a longitudinal direction between the first and second ends of the bottle. Furthermore, the main body comprises a well panel and a handle, wherein the well panel at least partly defines a recessed well and the handle spans at least a portion of the recessed well. The bottle comprises a synthetic polymeric material that makes up at least 90 percent of the total weight of the bottle. Additionally, the synthetic polymeric material comprises less than 1 weight percent of bisphenol A polycarbonate. Moreover, the bottle has a liquid holding capacity of at least 2.5 gallons and a weight of at least 600 grams and not more than 900 grams. Finally, the bottle has a drop impact resistance of at least 3 feet as measured by ASTMD 2463-95. In one embodiment, the bottles is a five gallon water bottle.
By substantially BPA-free, we mean that polycarbonate is not present in the bottle more than 10 weight % based on the total polymeric material weight percentages equaling 100 weight % in the bottle. In one embodiment, the amount of polycarbonate present in the bottle is not more than 5 weight % based on the total polymeric material weight percentages equaling 100 weight % in the bottle. The bottles of the invention can also be BPA-free. In another embodiment, the bottles of the invention contain no polycarbonate.
This invention solves the problem of providing a substantially BPA-free bottle. In another embodiment, this invention solves the problem of providing a bottle that has 2.5 gallons capacity or greater that is made using a terephthalate based polyester comprising 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 1,4-cyclohexamedimethanol residues. In another embodiment, this invention solves the problem of providing a bottle that has 5 gallons capacity that is made using a terephthalate based polyester comprising 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 1,4-cyclohexamedimethanol residues.
Embodiments of the present invention are described herein with reference to the following drawing figures, wherein:
In one embodiment, the present invention is directed to a large bottle having enhanced strength properties such as, for example, drop impact resistance. Such bottles may be suitable for use in liquid dispensers such as water coolers.
The bottle can have a liquid holding capacity of at least 2.5, 4.0, 4.5, or 4.75 gallons and/or not more than 10, 8, 6, or 5.5 gallons. In one embodiment, the bottle can have a liquid holding capacity of about 5 gallons. Furthermore, the bottle can have a weight of at least 600, 650, 700, or 725 grams and/or not more than 900, 850, 800, or 775 grams. To ensure that the bottle can fit into a standard liquid dispenser, the bottle can have a maximum diameter of at least 6, 8, or 10 inches and/or not more than 18, 14, or 12 inches.
The strength of the bottle can be measured in terms of drop impact resistance. In one embodiment, the bottle can have a drop impact resistance of at least 3, 4, or 5 feet as measured by ASTM D 2463-95. The enhanced strength of the bottle can be at least partly derived from its physical design. To further illustrate the physical design of the bottle, various features of the bottle are described in detail below with reference to the drawing figures.
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Certain aspects of the above-described bottle design enable the bottle to be produced from a substantially BPA-free material, while still maintaining the desired strength for the bottle. Thus, in one embodiment, the bottle of the present invention can be made from materials other than BPA-based polycarbonates. As used herein, “substantially BPA-free” refers to an article or material that contains less than 1, 0.5, 0.1, 0.05, or 0.01 weight percent of BPA-based polycarbonate.
In one embodiment of the present invention, the bottle can be at least partly formed from a substantially BPA-free synthetic polymeric material. The synthetic polymeric material can make up at least 50, 75, 90, 95, or 100 percent of the total weight of the bottle. In one embodiment, the bottle of the present invention can be formed by blow molding the synthetic polymeric material into the desired configuration discussed in detail above.
The synthetic polymeric material used to make the bottle can have a flexural modulus of at least 100,000, 150,000, 200,000, or 215,000 psi and/or not more than 350,000, 300,000, 250,000, or 230,000 psi as measured by ASTM D790. The synthetic polymeric material can have a flexural yield strength of at least 5,000, 7,000, or 8,500 psi and/or not more than 12,000, 10,000, or 9,500 psi as measured by ASTM D790. The synthetic polymeric material can have a tensile strength at yield of at least 4,000, 5,000, 6,000, 6,500, or 7,250 psi and/or not more than 10,000, 9,000, 8000, or 7,000 psi as measured by ASTM D638. The synthetic polymeric material can have an impact strength of at least 8, 12, 14, or 15 ft-lb/in as measured by ASTM D256. The synthetic polymeric material can have a glass transition temperature of at least 90, 100, or 110 and/or not more than 140, 130, or 120° C. as measured by ASTM E1640-09. The synthetic polymeric material can have a melt viscosity of at least 1,000, 2,000, or 3,000 poise and/or not more than 20,000, 15,000, 12,000, 10,000, 8,000, or 6,000 poise as measured at 1 radian per second on a rotary melt rheometer at 290° C. The synthetic polymeric material can have an inherent viscosity of at least 0.4, 0.5, 0.6, 0.65, or 0.7 and/or not more than 1.0, 0.9, 0.8, or 0.75, as determined in 60/40 (wt/wt) phenol/tetrachloroethane at a concentration of 0.5 grams per 100 milliliters at 25° C. The synthetic polymeric material can have a transmittance of at least 75, 85, or 88 percent as measured by ASTM D1003. The synthetic polymeric material can have a haze of less than 5, 3, or 1.5 percent as measured by ASTM D1003.
In one embodiment, the polyesters useful in the invention and/or the polyester compositions of the invention, with or without toners, can have color values L*, a* and b* which can be determined using a Hunter Lab Ultrascan Spectra Colorimeter manufactured by Hunter Associates Lab Inc., Reston, Va. The color determinations are averages of values measured on either pellets of the polyesters or plaques or other items injection molded or extruded from them. They are determined by the L*a*b* color system of the CIE (International Commission on Illumination) (translated), wherein L* represents the lightness coordinate, a* represents the red/green coordinate, and b* represents the yellow/blue coordinate. In certain embodiments, the b* values for the polyesters useful in the invention can be from −10 to less than 10 and the L* values can be from 50 to 90. In other embodiments, the b* values for the polyesters useful in the invention can be present in one of the following ranges: −10 to 9; −10 to 8; −10 to 7; −10 to 6; −10 to 5; −10 to 4; −10 to 3; −10 to 2; from −5 to 9; −5 to 8; −5 to 7; −5 to 6; −5 to 5; −5 to 4; −5 to 3; −5 to 2; 0 to 9; 0 to 8; 0 to 7; 0 to 6; 0 to 5; 0 to 4; 0 to 3; 0 to 2; 1 to 10; 1 to 9; 1 to 8; 1 to 7; 1 to 6; 1 to 5; 1 to 4; 1 to 3; and 1 to 2. In other embodiments, the L* value for the polyesters useful in the invention can be present in one of the following ranges: 50 to 60; 50 to 70; 50 to 80; 50 to 90; 60 to 70; 60 to 80; 60 to 90; 70 to 80; 79 to 90.
In one embodiment, the melt viscosity of the polyester(s) useful in the invention is less than 30,000 poise as measured a 1 radian/second on a rotary melt rheometer at 290° C. In another embodiment, the melt viscosity of the polyester(s) useful in the invention is less than 20,000 poise as measured a 1 radian/second on a rotary melt rheometer at 290° C.
In one embodiment, the melt viscosity of the polyester(s) useful in the invention is less than 15,000 poise as measured at 1 radian/second (rad/sec) on a rotary melt rheometer at 290° C. In one embodiment, the melt viscosity of the polyester(s) useful in the invention is less than 10,000 poise as measured at 1 radian/second (rad/sec) on a rotary melt rheometer at 290° C. In another embodiment, the melt viscosity of the polyester(s) useful in the invention is less than 8,000 poise as measured at 1 radian/second on a rotary melt rheometer at 290° C. In another embodiment, the melt viscosity of the polyester(s) useful in the invention is less than 6,000 poise as measured at 1 radian/second on a rotary melt rheometer at 290° C.
According to certain embodiments of the present invention, the synthetic polymeric material can be a polyester or copolyester. In one embodiment, the synthetic polymeric material can comprise glycol units derived from 2,2,4,4-tetramethyl-1,3-cyclobutanediol and/or 1,4-cyclohexanedimethanol. In a more specific example, the synthetic polymeric material can be a polyester having a dicarboxylic acid component and a glycol component, where the dicarboxylic component comprises at least 70, 80, 90, 95, or 100 mole percent of residues of terephthalic acid or an ester thereof (dimethyl terephthalate) and the glycol component comprises at least 10, 15, 20, 25, 30, 35 or 40 mole percent of 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and at least 90, 85, 80, 75, 70, 65 or 60 mole percent 1,4-cyclohexanedimethanol residues.
In one embodiment, the dicarboxylic acid component of the polyesters useful in the invention comprises 70 to 100 mole % terephthalic acid residues and/or dimethyl terephthalate residues and 0 to 30 mole % of other aromatic dicarboxylic acid residues having up to 20 carbon atoms. The acid component other can also contain 0 to 20 mole % of aliphatic dicarboxylic acid residues having up to 16 carbon atoms. Examples of modifying aromatic dicarboxylic acids which may be used in this invention include, but are not limited to, isophthalic acid, 4,4′-biphenyldicarboxylic acid, 1,4-, 1,5-, 2,6-, 2,7-naphthalenedicarboxylic acid, and trans-4,4′-stilbenedicarboxylic acid, and esters thereof. In one embodiment, isophthalic acid is the modifying aromatic dicarboxylic acid.
The carboxylic acid component of the polyesters useful in the invention can be further modified with up to 10 mole %, such as up to 5 mole % or up to 1 mole % of one or more aliphatic dicarboxylic acids containing 2-16 carbon atoms, such as, for example, malonic, succinic, glutaric, adipic, pimelic, suberic, azelaic and dodecanedioic dicarboxylic acids. Certain embodiments can also comprise 0.01 or more mole %, such as 0.1 or more mole %, 1 or more mole %, 5 or more mole %, or 10 or more mole % of one or more modifying aliphatic dicarboxylic acids. Yet another embodiment contains 0 mole % modifying aliphatic dicarboxylic acids. Thus, if present, it is contemplated that the amount of one or more modifying aliphatic dicarboxylic acids can range from any of these preceding endpoint values including, for example, from 0.01 to 10 mole % and from 0.1 to 10 mole %. The total mole % of the dicarboxylic acid component is 100 mole %.
Esters of terephthalic acid and the other modifying dicarboxylic acids or their corresponding esters and/or salts may be used instead of the dicarboxylic acids. Suitable examples of dicarboxylic acid esters include, but are not limited to, the dimethyl, diethyl, dipropyl, diisopropyl, dibutyl, and diphenyl esters. In one embodiment, the esters are chosen from at least one of the following: methyl, ethyl, propyl, isopropyl, and phenyl esters.
In other aspects of the invention, the glycol component for the polyesters useful in the bottle of the invention include but are not limited to at least one of the following combinations of ranges: 10 to 40 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 60 to 90 mole % 1,4-cyclohexanedimethanol residues; 10 to 35 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 65 to 90 mole % 1,4-cyclohexanedimethanol residues; and 10 to 30 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 70 to 90 mole % 1,4-cyclohexanedimethanol residues; 15 to 40 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 60 to 85 mole % 1,4-cyclohexanedimethanol residues; 15 to 35 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 65 to 85 mole % 1,4-cyclohexanedimethanol residues; 15 to 30 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 70 to 85 mole % 1,4-cyclohexanedimethanol residues; 15 to 25 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 75 to 85 mole % 1,4-cyclohexanedimethanol residues; 20 to 40 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 60 to 80 mole % 1,4-cyclohexanedimethanol residues; 20 to 35 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 65 to 80 mole % 1,4-cyclohexanedimethanol residues; 20 to 30 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 70 to 80 mole % 1,4-cyclohexanedimethanol residues; 25 to 40 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 60 to 75 mole % 1,4-cyclohexanedimethanol residues; 25 to 35 mole % 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 75 to 65 mole % 1,4-cyclohexanedimethanol residues.
In one embodiment, the polyester useful in the invention can have 70 to 100 mole percent terephthalic residues, 15 to 40 mole percent 2,2,4,4-tetramethyl-1,3-cyclobutanediol residues and 60 to 85 mole percent 1,4-cyclohexanedimethanol residues. In this embodiment, the polyester may contain residues of a branching agent.
All mole percentages of diacid residues or diol residues in the polyester useful in the invention are based on a total of 100 mole percent diacid residues and a total of 100 mole percent diol residues.
For certain embodiments of the invention, the polyesters useful in the invention may exhibit at least one of the following inherent viscosities as determined in 60/40 (wt/wt) phenol/tetrachloroethane at a concentration of 0.5 g/100 ml at 25° C.: 0.50 to 1.0 dL/g; 0.50 to 0.75 dL/g; 0.50 to 0.68 dL/g; 0.60 to 0.75 dL/g; 0.60 to 0.68 dL/g; 0.65 to 1.2 dL/g; 0.65 to 1 dL/g; or 0.65 to 0.75 dL/g.
In one embodiment, the polyester useful in the invention can have 70 to 100 mole percent terephthalic residues, 15 to 40 mole percent 2,2,4,4-tetra methyl-1,3-cyclobutanediol residues and 60 to 85 mole percent 1,4-cyclohexanedimethanol residues. In this embodiment, the polyester may contain residues of a branching agent.
Modifying glycols useful in the polyesters useful in the invention refer to diols other than 2,2,4,4,-tetramethyl-1,3-cyclobutanediol and 1,4-cyclohexanedimethanol and may contain 2 to 16 carbon atoms. Examples of suitable modifying glycols include, but are not limited to, ethylene glycol, diethylene glycol, 1,2-propanediol, 1,3-propanediol, neopentyl glycol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, p-xylene glycol or mixtures thereof. In one embodiment, the modifying glycol is ethylene glycol. In another embodiment, ethylene glycol is excluded as a modifying diol.
The polyesters useful in the polyesters compositions of the invention can comprise from 0 to 10 mole percent, for example, from 0.01 to 5 mole percent, from 0.01 to 1 mole percent, from 0.05 to 5 mole percent, from 0.05 to 1 mole percent, or from 0.1 to 0.7 mole percent, or 0.1 to 0.5 mole percent, based the total mole percentages of either the diol or diacid residues; respectively, of one or more residues of a branching monomer, also referred to herein as a branching agent, having 3 or more carboxyl substituents, hydroxyl substituents, or a combination thereof. In certain embodiments, the branching monomer or agent may be added prior to and/or during and/or after the polymerization of the polyester. The polyester(s) useful in the invention can thus be linear or branched.
Examples of branching monomers include, but are not limited to, multifunctional acids or multifunctional alcohols such as trimellitic acid, trimellitic anhydride, pyromellitic dianhydride, trimethylolpropane, glycerol, pentaerythritol, citric acid, tartaric acid, 3-hydroxyglutaric acid and the like. In one embodiment, the branching monomer residues can comprise 0.1 to 0.7 mole percent of one or more residues chosen from at least one of the following: trimellitic anhydride, pyromellitic dianhydride, glycerol, sorbitol, 1,2,6-hexanetriol, pentaerythritol, trimethylolethane, and/or trimesic acid.
The polyesters of the invention can comprise at least one chain extender. Suitable chain extenders include, but are not limited to, multifunctional (including, but not limited to, bifunctional) isocyanates, multifunctional epoxides, including for example, epoxylated novolacs, and phenoxy resins. In certain embodiments, chain extenders may be added at the end of the polymerization process or after the polymerization process. If added after the polymerization process, chain extenders can be incorporated by compounding or by addition during conversion processes such as injection molding or extrusion. The amount of chain extender used can vary depending on the specific monomer composition used and the physical properties desired but is generally about 0.1 percent by weight to about 10 percent by weight, preferably about 0.1 to about 5 percent by weight, based on the total weight of the polyester.
The polyesters useful in the invention can be made by processes known from the literature such as, for example, by processes in homogenous solution, by transesterification processes in the melt, and by two phase interfacial processes. Suitable methods include, but are not limited to, the steps of reacting one or more dicarboxylic acids with one or more glycols at a temperature of 100° C. to 315° C. at a pressure of 0.1 to 760 mm Hg for a time sufficient to form a polyester. See U.S. Pat. No. 3,772,405 for methods of producing polyesters, the disclosure regarding such methods is hereby incorporated herein by reference.
In one embodiment, the polyesters useful in this invention may also contain from 0.01 to 25% by weight or 0.01 to 20% by weight or 0.01 to 15% by weight or 0.01 to 10% by weight or 0.01 to 5% by weight of the total weight of the polyester composition of common additives such as colorants, dyes, mold release agents, flame retardants, plasticizers, nucleating agents, stabilizers, including but not limited to, UV stabilizers, thermal stabilizers and/or reaction products thereof, fillers, and impact modifiers. Examples of typical commercially available impact modifiers well known in the art and useful in this invention include, but are not limited to, ethylene/propylene terpolymers; functionalized polyolefins, such as those containing methyl acrylate and/or glycidyl methacrylate; styrene-based block copolymeric impact modifiers; and various acrylic core/shell type impact modifiers. For example, UV additives can be incorporated into articles of manufacture through addition to the bulk, through application of a hard coat, or through coextrusion of a cap layer. Residues of such additives are also contemplated as part of the polyester composition.
In one embodiment, the bottles of the invention can comprise at least one additional polymer chosen from at least one of the following: poly(etherimides), polyphenylene oxides, poly(phenylene oxide)/polystyrene blends, polystyrene resins, polyphenylene sulfides, polyphenylene sulfide/sulfones, poly(ester-carbonates), polycarbonates, polysulfones; polysulfone ethers, and poly(ether-ketones).
The synthetic polymeric material can comprise TRITAN™ WX500 or TRITAN™ WX510, commercially available from Eastman Chemical Company of Kingsport, Tenn.
The invention has been described in detail with reference to the embodiments disclosed herein, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
Number | Date | Country | Kind |
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PCT/US2012/038314 | May 2012 | US | national |
This application is a continuation-in-part application which claims priority to U.S. Non-Provisional Application Ser. No. 13/150,363 filed on Jun. 1, 2011; it also claims priority to PCT Application Serial No. PCT/US2012/038314 which was filed on May 17, 2012, the disclosures of which are herein incorporated by reference in their entirety to the extent they do not contradict the statements herein.
Number | Date | Country | |
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Parent | 13150363 | Jun 2011 | US |
Child | 13485014 | US |