CONTAINER SYSTEM AND METHOD OF MANUFACTURE

Description

TECHNICAL FIELD

The present disclosure generally relates to blow-molded containers and more particularly to plastic containers capable of high fill temperatures and pasteurization, and methods for making the same for food packaging.

BACKGROUND

Plastic blow-molded containers are commonly used for food packaging products. Many food and beverage products are sold to the consuming public in wide mouth jar-like blow-molded containers. These containers can be made from polyethylene terephythalate or other suitable plastic resins in a range of sizes. The empty blow-molded containers can be filled with food and/or beverage products at a fill site utilizing automated fill equipment.

For example, manufacture of such plastic blow-molded containers can include initially forming plastic resin into a preform, which may be provided by injection molding. Typically, the preform includes a mouth and a generally tubular body that terminates in a closed end. Prior to being formed into containers, preforms are softened and transferred into a mold cavity configured in the shape of a selected container. In the mold cavity, the preforms are blow-molded or stretch blow-molded and expanded into the selected container.

In certain applications, food packaging containers are subjected to a hot fill process such that the container is filled with a food and/or beverage product at a high temperature. As the food and/or beverage product cools within the container, stress and strain forces can develop in the container due to changes in the volume of the contents. These forces can adversely affect the structural integrity of the container, for example, causing deformation that distorts the container. In some cases, a distorted base hinders the container's ability to stand upright on a shelf. This disclosure describes an improvement over these prior technologies.

SUMMARY

In one embodiment, a plastic, hot-fillable container is provided. The container includes a blow molded body defining a longitudinal axis and including a base. The base includes a wall and a panel extending from the wall. The panel includes at least one radial segment such that at least the panel is substantially non-movable under temperature, pressure and/or volume changes within an interior of the body during a hot fill process. In some embodiments, container systems and methods of manufacturing containers are disclosed.

In one embodiment, the plastic, hot-fillable container includes a blow molded body having a side wall connected to a base and defining an interior of the container. The base includes a wall, a central portion and a panel. The wall is connected to the panel adjacent a standing surface. The panel includes at least one radial segment connected to the standing surface and extending toward the central portion. The segments are disposed with the panel such that the panel is substantially non-movable relative to the side wall under temperature, pressure and/or volume changes within the interior during a hot fill process.

In one embodiment, a plastic, hot-fillable PET container is provided. The container includes a blow molded body having a neck and defining a longitudinal axis. The body includes a base and a side wall connected to the base defining an interior of the container. The base includes a wall, a central portion and a panel. The wall is connected to the panel adjacent a standing surface. The panel includes a plurality of segments connected to the standing surface and extending radially in a transverse orientation relative to the axis. The segments are disposed with the panel such that the panel is substantially non-movable relative to the side wall under temperature, pressure and/or volume changes within the interior during a hot fill process. A metal closure is engageable with the neck.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more readily apparent from the specific description accompanied by the following drawings, in which:

FIG. 1 is a perspective view of one embodiment of a container system in accordance with the principles of the present disclosure;

FIG. 2 is a perspective view of components of the container system shown in FIG. 1;

FIG. 3 is a side view of the container system shown in FIG. 1, with components shown in phantom;

FIG. 4 is a bottom view of components of the container system shown in FIG. 1;

FIG. 5 is a break away cross-section view of the container system, taken along lines A-A shown in FIG. 4;

FIG. 6 is a perspective view of one embodiment of a container system in accordance with the principles of the present disclosure;

FIG. 7 is a side view, in part phantom, of the container system shown in FIG. 6;

FIG. 8 is a bottom view of components of the container system shown in FIG. 6;

FIG. 9 is a break away cross-section view of the container system shown in FIG. 6;

FIG. 10 is a perspective view of one embodiment of a container system in accordance with the principles of the present disclosure;

FIG. 11 is a perspective view of the container system shown in FIG. 10;

FIG. 12 is a side view, in part phantom, of the container system shown in FIG. 10;

FIG. 13 is a bottom view of the container system shown in FIG. 10;

FIG. 14 is a break away cross-sectional view of the container system taken along lines 14-14 shown in FIG. 13; and

FIG. 15 is a break away cross-sectional view of the container system taken along lines 15-15 shown in FIG. 13.

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 having a 16-ounce container made from PET 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 33 grams and employed with a method of manufacture including blow molding and trim steps.

The exemplary embodiments of blow-molded containers and more particularly, 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 16-ounce container made from PET 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 33 grams and employed with a method of manufacture including blow molding and trim steps.

In some embodiments, the present container system includes a container configured for selected food and/or beverage products. In some embodiments, the present container system includes a container configured for a PET hot filled and pasteurized salsa product. In some embodiments, the present container system includes a wide mouth PET container.

In some embodiments, the present container system has a container including a base having a panel, and including a selectively configured design such that the base and/or the panel are substantially non-movable under pressure and heat of a fill process for making food packaging products. In some embodiments, the present container system has a hot-fillable plastic beverage container including a static base that is structurally sound to withstand various forces relating to the hot fill process. In some embodiments, the container includes a static base configured to withstand rough handling during transportation.

In some embodiments, the present container system includes a container that is employed with a hot fill process for making food packaging products, the method including the step of filling one or more containers with a food and/or beverage at an elevated temperature after which the containers are capped. In some embodiments, the container includes a static base having a panel and a selectively configured design such that the base and/or the panel are substantially non-movable as the food and/or beverage cools within the container, and stress and strain forces develop in the container due to changes in the volume of the contents due to the hot fill process. In some embodiments, the container includes a static base having a panel and a selectively configured design such that the base and/or the panel are substantially non-movable in connection with containers that store products under pressure, such as carbonated beverages, which experience pressure changes due to changes in ambient temperature.

In some embodiments, the present container system includes a container having a static base configured to withstand mechanical stress inputs to the container structure while maintaining its container configuration. In some embodiments, the present container system includes a container having a static base configured to withstand negative pressure in the container, for example, as a hot-filled liquid cools, a shrinkage in container volume. In some embodiments, the present container system includes a container having a static base configured to resist deformation during handling, which may cause sudden increases in internal pressure.

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 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 to FIGS. 1-5, there are illustrated components of one embodiment of the system including a plastic, hot-fillable container 20.

Container 20 is configured for storing products such as food, food preparation and/or beverages. Container 20 includes a body 22 that defines a longitudinal axis X, as shown in FIG. 1. Body 22 has a length L1, as shown in FIG. 3. In some embodiments, length L1 is about 4.290 inches. In some embodiments, length L1 is from about 3 to about 8 inches. Body 22 includes a circumferential side wall 24 that extends between a top end 26 and a bottom end 28. Body 22 includes a substantially cylindrical configuration. In some embodiments, body 22 may include various configurations, such as, for example, oval, oblong triangular, square, polygonal, irregular, uniform, non-uniform, offset, staggered, and/or tapered. Body 22 may be manufactured by blow molding techniques, as described herein.

End 26 includes a surface 30. Surface 30 defines a centrally disposed cylindrical neck 32. Neck 32 includes a rib 34 and a plurality of angled threads 36. Rib 34 is disposed continuously about a circumference CC of neck 32 and is transverse to axis X. Rib 34 strengthens a neck finish of neck 32 and facilitates resistance of side load forces imparted on neck 32 by a closure, for example, a metal cap (not shown). Rib 34 is configured to optimize hoop rigidity, resist neck 32 deformation, prevent mis-capping and improve seal integrity with the cap. In some embodiments, rib 34 can be a plurality of ribs and/or can be disposed about at least a portion of circumference CC. In some embodiments, rib 34 is a plurality of 4 to 6 ribs and is not a continuous rib, and/or is disposed about at least a portion of the circumference CC of neck 32, for example, from about 300 to about 360 degrees.

Rib 34 is positioned between an opening surface 46 of neck 32 configured for facilitating filling of container 20, and threads 36. In some embodiments, rib 34 has a higher hoop strength or rigidity relative to neck 32. The hoop strength or rigidity of rib 34 adds stiffness to neck 32 so that neck 32 avoids deformation when force is applied to neck 32 during cap engagement. Threads 36 are angled relative to axis X. In some embodiments, threads 36 may include various configurations, such as, for example, non-angled, irregular, uniform, non-uniform, offset, staggered, and/or tapered. In some embodiments, threads 36 include five threads.

Threads 36 include an outer surface 52 defining a plurality of projections 54. Projections 54 are oriented on an upper portion 56 of threads 36. In some embodiments, projections 54 may be disposed at alternate orientations, relative to portion 56, such as, for example, parallel, transverse and/or angular orientations such as acute or obtuse and/or coaxial. In some embodiments, projections 54 may include various configurations, such as, for example, oval, triangular, square, polygonal, irregular, uniform, non-uniform, offset, staggered, and/or tapered. Projections 54 include a raised grip configuration of threads 36 engageable with an inner gasket surface of a cap to facilitate sealing engagement of the cap with threads 36. Neck 32 is configured for engagement with a cap (not shown), which engage threads 36 to fix the cap with neck 32. In some embodiments, neck 32 and/or the cap may include tamper resistant elements and/or tamper evident portions.

Body 22 includes a circumferential shoulder 66 defined from surface 30 of end 26. Shoulder 66 contacts wall 24 such that wall 24 extends from end 26 at shoulder 66 to end 28. Wall 24 is monolithic and is configured to resist deformation during filling of container 20 and/or during pasteurization of food, food preparation and/or beverages disposed within an interior chamber 68. In some embodiments, wall 24 is able to withstand a vacuum draw of greater than 3 In Hg and/or withstand an amount of elevated pressure of greater than 3 psi. In some embodiments, wall 24 may include various configurations, such as, for example, oval, oblong triangular, square, polygonal, irregular, uniform, non-uniform, offset, staggered, and/or tapered. Wall 24 has a diameter D2. In some embodiments, diameter D2 is about 3.200 inches. In some embodiments, diameter D2 is from about 2 to about 5 inches. Wall 24 has a length L2. In some embodiments, length L2 is about 2.264 inches. In some embodiments, length L2 is from about 1 to about 4 inches. In some embodiments, body 22 includes one or a plurality of walls, which may be concentric and/or continuous, for example in a polygonal cross section, or stepped.

Wall 24 includes a plurality of circumferential grooves 70 that are disposed perpendicular relative to longitudinal axis X. Grooves 70 are separated by circumferential segments 72 that are defined from wall 24. Grooves 70 are configured to provide flexibility to wall 24. In some embodiments, grooves 70 may include various configurations, such as, for example, parallel, irregular, uniform, non-uniform, offset, staggered, and/or tapered.

Body 22 includes a base 74 that extends to end 28, as shown in FIGS. 4 and 5. Base 74 includes one or more portions that are selectively configured to provide a base configuration that is substantially non-movable, as described herein, under pressure and heat of a fill process for making food packaging products. In some embodiments, base 74 has a static base configuration that is structurally sound to withstand various forces relating to the hot fill process. In some embodiments, base 74 maintains structural integrity and/or substantial rigidity in response to and/or to compensate for a change in temperature, pressure and/or volume within interior chamber 68 when interior chamber 68 is filled with food, food preparation and/or beverages or when said food, food preparation and/or beverages are pasteurized after container 20 is filled. In some embodiments, the selected portions of base 74 are non-movable in an outward and/or inward direction relative to wall 24 during temperature, pressure and/or vacuum application to prevent container 20 from deforming. In some embodiments, base 74 has a base configuration that avoids undesirable deformation during pressure and/or vacuum application, for example, which distorts the base and hinders the container's ability to stand upright on a shelf. Base 74 has a height H2. In some embodiments, base 74 has a height H2 of about 0.697 inches. In some embodiments, height H2 is from about 0.4 to about 2.0 inches. Base 74 has a diameter D3. In some embodiments, diameter D3 is about 3.380 inches. In some embodiments, diameter D3 is from about 2 to about 5 inches.

Base 74 includes a circumferential wall 78, a standing surface 79 and a panel 80 that is selectively configured to provide a base configuration that is substantially non-movable, as described herein and for example, under pressure and heat of a fill process for making food packaging products. Wall 78 is connected to panel 80 adjacent standing surface 79. In some embodiments, standing surface 79 is configured to support container 20 in a substantially upright position. In some embodiments, standing surface 79 includes a ring shape. Both wall 78 and panel 80 include portions that extend axially into interior chamber 68, as shown in FIG. 5. Panel 80 has a height H3. In some embodiments, panel 80 has a height H3 of about 0.729 inches. In some embodiments, height H3 is from about 0.4 to about 2.0 inches. In some embodiments, panel 80 has a horizontal orientation relative to a vertical orientation of wall 78. In some embodiments, base 74 includes a configuration such that at least panel 80 is substantially non-movable relative to the remaining portions of container 20. In some embodiments, base 74 includes a configuration such that panel 80, wall 78 and/or surface 79 are substantially non-movable relative to the remaining portions of container 20.

Panel 80 includes a step 82 centrally disposed with interior chamber 68 and extending from end 28. Step 82 has a diameter D4. In some embodiments, diameter D4 is about 2.680 inches. In some embodiments, diameter D4 is from about 1.0 to about 4.0 inches. Step 82 has a height H5 from end 28. In some embodiments, height H5 is about 0.060 inches. In some embodiments, height H5 is from about 0.010 to about 1.0 inches. Panel 80 includes an inner step 84 centrally disposed with and extending from step 82. Step 84 extends height H3 from end 28.

One or more components of step 84, as described herein, are selectively configured to provide a static base 74 that is substantially non-movable relative to wall 24, for example, to maintain structural integrity and/or substantial rigidity in response to and/or to compensate for a change in temperature, pressure and/or volume within interior chamber 68 to withstand various forces relating to the hot fill process. Step 84 includes a circular center portion 90 and a plurality of spaced apart radial segments 92, as shown in FIGS. 4 and 5. Portion 90 is tapered inwardly as it extends from end 28 and includes a recessed notch 94. Each segment 92 includes a convex arcuate portion 96 and planar side walls 98. Segments 92 are equidistantly disposed circumferentially about step 84. In some embodiments, this configuration of base 74 is advantageously substantially non-movable relative to wall 24 under pressure and heat of a fill process for making food packaging products, for example, as interior chamber 68 is filled with food, food preparation and/or beverages or when said food, food preparation and/or beverages are pasteurized after container 20 is filled. In some embodiments, this configuration of base 74 resists and/or prevents movement of one or more portions of base 74 in an outward and/or inward direction relative to wall 24 during temperature, pressure and/or vacuum application to prevent container 20 from deforming. In some embodiments, base 74 includes one or a plurality of segments 92. In some embodiments, segments 92 may be disposed about base 74 in a non-uniform orientation, staggered and/or offset. In some embodiments, portion 96 may have a uniform, non-uniform, undulating, planar, angled and/or stepped configuration. In some embodiments, walls 98 may have a uniform, non-uniform, undulating, angled and/or stepped configuration.

In some embodiments, the present container system is employed with a method for manufacturing container 20 and making food packaging products, as shown in FIG. 1 and described herein. In some embodiments, container 20 is filled with hot products such as food, food preparation and/or beverages in a hot fill process or pasteurized products in a pasteurization process. Positive pressure, which is pressure that is greater than that of the atmosphere, is induced in all directions inside interior chamber 68 of container 20. The configuration of base 74 is substantially non-movable relative to wall 24, as described herein, under pressure and heat of a fill process or when said food, food preparation and/or beverages are pasteurized after container 20 is filled. The components of panel 80, as described herein, resist and/or prevent movement of base 74 relative to wall 24 to prevent container 20 from deforming. After the product is cooled within interior chamber 68, vacuum is applied in all directions of interior chamber 68. Similarly, the components of panel 80 resist and/or prevent movement of base 74 relative to wall 24 to prevent container 20 from deforming.

In some embodiments, container 20 can withstand fill and pasteurization temperatures greater than 185 degrees Fahrenheit. In some embodiments, container 20 can withstand fill and pasteurization temperatures greater than 185 degrees Fahrenheit to about 220 degrees Fahrenheit.

Container 20 is made from PET. In some embodiments, container 20 may be fabricated from plastic and formed using injection and compression molding processes. In some embodiments, container 20 may 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, container 20, 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.

In some embodiments, container 20 has a crystallinity from about 23% to about 32%. In some embodiments, a preform of container 20 can be heated and stretched to produce a container 20 having a crystallinity between about 10 and about 50%. In some embodiments, the preform of container 20 includes a molecular weight between about 120,000 g/mol and about 500,000 g/mol.

A finished PET blow-molded, container 20 is 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 O₂ performance and improved MVTR performance.

In some embodiments, the present container system is employed with a method for manufacturing container 20. The method includes the steps of employing a single stage blow molding process and providing a preform that produces containers 20, as described herein. 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 container 20 on 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 neck 32 (e.g., including rib 34 and threads 36) 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. 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 dome does not contain additives.

In some embodiments, neck 32 is blow molded with rib 34 and threads 36. In some embodiments, rib 34 and threads 36 are manufactured and separately attached, applied and/or adhered to neck 32.

In some embodiments, during manufacture, container 20 is 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 elevated temperatures in the fill and pasteurization of the products. Positive pressure is induced in all directions inside interior chamber 68 of container 20 when container 20 is filled with the food and/or beverage products. In some embodiments, container 20 is 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 ln Hg during filling of container 20 with hot food and/or beverage products.

In one embodiment, as shown in FIGS. 6-9, container 20 includes body 22 having a base 174, similar to base 74 described herein with regard to the present system and methods. Base 174 has height H2 and diameter D3, as described herein. Base 174 includes a circumferential wall 178, a standing surface 179 and a panel 180 that is selectively configured to provide a static base configuration that is substantially non-movable, as described herein and for example, under pressure and heat of a fill process for making food packaging products. Both wall 178 and panel 180 extend axially into interior chamber 68, as shown in FIGS. 7-9. Panel 180 has a height HH3. In some embodiments, panel 180 has a height HH3 of about 0.538 inches. In some embodiments, height HH3 is from about 0.2 to about 2.0 inches.

Panel 180 includes a step 182 centrally disposed with interior chamber 68 and extending from end 28. Step 182 has a diameter DD4. In some embodiments, diameter DD4 is about 2.681 inches. In some embodiments, diameter DD4 is from about 1.0 to about 4.0 inches. Step 182 has a radius R1. In some embodiments, radius R1 is about 0.030 inches. In some embodiments, radius R1 is from about 0.010 to about 0.10 inches. Step 182 has a height HH5 from end 28. In some embodiments, height HH5 is about 0.050 inches. In some embodiments, height HH5 is from about 0.010 to about 0.10 inches. Panel 180 includes an inner step 184 centrally disposed with and extending from step 182. Step 184 extends height HH3 from end 28. Step 184 has a radius R2 that transitions from step 182. In some embodiments, radius R2 is about 0.030 inches. In some embodiments, radius R2 is from about 0.02 to about 0.05 inches.

One or more components of step 184, as described herein, are selectively configured to provide a base 174 that is substantially non-movable relative to wall 24, for example, to maintain structural integrity and/or substantial rigidity in response to and/or to compensate for a change in temperature, pressure and/or volume within interior chamber 68 to withstand various forces relating to the hot fill process. Step 184 includes a circular center portion 190 and a plurality of spaced apart radial segments 192, as shown in FIGS. 8 and 9. Portion 190 is tapered inwardly as it extends from end 28 and includes a recessed notch 194. Portion 190 has a radius R4. In some embodiments, radius R4 is about 0.375 inches. In some embodiments, radius R4 is from about 0.01 to about 0.50 inches. Each segment 192 includes a concave portion 196. Segments 192 are equidistantly disposed circumferentially about step 184 and spaced apart via arcuate convex surfaces 198. Surfaces 198 has a radius R3. In some embodiments, radius R3 is about 0.734 inches. In some embodiments, radius R3 is from about 0.1 to about 0.9 inches. In some embodiments, this configuration of base 174 is advantageously substantially non-movable relative to wall 24 under pressure and heat of a fill process for making food packaging products, for example, as interior chamber 68 is filled with food, food preparation and/or beverages or when food, food preparation and/or beverages are pasteurized after container 20 is filled. In some embodiments, this configuration of base 174 resists and/or prevents movement of one or more portions of base 174 in an outward and/or inward direction relative to wall 24 during temperature, pressure and/or vacuum application to prevent container 20 from deforming. In some embodiments, base 174 includes one or a plurality of segments 192. In some embodiments, segments 192 may be disposed about base 174 in a non-uniform orientation, staggered and/or offset. In some embodiments, portion 196 may have a uniform, non-uniform, undulating, planar, angled and/or stepped configuration. In some embodiments, surfaces 198 may have a uniform, non-uniform, undulating, angled and/or stepped configuration.

In one embodiment, as shown in FIGS. 10-15, the plastic, hot-fillable container system of the present disclosure includes a container 220, similar to container 20 described herein. Container 220 is configured for storing products such as food, food preparation and/or beverages and includes a body 222 that defines a longitudinal axis X1, as shown in FIG. 10. Body 222 has a length L4, as shown in FIG. 13. In some embodiments, length L4 is about 4.290 inches. In some embodiments, length L4 is from about 3 to about 8 inches. Body 222 includes a circumferential side wall 224 that extends between a top end 226 and a bottom end 228. Body 222 includes a substantially cylindrical configuration. In some embodiments, body 222 may include various configurations, such as, for example, oval, oblong triangular, square, polygonal, irregular, uniform, non-uniform, offset, staggered, and/or tapered. Body 222 may be manufactured by blow molding techniques, as described herein.

End 226 includes a surface 230. Surface 230 defines a centrally disposed cylindrical neck 232. Neck 232 includes a rib 234 and a plurality of angled threads 236. Rib 234 is disposed continuously about a circumference CC1 of neck 232 and is transverse to axis X1. Rib 234 strengthens a neck finish of neck 232 and facilitates resistance of side load forces imparted on neck 232 by a closure, for example, a metal cap (not shown). Rib 234 is configured to optimize hoop rigidity, resist neck 232 deformation, prevent mis-capping and improve seal integrity with the cap. In some embodiments, rib 234 can be a plurality of ribs and/or can be disposed about at least a portion of circumference CC1. In some embodiments, rib 234 is a plurality of 4 to 6 ribs and is not a continuous rib, and/or is disposed about at least a portion of the circumference CC1 of neck 232, for example, from about 300 to about 360 degrees.

Rib 234 is positioned between an opening surface 246 of neck 232 configured for facilitating filling of container 220, and threads 236. In some embodiments, rib 234 has a higher hoop strength or rigidity relative to neck 232. The hoop strength or rigidity of rib 234 adds stiffness to neck 232 so that neck 232 avoids deformation when force is applied to neck 232 during cap engagement. Threads 236 are angled relative to axis X1. In some embodiments, threads 236 may include various configurations, such as, for example, non-angled, irregular, uniform, non-uniform, offset, staggered, and/or tapered. In some embodiments, threads 236 include five threads.

Threads 236 include an outer surface 252 defining a plurality of projections 254. Projections 254 are oriented on an upper portion 256 of threads 236. In some embodiments, projections 254 may be disposed at alternate orientations, relative to portion 256, such as, for example, parallel, transverse and/or angular orientations such as acute or obtuse and/or coaxial. In some embodiments, projections 254 may include various configurations, such as, for example, oval, triangular, square, polygonal, irregular, uniform, non-uniform, offset, staggered, and/or tapered. Projections 254 include a raised grip configuration of threads 236 engageable with an inner gasket surface of a cap to facilitate sealing engagement of the cap with threads 236. Neck 232 is configured for engagement with a cap (not shown), which engage threads 236 to fix the cap with neck 232. In some embodiments, neck 232 and/or the cap may include tamper resistant elements and/or tamper evident portions.

Body 222 includes a circumferential shoulder 266 defined from surface 230 of end 226. Shoulder 266 contacts wall 224 such that wall 224 extends from end 226 at shoulder 266 to end 228. Wall 224 is monolithic and is configured to resist deformation during filling of container 220 and/or during pasteurization of food, food preparation and/or beverages disposed within an interior chamber 268. In some embodiments, wall 224 is able to withstand a vacuum draw of greater than 3 In Hg and/or withstand an amount of elevated pressure of greater than 3 psi. In some embodiments, wall 224 may include various configurations, such as, for example, oval, oblong triangular, square, polygonal, irregular, uniform, non-uniform, offset, staggered, and/or tapered. Wall 224 has a diameter D6. In some embodiments, diameter D6 is about 3.200 inches. In some embodiments, diameter D6 is from about 2 to about 5 inches. Wall 224 has a length L5. In some embodiments, length L5 is about 2.264 inches. In some embodiments, length L5 is from about 1 to about 4 inches. In some embodiments, body 222 includes one or a plurality of walls, which may be concentric and/or continuous, for example in a polygonal cross section, or stepped.

Wall 224 includes a plurality of circumferential grooves 270 that are disposed perpendicular relative to longitudinal axis X1. Grooves 270 are separated by circumferential segments 272 that are defined from wall 224. Grooves 270 are configured to provide flexibility to wall 224. In some embodiments, grooves 270 may include various configurations, such as, for example, parallel, irregular, uniform, non-uniform, offset, staggered, and/or tapered.

Body 222 includes a base 274 that extends to end 228. Base 274 includes one or more portions that are selectively configured to provide a base configuration that is substantially non-movable, as described herein, under pressure and heat of a fill process for making food packaging products. In some embodiments, base 274 has a base configuration that is structurally sound to withstand various forces relating to the hot fill process. In some embodiments, base 274 maintains structural integrity and/or substantial rigidity in response to and/or to compensate for a change in temperature, pressure and/or volume within interior chamber 268 when interior chamber 268 is filled with food, food preparation and/or beverages or when said food, food preparation and/or beverages are pasteurized after container 220 is filled. In some embodiments, the selected portions of base 274 are non-movable in an outward and/or inward direction relative to wall 224 during temperature, pressure and/or vacuum application to prevent container 220 from deforming. In some embodiments, base 274 has a static base configuration that avoids undesirable deformation during pressure and/or vacuum application, for example, which distorts the base and hinders the container's ability to stand upright on a shelf. Base 274 has a height H6. In some embodiments, height H6 is about 0.697 inches. In some embodiments, height H6 is from about 0.4 to about 2.0 inches. Base 274 has a diameter D7. In some embodiments, diameter D7 is about 3.380 inches. In some embodiments, diameter D7 is from about 2 to about 5 inches.

Base 274 includes a circumferential wall 278 connected to a panel 280 adjacent a wall portion, for example, a standing surface 278b. Wall 278 has a portion 278a and standing surface 278b that extends from portion 278a. Portion 278a is continuous with side wall 224 and standing surface 278b extends transverse to portion 278a, as shown in FIGS. 14 and 15. In some embodiments, standing surface 278b extends perpendicular to portion 278a. In some embodiments, standing surface 278b has a ring shape that encircles the bottom of container 220 to provide a support surface for disposal of container 220 with, for example, a surface of a shelf. In some embodiments, standing surface 278b is integrally and/or monolithically formed with portion 278a. In some embodiments, standing surface 278b is configured to support container 220 in a substantially upright position. In some embodiments, panel 280 has a horizontal orientation relative to a vertical orientation of wall 278.

Panel 280 of base 274 extends from portion 278b of wall 278 to a central portion 285 of base 274. Panel 280 is selectively configured to provide a configuration to base 274 that allows base 274 to be substantially non-movable relative to side wall 224 and/or neck 232, as described herein, under pressure and heat of a fill process for making food packaging products. Panel 280 extends axially into interior chamber 268, as shown in FIG. 12. Panel 280 has a height H7. In some embodiments, height H7 is about 0.729 inches. In some embodiments, height H7 is from about 0.4 to about 2.0 inches.

Panel 280 includes a step 282 centrally disposed with interior chamber 268. Step 282 has a diameter D8 (FIG. 15). In some embodiments, diameter D8 is about 2.680 inches. In some embodiments, diameter D8 is from about 1.0 to about 4.0 inches. Step 282 has a height H8 from end 228. In some embodiments, height H8 is about 0.060 inches. In some embodiments, height H8 is from about 0.010 to about 1.0 inches.

Base 274 is substantially non-movable relative to wall 224, for example, to maintain structural integrity and/or substantial rigidity in response to and/or to compensate for a change in temperature, pressure and/or volume within interior chamber 268 to withstand various forces relating to the hot fill process. Base 274 includes portion 285 and a plurality of spaced apart radial segments 292 positioned radially about portion 285, as shown in FIGS. 11 and 13. Segments 292 each include an end 292a that is connected to portion 278b of wall 278 and an opposite end 292b that is spaced apart from portion 285. In some embodiments, ends 292a are directly connected to portion 278b. In some embodiments, ends 292a are integrally and/or monolithically formed with portion 278b.

Portion 285 includes an inner dome extending from panel 280 and includes a center notch 294. Each segment 292 includes a concave arcuate portion 296 and arcuate side walls 298. Segments 292 are equidistantly disposed circumferentially about portion 285. In some embodiments, this configuration of base 274 is advantageously substantially non-movable relative to wall 224 under pressure and heat of a fill process for making food packaging products, for example, as interior chamber 268 is filled with food, food preparation and/or beverages or when said food, food preparation and/or beverages are pasteurized after container 220 is filled. In some embodiments, this configuration of base 274 resists and/or prevents movement of one or more portions of base 274 in an outward and/or inward direction relative to wall 224 during temperature, pressure and/or vacuum application to prevent container 220 from deforming. In some embodiments, base 274 includes one or a plurality of segments 292. In some embodiments, segments 292 may be disposed about base 274 in a non-uniform orientation, staggered and/or offset. In some embodiments, portion 296 may have a uniform, non-uniform, undulating, planar, angled and/or stepped configuration. In some embodiments, walls 298 may have a uniform, non-uniform, undulating, angled and/or stepped configuration. In some embodiments, base 274 includes a configuration such that at least panel 280 is substantially non-movable relative to the remaining portions of container 220. In some embodiments, base 274 includes a configuration such that panel 280, wall 278 and/or surface 278b are substantially non-movable relative to the remaining portions of container 220.

In some embodiments, the present container system is employed with a method for manufacturing container 220 and making food packaging products, as shown in FIG. 10 and described herein. In some embodiments, container 220 is filled with hot products such as food, food preparation and/or beverages in a hot fill process or pasteurized products in a pasteurization process. Positive pressure, which is pressure that is greater than that of the atmosphere, is induced in all directions inside interior chamber 268 of container 220. The configuration of base 274 is substantially non-movable relative to wall 224, as described herein, under pressure and heat of a fill process or when said food, food preparation and/or beverages are pasteurized after container 220 is filled. The components of panel 280, as described herein, resist and/or prevent movement of base 274 relative to wall 224 to prevent container 220 from deforming. After the product is cooled within interior chamber 268, vacuum is applied in all directions of interior chamber 268. Similarly, the components of panel 280 resist and/or prevent movement of base 274 relative to wall 224 to prevent container 20 from deforming.

In some embodiments, container 220 can withstand fill and pasteurization temperatures greater than 185 degrees Fahrenheit. In some embodiments, container 220 can withstand fill and pasteurization temperatures greater than 185 degrees Fahrenheit to about 220 degrees Fahrenheit.

Container 220 is made from PET. In some embodiments, container 220 may be fabricated from plastic and formed using injection and compression molding processes. In some embodiments, container 220 may be fabricated from PES, PE, HDPE, PVC, PVDC (Saran), LDPE, PP, PS, HIPS, PA (Nylons), ABS, PE/ABS, PC, PC/ABS, and/or PU. In some embodiments, container 220, 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.

In some embodiments, container 220 has a crystallinity from about 23% to about 32%. In some embodiments, a preform of container 220 can be heated and stretched to produce a container 220 having a crystallinity between about 10 and about 50%. In some embodiments, the preform of container 220 includes a molecular weight between about 120,000 g/mol and about 500,000 g/mol.

A finished PET blow-molded, container 220 is 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 O₂ performance and improved MVTR performance.

In some embodiments, the present container system is employed with a method for manufacturing container 220. The method includes the steps of employing a single stage blow molding process and providing a preform that produces containers 220, as described herein. 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 container 220 on 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 neck 232 (e.g., including rib 234 and threads 236) 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. 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 dome does not contain additives.

In some embodiments, neck 232 is blow molded with rib 234 and threads 236. In some embodiments, rib 234 and threads 236 are manufactured and separately attached, applied and/or adhered to neck 232.

In some embodiments, during manufacture, container 220 is 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 elevated temperatures in the fill and pasteurization of the products. Positive pressure is induced in all directions inside interior chamber 268 of container 220 when container 220 is filled with the food and/or beverage products. In some embodiments, container 220 is 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 container 220 with hot food and/or beverage products.

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.