CA2557639A1

CA2557639A1 - Plastic container with handle and method of making

Info

Publication number: CA2557639A1
Application number: CA002557639A
Authority: CA
Inventors: Thomas E. Nahill
Original assignee: Graham Packaging Pet Technologies Inc.; Thomas E. Nahill
Current assignee: Graham Packaging Pet Technologies Inc
Priority date: 2004-02-27
Filing date: 2005-02-28
Publication date: 2005-09-15
Also published as: WO2005085078A1; AR048165A1

Abstract

A plastic container (10) and a method of making the plastic container provide a molded container body (12) having an open upper (20) end and a handle (14) and externally threaded finished (16) attached to the container body after the container body has been molded. In one preferred form, the handle and finish are formed as a single component of molded plastic construction. In another preferred form, the handle and finish are separate components of molded plastic construction.

Description

PLASTIC CONTAINER WITH HANDLE AND
METHOD OF MAKING
Field of the Invention This invention relates generally to the manufacture of containers, and more particularly to the manufacture of plastic containers having handles.
Background of the Invention Containers for flowable products, such as liquids and granular products, have been formed of plastic by a variety of methods. For example, plastic containers have been blew molded to provide a container body with an integral finish and handle. Plastic containers have been formed with a container body including a finish integral with the container body and a handle separately attached to the container. Other containers have been formed by positioning an injection molded handle and finish in a blow mold so that the handle and finish are incorporated onto the container as it is blow molded.
In at least some instances, it may be desirable to form the container body separately from the finish and handle so that the molds used to form the container body can be more simple in design in that they do not require pockets to form or hold the handle. It may also be desirable to use a different plastic material for strength, color, esthetics or cost issues, for example, wherein the handle and finish need not be made of the same material as the container body.
Summary of the Invention A plastic container and a method of making the plastic container provide a molded container body having an open upper end, and a handle and externally threaded finished attached to the container body after the container body has been molded. The container can be prepared by, for example, molding from a parison or preform. The handle and finish can be formed as a single component of molded plastic construction or the handle and finish can be separate components of molded plastic construction.
The handle and/or finish can be attached to the container body by various methods including, for example, bonding or adhering onto the container body; welding onto the container body; press-fitting onto the container body; and use of a thread and bead interlocking engagement. The container body can include a pocket and a portion of the handle can be disposed in the pocket. The portion of the handle in the pocket can be permanently attached, for example by welding, or can be held in place by a snap-fit arrangement of beads on the handle and/or in the pocket.
Where the handle and the finish are separate pieces, the handle can be attached to the container body and then the finish attached to the container body so that a portion of the finish overlies a portion of the handle. The container body can include an annular neck, and the handle can have a mounting portion for receipt around the neck, the finish capable of being received around the neck. In such an embodiment, the handle and finish are attached by disposing the mounting portion of the handle over the neck, and attaching the finish to the neck. The finish can be, for example, swaged or welded onto the neck.
Desirably, manufacture of the container body can be simplified and the choice of materials for the container body, handle and finish are increased. For example, if the container body is used to store a food or beverage product, the handle and/or finish need not be formed of a food-grade plastic since such plastics may be more expensive than other materials, including process regrind or post consumer recycled materials. The handle and finish may also be formed of a different material based on certain physical characteristics including strength, durability, color, and ease of formation by various manufacturing methods including injection molding, to name a few.
A plastic container according to the invention can thus include a container body of plastic construction defining an interior volume and having an annular neck adj acent to an open end; a finish received over and attached to the neck; and a handle formed as a separate component from the container body and carried by one of the container body and the finish. The finish and the handle can be separately formed and the handle disposed, at least in part, around the neck and in between the finish and the container body. The handle can include a mounting portion and a grip portion integrally formed with the mounting portion, where the mounting portion is received on the neck, and the grip having at least a portion that extends outwardly from the container body. The mounting portion can be fixed to at least one of the neck and the container body. When the finish is fixed to the neck the mounting portion can be trapped between the finish and the container body. The mounting portion can be annular and received around the neck in assembly and the finish can be fixed to the mounting portion. The container neck can have a cylindrical outer surface and the finish can have a cylindrical inner surface with a diameter adapted for a press-fit receipt of the finish on the neck. The finish, handle and container body can be attached and configured as described above.

Brief Description of the Drawings These and other objects, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and best mode, appended claims and accompanying drawings in which:
FIG. 1 is a fragmentary side view of one embodiment of a container including a container body and an externally threaded finish and handle attached to the container body;
FIG. 2 is a fragmentary exploded perspective view of the container of FIG. 1 illustrating the handle and integral finish removed from the container body;
FIG. 3 is a fragmentary side view of a second embodiment of a container including a container body and a handle and finish attached to the container body;
FIG. 4 is a fragmentary exploded perspective view of the container of FIG. 3 illustrating the handle and finish adapted to be separately attached to the container body;
FIG. 5 is a fragmentary side view of a third embodiment of a container having an integral handle and finish assembly attached to a container body with a portion of the handle received in a pocket of the container body;
FIG. 6 is a fragmentary side view taken in the direction of the arrow 6 in FIG. 5;
FIG. 7 is a fragmentary side view of a fourth embodiment of a container including a handle and a finish separately attached to a container body with one end of the handle received in a pocket of the body;
FIG. 8 is a fragmentary side view of the container taken generally in the direction of the arrow 8 in FIG. 7;
FIG. 9 is a fragmentary exploded perspective view, with a portion in section, of a fifth embodiment of a container; and FIG. 10 is a fragmentary exploded perspective view, with a portion in section, of a sixth embodiment of a container.
Detailed Description of the Preferred Embodiments Refernng in more detail to the drawings, FIGS. 1 and 2 illustrate one embodiment of a container 10 including a container body 12 of plastic construction that is molded separately from a handle 14 and an externally threaded finish 16 that are attached to the container body 12 after the container body 12 is molded. The container body can be prepared by methods known in the art including blow molding techniques such as extrusion blow molding and stretch blow molding. For example, the container body can be stretch blow molded from a preform as is generally known in the art. The container body 12 may be of substantially any shape and formed from substantially any material to define an interior volume in which a product is received.
Desirably, the handle 14 and finish 16 can be formed by a different process and of different materials or color than the container body 12, increasing the choice of materials available and potentially reducing the material cost of the handle 14 and finish 16, and of the container 10 generally. Also, providing the handle 14 and finish 16 separately from and after the container body 12 is formed, simplifies the design of the container body 12 and of the molds used to make it.
As best shown in FIG. 2, the container body 12 may include an upstanding, annular neck 18 defining an open upper end 20 and mouth of the container body 12 through which a product may be added to or discharged from the container 10. The annular neck 18 can be of any shape, for example generally cylindrical, that is complementary of the internal portion of the finish 16. At a base of the neck 18, a radially outwardly extending collar 22 may be provided that can have a generally flat, annular face 24 providing a seating surface for the handle 14 and finish 16 when attached to the container body 12. The container body 12 may be formed of generally any shape, size and material as desired for a wide range of applications.
As best shown in FIG. 2, the handle 14 and finish 16 can be formed as a single component of plastic construction. The finish 16 is generally cylindrical, annular and has an inner surface 26 with a shape and diameter sized to be closely received about an exterior surface 28 of the neck 18. For example, the inner surface 26 can be generally cylindrical. The finish 16 can have one or more external threads or beads 30 capable of receiving a closure or other seal (not shown) to close the open upper end 20 of the container body 12. The finish 16 can include a generally radially outwardly extending flange 32 having a generally planar and annular end face 34 adapted to be received closely adjacent to the face 24 of the collar 22. In such an embodiment, the finish 16 is firmly seated on the collar 22 to ensure proper location and attachment of the finish 16 to the collar 22 and neck 18.
The inner surface 26 of the finish 16 and the outer surface 28 of the neck 18 may each be formed smooth and generally as right circular cylinders. To connect the finish 16 to the container body 12, the flange 32 and collar 22 may be welded together and the inner surface 26 of the finish 16 may be welded to the neck 18, if desired. The finish 16 may also be adhered or otherwise chemically or molecularly bonded to the neck 18 and/or collar 22. As shown in FIG. 9, the finish 16 may also be mechanically interlocked with the container body 12 such as by, for example and without limitation, overlapping and opposed beads 36, 38 formed on the finish 16 and the neck 18 respectively, providing for a snap or threaded receipt of the finish 16 on the neck 18. As shown in FIG. 10, the finish 16 and neck 18 may have mating threads 37, 39 to retain the finish 16 on the neck 18. The finish may be non-removably received on the neck. Of course, other methods or ways of attaching the finish 16 to the neck 18 may be employed, including mechanical fasteners, an interference or press fit, swaging, and various welding processes.
The handle 14 is integrally formed with and preferably of the same material as the finish 16 in this embodiment. In the embodiment of FIGS. 1 and 2, the handle 14 extends generally radially from an axis of the inner surface 26 of the finish 16, includes a generally right angle bend 40 to a grip portion 41 extending generally axially downwardly along the side of the container body 12. So that the handle 14 may be firmly grasped and enclosed in a person's hand, the axially extending grip portion 41 of the handle 14 can be spaced outwardly from the container body 12 providing a gap 42 between them sufficient to receive a person's fingers in an ergonomical fashion. The handle 14 is preferably of sufficient strength to prevent undue bending of the handle 14 when dispensing product from a filled container 10. The finish 16 with external threads 30 and the handle 14 may be integrally molded by a wide range of processes, including inj ection molding, and may be formed of a wide range of materials including materials that may not be suitable for the container body 12.
To improve the stability of the handle and its connection to the container body, an alternate embodiment of the container 10' shown in FIGS. 5 and 6 includes a container body 12', and an integral finish 16' and handle 14' assembly separately attached to the container body 12'. At its end 50 opposite the finish 16', the handle 14' extends into a pocket 52 formed in the container body 12'.
The handle 14' and pocket 52 may be provided with opposed overlapping beads 56, 58, respectively, providing a snap fit retention of the handle 14' within the pocket 52 or, the pocket 52 may be of sufficient depth so that the beads 56, 58 and a snap retention is not required and removal of the handle 14' from the pocket 52 is not possible without severely bending or breaking the handle 14'.
In at least that construction, the end 50 of the handle 14' should be received in the pocket 52 at the same time that the handle 14' and finish 16' assembly is disposed on the container body 12'. The pocket 52 may be sized to closely receive the handle 14' providing support against rotation or turning of the container body 12' relative to the handle 14' for more stable control and handling of the container 10' and dispensing product therefrom. With the exception of the elongated handle 14' extending into the pocket 52 of the container body 12', the container 10' shown in FIGS. S and 6 may be substantially identical to the container 10 shown in FIGS. 1 and 2. Hence, the container 10' of FIGS. 5 and 6 will not be further described.
Another exemplary embodiment of a container 60 is shown in FIGS. 3 and 4. As best shown in FIG. 4, the container 60 includes a container body 62, a handle 64 and finish 66, each provided as separate components of molded plastic construction. The container body 62 can include a neck 68 that may or may not include a collar as discussed with reference to the container shown in FIGS. 1 and 2, and is shown in FIGS. 3 and 4 without any such collar. Otherwise, the container body 62 may be substantially identical to the container body 12 discussed with reference to the container 10 shown in FIGS. 1 and 2 and hence, will not be discussed fizrther.
As best shown in FIG. 4, the handle 64 includes a mounting portion 70 shown as a generally cylindrical ring having an inner surface 72 with a diameter sized to be closely received around the outer surface 74 of the neck 68 on the container body 62. A lower surface 76 of the mounting ring 70 is preferably received around a lower end of the neck 68 and in assembly is seated against and abuts the container body 62 immediately adj scent to the neck 68. An upper face 78 of the mounting ring 70 provides a planar seat against which the finish 68 is firmly received, as shown in FIG. 3.
Otherwise, the handle 64 may be substantially identical in shape, construction and method of manufacture as the handle 14 discussed with reference to FIGS. 1 and 2. For example, the handle 64 may include a first portion extending generally radially from the mounting ring 70, and an axially extending portion extending along the side of the container body 62 preferably with a gap between them to provide an ergonomical grip. While the mounting ring 70 is shown to be completely annular, it does not have to be. For example, the mounting ring 70 may be a partial annulus, preferably surrounding more than half of the circumference of the neck, or the mounting ring 70 may have a non-circular shape.
The finish 66, while separate from the handle 64 and container body 62, may be generally as set forth with respect to the container 10 shown in FIGS. 1 and 2. The finish 66 has an inner surface 80 that can be generally cylindrical and is of a diameter sized to be closely received around the outer surface 74 of the neck 68 on the container body 62. Desirably, as shown in FIG. 3, a generally radially outwardly extending flange 82 at one end of the finish 66 provides a generally planar surface 83 received against the adj scent face 78 of the mounting ring 70 of the handle 64 in assembly. The finish 66 can include one or more external threads 84 to receive an internally threaded cap (not shown) closing the open upper end 86 of the container body 62 in a conventional manner. The inner surface 80 of the finish 66 and the outer surface 74 of the neck 68 may be as disclosed with reference to the embodiment of the container 10 shown in FIGS. 1 and 2.
In assembly, the mounting ring 70 of the handle 64 is disposed over the neck 68, and the finish 66 is likewise disposed over the neck 68 and on the mounting ring 70, trapping the handle 64 between the finish 66 and container body 12. The handle 64 and finish 66 may be attached to the neck 68 and/or the container body 12 by any suitable method including those already discussed with reference to other embodiments. If the finish 66 is firmly attached to the neck 68, it may not be necessary to separately permanently adhere the handle 64 to the container body 12 or the finish 66 as the handle 64 is trapped between the finish 66 and container body 12.
In an alternate form, as shown in FIGS. 7 and 8, a container 60' may include a container body 62' a handle 64' and a finish 66' each formed as separate components of molded plastic construction, like the embodiment shown in FIGS. 3 and 4. To further anchor or attach the handle 64' with the 1 S container body 62', the handle 64' may extend into a pocket 90 formed in the container body 62', as discussed with reference to the container 10' shown in FIGS. 5 and 6.
Otherwise, the container body 62', handle 64' and finish 66' may be the same as the container body 62, handle 64 and finish 66 as shown in and described with reference to FIGS. 3 and 4.
Forming the finish and handle separately from the container body provides a number of possible advantages. For example, without limitation, the container body can be of a simpler design and the molds used to make the container body can also be of a simpler design without need to form a handle or an integral finish and its threads.
The container can be prepared from a monolayer plastic material, such as a polyamide, for example, nylon; a polyolefin such as polyethylene, for example, low density polyethylene (LDPE) or high density polyethylene (HDPE), or polypropylene; a polyester, for example polyethylene terephthalate (PET), polyethylene naphtalate (PEN); or others, which can also include additives to vary the physical or chemical properties of the material. For example, some plastic resins can be modified to improve the oxygen permeability. Alternatively, the container can be prepared from a multilayer plastic material. The layers can be any plastic material, including virgin, recycled and reground material, and can include plastics or other materials with additives to improve physical properties of the container. In addition to the above-mentioned materials, other materials often used in multilayer plastic containers include, for example, ethylvinyl alcohol (EVOH) and tie layers or binders to hold together materials that are subject to delamination when used in adjacent layers. A
coating may be applied over the monolayer or multilayer material, for example to introduce oxygen barrier properties. In an exemplary embodiment, the present container is prepared from PET. The handle and finish can be prepared from any suitable material including, by way of example, low density polyethylene (LDPE) or high density polyethylene (HDPE), or polypropylene; a polyester, for example polyethylene terephthalate (PET), polyethylene naphtalate (PEN);
or others.
The material used for the container body can be different from that used for the handle and finish, and in the embodiments wherein the handle and finish are separate components, they may each be made from different materials. Desirably, the least expensive materials can be chosen for each part to provide a more economical manufacture of a container. For example, without limitation, if the container is used to store a food or beverage product, the container body can be made of a food grade plastic, while the handle, which is not in contact with the product in the container, can be formed of substantially any material, including process regrind and post-consumer recycled materials. The handle andlor container finish may also be formed of a different color and by different methods than the container body as desired for a wide range of applications.
Those of ordinary skill in the art will appreciate that the preceding description of presently preferred embodiments of containers is provided in terms of description, and not limitation. While certain obj ects, features and advantages have been attributed to the disclosed embodiments generally and specifically, a container embodying the spirit and scope of the claimed subject matter may achieve all, some or none of the stated advantages, or different advantages than those discussed.
Further, while certain alternate forms or embodiments have been disclosed, skilled artisans will recognize that many modifications and substitutions can be made without departing from the sprit and scope of the invention.

Claims

1. A method of making a container with attached handle, which includes the steps of:

(a) providing a plastic preform, (b) molding said preform to form a container body having an open upper end, and then (c) subsequent to said step (b), attaching a handle and a finish to said open upper end of said container body.

2. The method set forth in claim 1 wherein said step (c) includes providing said handle and finish as a single component of molded plastic construction.

3. The method set forth in claim 1 wherein said step (c) includes providing said handle and finish as separate components of molded plastic construction.

4. The method set forth in claim 1 wherein said step (c) is accomplished by welding said handle and finish onto the container body.

5. The method set forth in claim 2 wherein said container body includes an annular neck and said step (c) is accomplished by press-fitting a portion of said single component onto said neck.

6. The method of claim 5 wherein said neck includes at least one of an annular thread and a bead for interlocking engagement with said single component when said single component is received on the neck.

7. The method of claim 2 wherein said container body includes an annular neck and a radially outwardly extending collar adjacent to the neck, said step (c) is accomplished by disposing a portion of said single component over said neck until said single component engages said collar.

8. The method of claim 7 wherein said single component is permanently connected to said collar.

9. The method of claim 8 wherein said single component is welded to said collar.

10. The method of claim 8 wherein said single component is bonded to said collar.

11. The method of claim 8 wherein said single component is adhered to said collar.

12. The method of claim 8 wherein said neck and said single component include at least one of opposed beads and mating threads to retain said single component on said neck.

13. The method of claim 2 wherein said container body includes a pocket and said step of attaching said handle to said container body includes disposing a portion of said handle into said pocket.

14. The method of claim 13 wherein said portion of said handle is welded to said container body in the area of the pocket.

15. The method of claim 13 wherein said handle includes a bead and is snap-fit into said pocket.

16. The method of claim 3 wherein said handle is attached to said container body and then said finish is attached to said container body so that a portion of said finish overlies a portion of the handle.

17. The method of claim 1 wherein step (b) is accomplished by blow molding said preform.

18. The method of claim 3 wherein said container body includes an annular neck, said handle has a mounting portion for receipt around said neck, and said finish is capable of being received around said neck, and wherein step (c) is accomplished by disposing said mounting portion of said handle over said neck, and attaching said finish to said neck.

19. The method of claim 18 wherein said finish is swaged onto said neck.

20. The method of claim 18 wherein said finish is welded to said neck.

21. The method of claim 3 wherein said container body includes a pocket and an end of said handle is disposed in said pocket when said handle is attached to said container body.

22. The method of claim 21 wherein said pocket and said handle have generally opposed beads for snap-receipt and retention of said handle in said pocket.

23. A plastic container, including:

a container body of plastic construction defining an interior volume and having an annular neck adjacent to an open end of the container;

a finish received over and attached to said neck; and a handle formed as a separate component from the container body and carried by one of the container body and the finish.

24. The container of claim 23 wherein said finish and said handle are integrally formed as a single component.

25. The container of claim 24 wherein said finish and said handle are of plastic construction.

26. The container of claim 23 wherein said finish and said handle are separately formed and said handle is disposed at least in part around said neck and in between said finish and said container body.

27. The container of claim 26 wherein said handle includes a mounting portion and a grip portion integrally formed with the mounting portion, said mounting portion being received on said neck and said grip having at least a portion that extends outwardly from said container body.

28. The container of claim 27 wherein said mounting portion is fixed to at least one of said neck and said container body.

29. The container of claim 27 wherein said finish is fixed to said neck and said mounting portion is trapped between said finish and said container body.

30. The container of claim 27 wherein said mounting portion is annular and is received around said neck in assembly.

31. The container of claim 29 wherein said finish is also fixed to said mounting portion.

32. The container of claim 23 wherein said neck has a cylindrical outer surface and said finish has a cylindrical inner surface with a diameter adapted for a press-fit receipt of said finish on said neck.

33. The container of claim 23 wherein said finish includes a bead for snap-receipt of said finish on said container body.

34. The container of claim 33 wherein said neck includes a bead that in assembly is generally opposed to said bead on said finish.

35. The container of claim 23 wherein said container body includes a pocket and a portion of said handle is received in said pocket when said handle is received on said container body.

36. The container of claim 35 wherein said handle includes a bead for snap-receipt in said pocket.

37. The container of claim 36 wherein said container body includes a bead in said pocket that in assembly is generally opposed to said bead of said handle.

38. The container of claim 23 wherein said finish and said neck include mating threads to retain the finish on the neck.