US20050158495A1 - Lightweight container and method of manufacture - Google Patents

Lightweight container and method of manufacture Download PDF

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Publication number
US20050158495A1
US20050158495A1 US10/746,406 US74640603A US2005158495A1 US 20050158495 A1 US20050158495 A1 US 20050158495A1 US 74640603 A US74640603 A US 74640603A US 2005158495 A1 US2005158495 A1 US 2005158495A1
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US
United States
Prior art keywords
preform
container
inch
sidewall
wall thickness
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US10/746,406
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English (en)
Inventor
Thomas Nahill
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Graham Packaging Pet Technologies Inc
Original Assignee
Graham Packaging Pet Technologies Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Graham Packaging Pet Technologies Inc filed Critical Graham Packaging Pet Technologies Inc
Priority to US10/746,406 priority Critical patent/US20050158495A1/en
Assigned to CONTINENTAL PET TECHNOLOGIES, INC. reassignment CONTINENTAL PET TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: NAHILL, THOMAS E.
Assigned to GRAHAM PACKAGING PET TECHNOLOGIES, INC. reassignment GRAHAM PACKAGING PET TECHNOLOGIES, INC. CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: CONTINENTAL PET TECHNOLOGIES, INC.
Priority to EP04815387A priority patent/EP1706327A1/fr
Priority to PCT/US2004/043304 priority patent/WO2005066027A1/fr
Assigned to DEUTSCHE BANK AG CAYMAN ISLANDS BRANCH reassignment DEUTSCHE BANK AG CAYMAN ISLANDS BRANCH GRANT OF SECURITY INTEREST Assignors: GRAHAM PACKAGING COMPANY, L.P.
Assigned to DEUTSCHE BANK AG CAYMAN ISLANDS BRANCH AS SECOND-LIEN COLLATERAL AGENT reassignment DEUTSCHE BANK AG CAYMAN ISLANDS BRANCH AS SECOND-LIEN COLLATERAL AGENT GRANT OF SECURITY INTEREST Assignors: GRAHAM PACKAGING COMPANY, L.P.
Publication of US20050158495A1 publication Critical patent/US20050158495A1/en
Assigned to GRAHAM PACKAGING COMPANY, L.P. reassignment GRAHAM PACKAGING COMPANY, L.P. RELEASE OF SECURITY INTERESTS Assignors: DEUTSCHE BANK AG, GAYMAN ISLANDS BRANCH, AS COLLATERAL AGENT
Assigned to GRAHAM PACKAGING COMPANY, L.P. reassignment GRAHAM PACKAGING COMPANY, L.P. RELEASE OF SECURITY INTEREST IN CERTAIN PATENT COLLATERAL Assignors: DEUTSCHE BANK AG CAYMAN ISLANDS BRANCH, AS COLLATERAL AGENT AND GRANTEE
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/02—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents
    • B65D1/0223—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by shape
    • B65D1/023—Neck construction
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C49/20—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor of articles having inserts or reinforcements ; Handling of inserts or reinforcements
    • B29C2049/2021—Inserts characterised by the material or type
    • B29C2049/2026—Neck portions
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    • B29C2049/7879—Stretching, e.g. stretch rod
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    • B29C2949/0861—Other specified values, e.g. values or ranges
    • B29C2949/0862—Crystallinity
    • B29C2949/0865—Crystallinity at the body portion
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2949/00—Indexing scheme relating to blow-moulding
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    • B29C2949/22—Preforms or parisons whereby a specific part is made of only one component, e.g. only one layer at neck portion
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/53—Joining single elements to tubular articles, hollow articles or bars
    • B29C66/534—Joining single elements to open ends of tubular or hollow articles or to the ends of bars
    • B29C66/5344—Joining single elements to open ends of tubular or hollow articles or to the ends of bars said single elements being substantially annular, i.e. of finite length, e.g. joining flanges to tube ends
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
    • B29C66/542—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles joining hollow covers or hollow bottoms to open ends of container bodies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/04—Polymers of ethylene
    • B29K2023/06—PE, i.e. polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/10—Polymers of propylene
    • B29K2023/12—PP, i.e. polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/004—Semi-crystalline
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0041—Crystalline
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0041—Crystalline
    • B29K2995/0043—Crystalline non-uniform
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]

Definitions

  • the present invention relates to blow molded plastic containers, to preforms for blow molding such containers, and to methods of making such preforms and containers.
  • a container preform having a body and a finish with one or more external threads.
  • the preform finish typically is molded to its final geometry, while the body of the preform subsequently is blow molded to the desired geometry of the container body.
  • the preform may be of monolayer construction, or may be of multilayer construction in which one or more intermediate layers in the preform body may or may not extend into the finish area of the preform.
  • U.S. Pat. Nos. 4,609,516, 4,710,118 and 4,954,376 illustrate injection molding of multilayer container preforms.
  • Molding the finish portion of the container as part of the preform presents a number of problems.
  • the plastic material typically is injected into a mold cavity at the closed end of the preform body, so that the material must flow along the sides of the preform cavity into the area in which the finish is molded.
  • the finish typically requires more accurate and stable dimensioning than the body of the preform, which may limit the cycle time of the molding process.
  • the difficulty in forming the finish limits how thin the wall of the preform body can be. By the time a thick preform finish fills, the sidewall of the preform body can begin to cool if it is too thin.
  • a hollow plastic container in accordance with a presently preferred aspect of the invention includes an open finish, a closed bottom and a sidewall connecting the finish to the bottom.
  • the container sidewall is ultra thin, preferably having a radial wall thickness of not more than 0.008 inch, and more preferably in the range of about 0.003 to 0.004 inch thick. (All references to radial sidewall thickness refer to average radial wall thickness, and not to isolated thin or thick spots in the wall.)
  • a method of making a container in accordance with another aspect of the present invention includes molding a preform having a neck with an open end, a closed bottom and a sidewall with a thickness of not more than 0.08 inch, more preferably in the range of about 0.04 to 0.05 inch.
  • the sidewall and bottom of the preform are blow molded to form a container having a wall thickness of not more than 0.008 inch, and more preferably in the range of about 0.003 to 0.004 inch.
  • a separately formed finish ring is attached to the neck of the preform either prior to or subsequent to blow molding the preform body.
  • a thin-wall container that has particular utility for hot-fill applications—i.e., applications in which the container is filled with hot fluid product at a temperature of about 185° F. (Different packagers use different hot-fill temperatures, which typically are about 185° F.)
  • the container sidewall has a thickness of not more than 0.008 inch, and a stretch ratio of about eight to ten as compared with the preform prior to blow molding.
  • FIG. 1 is an elevational view of a preform assembly in accordance with one presently preferred embodiment of the invention
  • FIG. 1A is a fragmentary sectional view of the portion of FIG. 1 within the circle 1 A;
  • FIG. 2 is an exploded perspective view of the preform assembly illustrated in FIG. 1 ;
  • FIG. 3 is an elevational view of a package that includes a container blow molded from the preform assembly of FIG. 1 ;
  • FIG. 3A is a fragmentary sectional view of the portion of FIG. 3 within the circle 3 A.
  • FIGS. 1-2 illustrate a preform assembly 10 in accordance with one exemplary aspect of the invention as comprising a preform 12 and a separate finish ring 14 externally secured to the neck of preform 12 .
  • Preform 12 includes a body 16 having a closed lower end and a neck 18 integrally molded with body 16 .
  • Body 16 typically is cylindrical.
  • a flange 20 preferably extends radially outwardly from the open end of neck 18 remote from body 16 .
  • Neck 18 and flange 20 surround the open mouth of preform 12 .
  • Finish ring 14 may be circumferentially continuous or circumferentially split to facilitate attachment to preform 12 .
  • Finish ring 14 includes an annular cylindrical wall 22 having one or more external threads or thread segments 24 .
  • a support flange 26 extends radially outwardly from the lower end of wall 22 , giving finish ring 14 a generally L-shaped cross section in the illustrated embodiment of the invention.
  • Finish ring 14 may also include a bead for cooperating with tamper-indicating structure on the package closure.
  • Finish ring 14 is externally secured to the surface of preform neck 18 by any suitable means, such as insert molding, press-fit, adhesive, ultrasonic welding, etc. Finish ring 14 may be secured to neck 18 either prior to or subsequent to blow molding container body 28 ( FIG. 3 ).
  • Preform 12 may be of monolayer construction as illustrated in FIG. 1A , or of multilayer construction. Preform 12 may be fabricated by injection or compression molding. Preform 12 may be of any suitable crystalizable polyester construction, such as polyethylene terephthalate (PET), polyethylene naphthalate (PEN), blends or copolymers of PET and/or PEN, or process regrind that consists essentially of PET and/or PEN. Finish ring 14 may be of any suitable material construction, either the same as or more preferably different from the material construction of the preform. For example, finish ring 14 can be of PET, post consumer resin (PCR), process required (REG), polypropylene (PP), polyethylene (PE) or polyethylene naphthlate (PEN) construction. When finish ring 14 is of polyester construction (e.g., PET or PEN), the finish ring may be wholly or partially crystalized.
  • PET polyethylene terephthalate
  • PEN polyethylene naphthalate
  • Finish ring 14 may be of any suitable material construction, either
  • preform 12 has a wall thickness that is greatly reduced as compared with the prior art—i.e., an ultra thin wall thickness.
  • Wall 16 has a radial thickness of not more than 0.08 inch, most preferably in the range of about 0.04 to 0.05 inch.
  • finish ring 14 is separately formed and secured to the neck of the preform body, rather than being molded integrally with the preform body and thereby limiting the thinness of the preform body as previously discussed.
  • radial and axial stretching of the preform material reduces the thickness of the container wall 30 , preferably to not more than about 0.008 inch, more preferably to not more than 0.008 inch for hot fill application and not more than 0.006 inch for cold fill applications, and most preferably to the range of about 0.003 to 0.004 inch for either application.
  • Containers having such a reduced wall thickness are sufficiently strong to retain the contents of the container when the container is filled and capped by a closure 32 ( FIG. 3 ).
  • the ultra thin container sidewall greatly reduces the amount of material and therefore the cost of the container. Furthermore, the container sidewalls can be substantially crushed when empty to reduce the shipping volume to the packager, and will reassume the blow-molded geometry when filled.
  • Provision of very thin-walled preforms in accordance with one aspect of the present invention has a number of advantages over the prior art.
  • very small preforms of normal wall thickness are used to blow mold thin-walled containers.
  • the blow molding operation results in high levels of molecular orientation in the container wall, with the preform-to-container stretch ratio typically being on the order of about ten to twelve.
  • These high stretch ratios result in severe shrinkage and distortion during hot fill applications.
  • a larger preform having thin walls is used in accordance with the present invention, reducing the stretch ratio to a range of about eight to ten, which will not shrink and distort during hot fill.
  • the use of a thin-wall preform yields more uniform stretch orientation levels across the thickness of the container wall.
  • Thin-wall preforms and containers have a further advantage in hot fill applications in that vacuum panels molded into the container wall operate very efficiently because of the reduced wall thickness. That is, the reduced thickness of the panels permits the panels readily to flex inwardly as the hot-filled package cools, reducing distortion to the remainder of the container.
  • containers for hot fill applications normally have a wall thickness of about 0.012 to 0.015 inch and are blown from a preform having a wall thickness of about 0.15 to 0.18 inch
  • the present invention provides a container for hot fill applications having a wall thickness of not more than 0.008 inch blown from a preform having a wall thickness of about 0.08 inch.
  • the thin-wall preforms of the present invention possess the further advantage that they are less sensitive to moisture than are preforms having thicker walls. For example, it has been found that preforms having a moisture content of 2000 to 3000 ppm can be blow molded satisfactorily. Thin-wall preforms also possess the advantage that they can be blow molded around tighter radii on the mold face, providing additional flexibility in container design.
  • the thin-wall preforms of the present invention possess an unexpected additional advantage.
  • thermal crystallization occurs in the preform wall, followed by strain crystalization during blow molding.
  • strain crystalization occurs in the preform wall, followed by strain crystalization during blow molding.
  • up to 28% to 35% total sidewall crystallization was obtained, which improved hot-fill performance of the resulting container without affecting the clarity of the container wall.
  • Total sidewall crystalinity can be measured employing any suitable technique, such as the ASTM 1505 density gradient column technique.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
US10/746,406 2003-12-24 2003-12-24 Lightweight container and method of manufacture Abandoned US20050158495A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US10/746,406 US20050158495A1 (en) 2003-12-24 2003-12-24 Lightweight container and method of manufacture
EP04815387A EP1706327A1 (fr) 2003-12-24 2004-12-23 Ensemble preforme, recipient leger et procede de fabrication associe
PCT/US2004/043304 WO2005066027A1 (fr) 2003-12-24 2004-12-23 Ensemble preforme, recipient leger et procede de fabrication associe

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US10/746,406 US20050158495A1 (en) 2003-12-24 2003-12-24 Lightweight container and method of manufacture

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US20050158495A1 true US20050158495A1 (en) 2005-07-21

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US (1) US20050158495A1 (fr)
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US20070210026A1 (en) * 2006-03-06 2007-09-13 Plastipak Packaging, Inc. Lightweight plastic container and preform
US20070292642A1 (en) * 2006-06-16 2007-12-20 Graham Packaging Company, L.P. Lightweight preform and method of manufacture
US20090095702A1 (en) * 2007-10-16 2009-04-16 Graham Packaging Company, L.P. Hot-fillable container and method of making
US7866496B2 (en) 2007-09-21 2011-01-11 Stokely-Van Camp, Inc. Lightweight finish for hot-fill container
WO2014078259A1 (fr) * 2012-11-16 2014-05-22 Illinois Tool Works Inc. Procédé pour la production de système de remplissage de carburant moulé par extrusion-soufflage pour un véhicule automobile et système de remplissage pour un véhicule automobile
US20170036848A1 (en) * 2014-02-18 2017-02-09 Petainer Large Container Ip Limited Plastic aerosol container, preform and method
US10214312B2 (en) 2006-03-06 2019-02-26 Plastipak Packaging, Inc. Lightweight plastic container and preform
USD955882S1 (en) * 2018-12-13 2022-06-28 Integrated Plastics Pty Limited Pre-form with handle
USD966895S1 (en) * 2018-12-13 2022-10-18 Integrated Plastics Pty Ltd Pre-form with handle
US12017816B2 (en) 2023-10-06 2024-06-25 Plastipak Packaging, Inc. Lightweight plastic container and preform

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ITMO20070024A1 (it) 2007-01-26 2008-07-27 Sacmi Preforma per ottenere contenitori
EP2168751A1 (fr) * 2008-09-29 2010-03-31 Nestec S.A. Procédé de fabrication d'un récipient tel qu'une bouteille à partir d'une préforme en polymère thermoplastique, préforme et récipient correspondants
DE102009038608A1 (de) * 2009-08-26 2011-03-17 Krones Ag Kunststoffflasche

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US10266299B2 (en) 2006-03-06 2019-04-23 Plastipak Packaging, Inc. Lightweight plastic container and preform
US9738409B2 (en) 2006-03-06 2017-08-22 Plastipak Packaging, Inc. Lightweight plastic container and preform
US9522759B2 (en) 2006-03-06 2016-12-20 Plastipak Packaging, Inc. Lightweight plastic container and preform
US11834222B2 (en) 2006-03-06 2023-12-05 Plastipak Packaging, Inc. Lightweight plastic container and preform
US11560250B2 (en) 2006-03-06 2023-01-24 Plastipak Packaging, Inc. Lightweight plastic container and preform
US10457437B2 (en) 2006-03-06 2019-10-29 Plastipak Packaging, Inc. Lightweight plastic container and preform
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US20090095702A1 (en) * 2007-10-16 2009-04-16 Graham Packaging Company, L.P. Hot-fillable container and method of making
WO2014078259A1 (fr) * 2012-11-16 2014-05-22 Illinois Tool Works Inc. Procédé pour la production de système de remplissage de carburant moulé par extrusion-soufflage pour un véhicule automobile et système de remplissage pour un véhicule automobile
US20170036848A1 (en) * 2014-02-18 2017-02-09 Petainer Large Container Ip Limited Plastic aerosol container, preform and method
USD955882S1 (en) * 2018-12-13 2022-06-28 Integrated Plastics Pty Limited Pre-form with handle
USD966895S1 (en) * 2018-12-13 2022-10-18 Integrated Plastics Pty Ltd Pre-form with handle
US12017816B2 (en) 2023-10-06 2024-06-25 Plastipak Packaging, Inc. Lightweight plastic container and preform

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WO2005066027A1 (fr) 2005-07-21

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