Abstract: A method of making a polyester container having an enhanced level of crystallinity in the sidewall while maintaining a low level of crystallinity in a thickened base portion. The container is particularly useful as a refillable container which can withstand higher caustic wash temperatures and exhibits reduced flavor carryover, or as a hot-fill container. According to the method, a sidewall-forming section of a preform is initially expanded, heated to contract and crystallize the same, and than reexpanded; a base-forming portion of the preform is shielded from the heat treatment and is expanded either before or after the heat treatment step.

Abstract: A multilayer plastic container having enhanced strength for high temperature and pressure applications such as the pasteurization of carbonated juice drinks. The container is commercially cost-effective in comparison to prior art pasteurizable glass containers, and provides all of the advantages of plastic over glass, i.e., lightweight, shatter-resistant, etc. In a particular embodiment, the multilayer container includes inner and outer layers of a relatively high IV virgin PET, e.g., 0.85-0.90 dl/g, and a core layer of post-consumer PET having a substantially lower IV. The container has a relatively tall and slender profile, with high orientation levels in the panel and shoulder, and an oriented thick-walled base with feet. The base preferably has a high profile and angled foot pads which are allowed to move outwardly under creep.

Abstract: A method of forming a multi-layer polyester preform and container, particularly suitable for refillable PET carbonated beverage bottles, having an interior layer of high copolymer polyester material which resists hazing in the preform injection stage, and at least one exterior layer of a polyester to achieve enhanced strain-induced crystallization in the exterior layer during blow molding. The container can withstand higher caustic wash temperatures and exhibits reduced flavor carryover from one product to another.

Abstract: An oxygen scavenging composition, method of making the same, and multilayer container structures thereof which enable accelerated activation of the oxygen scavenging property and/or barrier layers to prevent depletion of the oxygen scavenging property. In making a container wall, or a precursor thereof such as a preform, a base polymer is used including post-consumer polyethylene terephthalate (PC-PET) and an oxygen scavenger. A resulting multilayer package wall may include an oxygen scavenging core layer and an inner layer of a material having a high oxygen barrier condition prior to product filling, and a second lower oxygen barrier condition after product filling. The inner layer thus allows oxygen entrapped in the container during product filling to be transmitted through the inner layer and absorbed by the core oxygen scavenging layer, in order to increase the product shelf life.

Abstract: A method of forming a multi-layer polyester preform and container, particularly suitable for refillable PET carbonated beverage bottles, having an interior layer of high copolymer polyester material which resists hazing in the preform injection stage, and at least one exterior layer of a polyester to achieve enhanced strain-induced crystallization iin the exterior layer during blow molding. The container can withstand higher caustic wash temperatures and exhibits reduced flavor carryover from one product to another.

Abstract: A panel design for a hot-fillable plastic container has a tall and slender panel section. The panel configuration provides increased resistance to longitudinal bending and hoop failure, yet provides good hoop flexibility to maximize vacuum panel movement. The panel section has a substantially cylindrical circumference with a plurality of vacuum panels symmetrically disposed about the panel circumference, post walls between the vacuum panels, and land areas above and below the vacuum panels. The ratio of vacuum panel height D to panel diameter C is on the order of 0.85 to 1.05. Longitudinal post ribs are provided in the post walls. The land areas above and below the vacuum panels are of a height E greater than on the order of 0.45 inch, and the ratio of the land area height E to panel diameter C is on the order of greater than 0.1. Circumferential hoop ribs are provided in the land areas to prevent ovalization and hoop collapse.

Abstract: A method for post-mold attachment of a handle to a strain-oriented plastic container body. The method utilizes thermal shrinkage of the oriented container body to engage the handle; for example, a highly-oriented recess is molded in the container body and then shrunk to engage a complimentary-shaped lug on the handle. The method is useful for both hot-fillable and pasteurizable containers, and is particularly useful for making larger-sized containers, wherein the weight of the product and size of the container make handling and pouring difficult.

Abstract: A multilayer preform and container, and method of forming the same, having at least one layer including polyethylene naphthalate (PEN) to provide enhanced oxygen barrier performance and thermal stability. The PEN layer may be a homopolymer, copolymer, or blend of PEN. In a first high-PEN embodiment, the exterior layer contains on the order of 80-100% PEN and 0-20% PET by total weight of the layer, and a core layer of a non-strain hardenable polyester such as PETG. In a second low-PEN embodiment, the exterior layer includes a strain hardenable low-PEN copolymer or blend including on the order of 1-20% PEN and 80-99% PET, and the core layer is a strain-hardenable polyester such as a low-copolymer PET. In a third mid-range PEN embodiment, the exterior wall includes a substantially amorphous PEN copolymer or blend containing on the order of 20-80% PEN and 80-20% of another polyester such as PET, and a strain-hardened core layer of polyester such as a low-copolymer PET.

Abstract: A fluid supply apparatus for a blow mold, which includes a control valve having multiple positions for alternatively supplying fluid to the blow mold from a fluid supply and a metering chamber. The control valve has a further position configured to fill the metering chamber with fluid, and empty the blow mold chamber into an exhaust conduit. The apparatus is useful for performing pulse blow inflations at a high-strain rate in order to increase the crystallinity level in the body of a container.

Abstract: Method of making a refillable polyester container having a low orientation base with improved resistance to caustic wash cracking. The method includes providing a preform with an upper base-forming thickened portion which resists axial elongation (thereby increasing the orientation of the body) and a lower base-forming tapered portion which decreases in thickness so as to gradually reduce the wall thickness of a central dome in the container base. The bottom of the preform base includes a central thickened region which is maintained in a recess during blowing to insure centering and prevent the formation of stress concentrations.

Abstract: Method of making multilayer preforms which resist delamination and in a reduced cycle time. A first array of preforms are molded onto a first array of cores in an associated array of mold cavities, the cores and preforms are removed from the mold cavities as soon as possible without significant physical preform deformation, and the preforms are then cooled on the cores while a second array of cores is positioned in the mold cavities. Cooling on the cores prevents delamination of the preform layers and reduces the in-mold cooling time. Providing multiple sets of cores on a rotating turret further reduces the cycle time compared to the prior art use of robotic cooling tubes.

Abstract: An apparatus for making a blow-molded container from a strain-hardenable polymer, the container having deep recesses for secure "post mold" attachment of a handle. The container is formed in a modified blow mold having retractable blades. The blades are partially extended for blow molding partial recesses, and then further extended for mechanically forming the deep handle recesses. The mechanical forming operation overcomes the stretch limits imposed by strain-hardening of the plastic material during blow molding, and the "post-mold" attachment of the handle provides a reduced cycle time and lower level of defects compared to the known "in-mold" handle forming operations.

Abstract: A method of making a polyester container having an enhanced level of crystallinity in the sidewall while maintaining a low level of crystallinity in a thickened base portion. The container is particularly useful as a refillable container which can withstand higher caustic wash temperatures and exhibits reduced flavor carryover, or as a hot-fill container. According to the method, a sidewall-forming section of a preform is initially expanded, heated to contract and crystallize the same, and than reexpanded; a base-forming portion of the preform is shielded from the heat treatment and is expanded either before or after the heat treatment step.

Abstract: A preform transfer and coating apparatus and method is provided which utilizes a carrier plate to receive a newly-molded batch of preforms from the molding apparatus preform handling plate. A transfer apparatus automatically moves the carrier plate from a preform-receiving position to a preform-coating position where the preforms are dipped into a coating liquid, after which the coated preforms are moved transversely back towards a starting position where they are discharged into a gaylord or onto a conveyor which feeds a standard gaylord packaging system. There is also a sample-taking apparatus which removes preforms prior to coating.

Abstract: A method and apparatus for forming a plastic container having an enhanced level of crystallinity for improved thermal stability. A substantially amorphous and transparent preform in the molecular orientation temperature range is expanded by a pulse-blow process one or more times to form an intermediate article, prior to a final expansion step to the full container dimensions. The pulse-blow step is conducted at a relatively high-strain rate to maximize the formation of crystal nucleation sites, followed by deflation to relax the amorphous orientation, and the final expansion step is conducted at a low-strain rate to minimize the amorphous orientation. The resulting container has a higher thermal deformation temperature and reduced thermal shrinkage and is particularly adapted for use as a refillable or hot-fill beverage container. A blow-mold and fluid supply apparatus is provided, including a metering chamber and piston, for alternatively supplying the high and low-strain rate inflations.

Abstract: A hot-fillable plastic container having a panel section with vacuum panels and an end grip, which panel section resists ovalization and other deformation during filling, product cooling, and handling. The container has a substantially-cylindrical panel section, with a pair of vertically-elongated vacuum panels disposed on opposing sides of a vertical plane passing through a vertical centerline of the container. Front and rear label attachment areas are provided between the vacuum panels. A pair of vertical ribs are disposed on either side of each vacuum panel which act as hinge points to maximize movement of a concave recess in the vacuum panel; the vertical ribs also resist longitudinal bending.

Abstract: A method of making a blow-molded container from a strain-hardenable polymer, the container having deep recesses for secure "post mold" attachment of a handle. The container is formed in a modified blow mold having retractable blades. The blades are partially extended for blow molding partial recesses, and then further extended for mechanically forming the deep handle recesses. The mechanical forming operation overcomes the stretch limits imposed by strain-hardening of the plastic material during blow molding, and the "post-mold" attachment of the handle provides a reduced cycle time and lower level of defects compared to the known "in-mold" handle forming operations.