BOTTLE, INJECTION BLOW MOLDING CORE ROD FOR THE BOTTLE AND RELATED METHOD

Abstract

A bottle for containing an item, generally a pharmaceutical product, wherein the bottle includes a body having a bottom wall and sidewalls, a neck extending from a top portion of the sidewalls and a thread defined on the neck. The neck defining a mouth of the bottle, an internal surface and an external surface. A neck thickness is defined between the internal surface and the external surface. The thread defines a thread thickness. The thread thickness is substantially the same as the neck thickness.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. Provisional Patent Application No. 63/177,105, filed Apr. 20, 2021 and titled, “Bottle, Injection Blow Molding Core Rod for the Bottle and Related Method,” the entire contents of which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

Injection blow molding (“IBM”) is a polymeric molding technique typically utilized to manufacture small medical, pharmaceutical, cosmetic, and other single serve bottles. The IBM process forms the bottles with the body and neck in a single process, such that the body and neck are integrally formed. The IBM process typically involves injection molding a preform onto a core pin, opening an initial mold while the polymeric injected material is still hot, placing a larger mold over the preform, inflating the preform into a desired final shape, cooling the shaped product and removing the product from the core rod. The IBM process is designed for mass production of thousands, hundreds of thousands or more products. Small medical and pharmaceutical bottles are often manufactured using the IBM process. Efficiency in the process is desirable and the cooling process can be a limiting factor. The bottles formed by the IBM process often have variable thicknesses in their final form, such as having a greater thickness at threads in the neck of the bottle. The bottle necks have a smooth internal cylindrical surface while the threads extend radially outwardly from an outside surface of the neck such that the thickness of the bottles in the area of the threads is greater than other sections of the bottle. The thicker threads require additional cooling time because the central portion of the threads require additional time for cooling. It would be desirable to design, implement and deploy a bottle, IBM molding equipment and method that reduces the cooling cycle to reduce cycle times for the production of each final bottle.

BRIEF SUMMARY OF THE INVENTION

Briefly stated, the preferred invention is directed to a bottle for containing an item, generally a pharmaceutical product, wherein the bottle includes a body having a bottom wall and sidewalls, a neck extending from a top portion of the sidewalls and a thread defined on the neck. The neck defining a mouth of the bottle, an internal surface and an external surface. A neck thickness is defined between the internal surface and the external surface. The thread defines a thread thickness. The thread thickness is substantially the same as the neck thickness. In the preferred embodiment, the thread thickness and neck thickness are not necessarily identical, but are substantially the same, thereby resulting in substantially the same thread and neck thicknesses that generally cure at a similar rate and time and resulting in an internal groove on the neck that facilitates protrusion of the threads from the outer surface of the neck while maintaining substantially the same thread and neck thickness.

In another aspect, the preferred invention is directed to an injection blow molding core rod assembly for manufacturing a bottle having a core rod base, a neck forming section connected to the core rod base, and a core rod tip connected to the neck forming section. The neck forming section having outwardly extending thread forms. The neck forming section positioned between the core rod base and the core rod tip.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of a preferred embodiment of the bottle, injection blow molding core rod for the bottle and related method of the present device, system and method, will be better understood when read in conjunction with the appended drawings. For the purposes of illustrating the preferred bottle, injection blow molding core rod for the bottle and related method, there is shown in the drawings a preferred embodiment of the present invention. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. In the drawings:

FIG. 1 illustrates a front elevational, partial cross-sectional view of a bottle in accordance with a preferred embodiment of the present invention;

FIG. 2 illustrates a front elevational view of a core rod in accordance with a preferred embodiment of the present invention used in a manufacturing method to construct the bottle of FIG. 1; and

FIG. 2A illustrates a magnified front elevational view of a portion of the core rod of FIG. 2, taken from within circle 2A of FIG. 2.

DETAILED DESCRIPTION OF THE INVENTION

Certain terminology is used in the following description for convenience only and is not limiting. Unless specifically set forth herein, the terms “a,” “an,” and “the” are not limited to one element but instead should be read as meaning “at least one”. The words “right,” “left,” “lower,” and “upper” designate directions in the drawings to which reference is made. The words “inwardly” or “distally” and “outwardly” or “proximally” refer to directions toward and away from, respectively, the geometric center of the preferred bottle, injection blow molding core rod for manufacturing the bottle and related parts thereof. The terminology includes the above-listed words, derivatives thereof and words of similar import.

It should also be understood that the terms “about,” “approximately,” “generally,” “substantially” and like terms, used herein when referring to a dimension or characteristic of a component of the preferred invention, indicate that the described dimension/characteristic is not a strict boundary or parameter and does not exclude minor variations therefrom that are functionally the same or similar, as would be understood by one having ordinary skill in the art. At a minimum, such references that include a numerical parameter would include variations that, using mathematical and industrial principles are accepted in the art (e.g., rounding, measurement or other systematic errors, manufacturing tolerances, etc.).

Referring to FIGS. 1-2A, a preferred embodiment of the present invention is directed to a bottle, generally designated 10, for containing an item, such as a pharmaceutical product. The bottle 10 includes a body 12 having a bottom wall 12a and sidewalls 12b and a neck 14 extending from a top portion of the sidewalls 12b. The neck 14 defines a mouth 16 of the bottle 10 that opens into a storage cavity inside the body 12. The neck 14 includes an internal surface 14a and an external surface 14b. The bottle 10 also includes a thread 20 defined on the neck 14. The thread 20 is associated with or are releasably engageable with internal threads on a cap (not shown). The cap is selectively mountable to the neck 14 of the bottle 20 using the threads 20 to alternately close and open the storage cavity.

In the preferred embodiment, the internal surface 14a includes an internal groove 18 defined thereon. The internal groove 18 is associated with the thread 20 or is positioned on the internal surface 14a opposite or mirroring the thread 20. The internal groove 18 of the preferred embodiment has a generally helical shape, although the internal groove 18 is not so limited. The internal groove 18 may have nearly any size and shape that follows or mirrors the threads 20, as is described in greater detail below.

A neck thickness t_n is defined between the internal surface 14a and the external surface 14b of the neck 14 and a thread thickness t_t is defined between the internal surface 14a in the internal groove 18 and the external surface 14b at the thread 20. The neck thickness t_n is substantially the same as the thread thickness t_t. In prior art bottles, the internal surface does not include the internal groove 18, such that a section of the neck adjacent the thread is thicker than other portions of the neck. As a result of constructing the neck 14 with substantially the same neck and thread thicknesses t_n, t_t, the neck 14 cures and cools at substantially the same rate in both the area of the threads 20 and the remainder of the neck 14. This substantially the same or equivalent neck and thread thickness t_n, t_t requires approximately the same amount of time to cool, instead of the thicker threaded sections of the prior art necks requiring additional time to cure and cool. Processing time with the substantially equivalent neck and thread thickness t_n, t_t, is therefore realized to improve the efficiency of the manufacturing process of the preferred bottle 10.

The thread thickness t_t of the preferred bottle 10 is substantially equivalent to the neck thickness t_n for at least the above-described reasons. In the preferred embodiment, the thread thickness t_t and the neck thickness t_n define a thickness ratio comprised of the thread thickness t_t divided by the neck thickness t_n. The thickness ratio is preferably less than two, more preferably less than or equal to one and three-quarters, one and one-half, or one and one-quarter and further preferably approximately one. The thickness ratio is not specifically limited to these indicated ratios and may include alternative ratios depending on designer preferences, thread type, bottle type, structural integrity considerations and additional design factors. As a non-limiting example, the neck thickness t_n may be approximately one and twenty-two hundredths millimeters (1.22 mm) and the thread thickness t_t may be approximately two and sixteen hundredths millimeters (2.16 mm), resulting in a thickness ratio of one and seventy-seven hundredths (1.77).

In the preferred embodiment, the neck 14 defines an outside neck diameter D_n and the body 12 defines an outside body diameter Db. The outside body diameter Db of the preferred embodiment is greater than the outside neck diameter D_n, such that the storage cavity is relatively large compared to the volume within the neck 14. The neck 14 of the preferred embodiment defines a neck height H_n and the body 12 defines a body height H_b. The body height H_n is greater than the neck height H_b, such that the volume of the storage cavity is larger than the volume of the neck void. The body height H_n is not limited to being greater than the neck height H_b and the outside body diameter Db is not limited to being greater than the outside neck diameter D_n, but the bottle 10 is typically configured in this manner to maximize storage volume and limit the size of the mouth 16 of the bottle 10 to retain the contents of the bottle 10, which may be comprised of a pharmaceutical product. The neck height H_b may, however, be greater than the body height H_n and the outside neck diameter D_n may be greater than the outside body diameter D_b without significantly impacting the performance and use of the preferred bottle 10.

The thread thickness t_t and the neck thickness t_n of the preferred bottle 10 are approximately one to three millimeters (1-3 mm) but are not so limited and may be smaller or larger depending on designer preferences, expected loading, application preferences and other factors related to the preferred bottle 10. The thread thickness t_t and the neck thickness t_n may have nearly any dimension as long as the dimension permits functioning of the preferred bottle for its desired application, is able to withstand the normal operating conditions of bottle 10 and take on the preferred size and shape of the bottle 10.

The threads 20 of the preferred bottle 10 are comprised of a modified buttress shape but are not so limited. The threads 20 may take on nearly any thread type or shape that is able to be formed on the neck 14, carry the loads of the bottle 10, releasably attach the cap to the neck 14 and withstand the normal operating conditions of the bottle 10. The threads 20 may be comprised of alternative types, such as sharp V, unified, Whitworth, modified square, square, ACME, B&S Worm, knuckle, Dardelet and related types of threads 20. Each of these threads 20 are preferably designed and configured such that the internal groove 18 is formed in association with the threads 20 such that the thread thickness t_t is substantially the same as the neck thickness t_n.

The preferred bottle 10 also includes a bead or support ledge 23 positioned on the neck 14 or between the neck 14 and the body 12 and a bottle shoulder 22 positioned between the bead or support ledge 23 and the body 12. The bead or support ledge 20 and the shoulder provides a transition between the neck 14 and the body 12. The bead or support ledge 23 preferably includes an internal ledge groove 19 similar to the internal groove 18 of the threads 20, thereby resulting in a relatively consistent thickness of the neck 14 at the bead or support ledge 23. The internal ledge groove 19 preferably has a cylindrical shape that mirrors or follows the shape and size of the support ledge 23. The internal ledge groove 19 of the support ledge 23 facilitates relatively even and consistent curing of the bottle 10 near the bead or support ledge 23. The support ledge 23 is not limited to inclusion of the internal ledge groove 19 and the internal surface 14a may be substantially continuous adjacent the support ledge 23 without the internal ledge groove 19 at the internal surface 14a adjacent the support ledge 23 without significantly impacting the manufacturing or function of the bottle 10. The bottle 10 is not limited to inclusion of the bottle shoulder 22 and the bead or support ledge 23 and may be constructed without the bottle shoulder 22 and the bead or support ledge 23 without significantly impacting the design, configuration and operation of the bottle 10.

A ledge thickness t₁ is defined between the internal surface 14a in the internal ledge groove 19 and the external surface 14b at the support ledge 23. The neck thickness t_n is substantially the same as the ledge thickness t₁. As a result of constructing the neck 14 with substantially the same neck and ledge thicknesses t_n, t₁, the neck 14 cures and cools at substantially the same rate in both the area of the support ledge 23 and the remainder of the neck 14. This substantially the same or equivalent neck and ledge thickness t_n, t₁ requires approximately the same amount of time to cool, instead of the thicker threaded sections and support ledge sections of the prior art necks requiring additional time to cure and cool. Processing time with the substantially equivalent neck and ledge thickness t_n, t₁, is therefore realized to improve the efficiency of the manufacturing process of the preferred bottle 10.

The ledge thickness t₁ of the preferred bottle 10 is substantially equivalent to the neck thickness t_n for at least the above-described reasons. In the preferred embodiment, the ledge thickness t₁ and the neck thickness t_n define a ledge thickness ratio comprised of the ledge thickness t₁ divided by the neck thickness t_n. The ledge thickness ratio is preferably less than two, more preferably less than or equal to one and three-quarters, one and one-half, or one and one-quarter and further preferably approximately one. The neck, thread and ledge thicknesses t_n, t_t, t₁ are each substantially the same or equivalent, as described herein, such that the areas of the neck 14 require approximately the same amount of time to cool, instead of the thicker threaded sections and support ledge sections of the prior art necks requiring additional time to cure and cool. The ledge thickness ratio is not specifically limited to these indicated ratios and may include alternative ratios depending on designer preferences, ledge type, bottle type, structural integrity considerations and additional design factors. Processing time with the substantially equivalent neck, thread and ledge thickness t_n, t_t, t₁, is therefore realized to improve the efficiency of the manufacturing process of the preferred bottle 10.

The bottle 10 of the preferred embodiment is constructed utilizing IBM with an injection blow molding core rod assembly 30, although the system is not limited to blow molding and may be comprised of other forms of injection molding. The injection blow molding core rod assembly 30 includes a core rod base 32, a neck forming section 34 connected to the core rod base 32 and a core rod tip 36 connected to the neck forming section 34. The neck forming section 34 has outwardly extending thread forms 34a that extend radially outwardly from the neck forming section 34. The neck forming section 34 is positioned between the core rod base 32 and the core rod tip 36 such that the neck forming section 34 forms and defines the threads 20 of the preferred bottle 10 with the internal groove 18 to facilitate relatively rapid cooling and manufacture of the bottle 10. The neck forming section 34 also preferably includes a raised ring 35 that defines the internal ledge groove 19, which is associated with the support ledge 23. The raised ring 35 has a generally cylindrical shape and forms the internal ledge groove 19 that also has a relatively cylindrical shape on the neck 14. The bottle 10 is not limited to including the raised ring 35 and the internal ledge groove 19 and may be designed and configured without the raised ring 35, may include the raised ring 35 without the internal ledge groove 19 or may be otherwise designed and configured with differently shaped and sized raised rings 35 and internal ledge grooves 19 without significantly impacting the operation and function of the bottle 10.

The outwardly extending thread forms 34a have a generally helical shape in the preferred embodiment but are not so limited and may have alternative shapes depending on the desired threads 20 that are formed on the neck 14. The neck forming section 34 preferably defines the internal neck diameter D_n, as well as the internal grooves 18 on the neck 14. The outwardly extending thread forms 34a extend outwardly relative to the internal neck diameter D_n to define the threads 20. The core rod base 32 of the preferred embodiment defines a base diameter D_x. The base diameter D_x is preferably greater than the internal neck diameter D_n. The core rod tip 36 may taper from a proximal end that is attached to the neck forming section 34 toward a distal end but is not so limited and may not include a taper or may include alternative shapes based on designer preferences and specific alternative designs. The core rod tip 36 is not necessarily a separate component from the neck forming section 34 and may be integrally formed with the neck forming section 34 or alternatively, may be split into separate components that are engaged together.

Referring to FIGS. 2 and 2A, a partial view of the core rod assembly 30 is shown that is used in the IBM process of the preferred embodiment. In FIG. 2A, the profile with the outwardly extending thread forms 34a are added to define the internal groove 18. The thread forms 34a are machined on the core rod assemblies 30 in the preferred helical pattern and are positioned to be inside the area or adjacent to the threads 20 that are formed on the external surface 14b of the blown bottle 10.

Referring to FIG. 1, the finished molded bottle 10 is shown with the internal grooves 18 and the threads 20. The groove 18 on the internal surface 14a of the neck 14 is created by this newly designed outwardly extending thread form 34a on the core rod assembly 30. The groove 18 substantially defines a female thread form defined on the internal surface 14a of the neck 14 and the female thread form coincides with the male threads 20 formed on the external surface 14b of the neck 14. The external mold portion on the neck forming section 34 of the preferred core rod assembly 30 forms the internal groove 18 of the bottle 10 during the injection blow molding process.

A benefit of using the preferred core rod assembly 30 to mold the bottles 10 is that it results in the wall thickness, including the neck thickness t_n and the thread thickness t_t of the bottle 10, to be more uniform throughout the length or height of the neck 14. In prior art bottles, a thicker amount of plastic material is defined at the thread on the bottle between the external surface of the threads and the internal surface of the neck. Because cycle time is directly related to the thickness of the plastic that you are trying to mold, this new design of the preferred bottle 10 and the core rod assembly 30 allow a decrease in cycle times that are necessary to manufacture the preferred bottles 10.

It will be appreciated by those skilled in the art that changes could be made to the embodiment described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiment disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the present description.

Claims

1-13. (canceled)

14. An injection blow molding core rod assembly for manufacturing a bottle, the core rod assembly comprising:

a core rod base;

a neck forming section connected to the core rod base, the neck forming section having outwardly extending thread forms; and

a core rod tip attached to the neck forming section, the neck forming section positioned between the core rod base and the core rod tip.

15. The core rod assembly of claim 14, wherein the outwardly extending thread forms have a generally helical shape.

16. The core rod assembly of claim 14, wherein the neck forming section defines an internal neck diameter, the outwardly extending thread forms extending outwardly relative to the internal neck diameter.

17. The core rod assembly of claim 14, wherein the core rod base defines a base diameter and the neck forming section defines an internal neck diameter, the base diameter being greater than the internal neck diameter.

18. The core rod assembly of claim 14, wherein the core rod tip tapers from a proximal end toward a distal end, the proximal end connected to the neck forming section.

19. The core rod assembly of claim 14, wherein the core rod tip is integrally formed with the neck forming section.

20. The core rod assembly of claim 14, wherein the core rod tip is mechanically connected to the neck forming section.