HOT-FILLABLE PLASTIC CONTAINER

Plastic container comprises a container body having a bottom portion, a sidewall portion and an upper portion, with a chamber defined therein. The bottom portion includes a support surface and a variable dynamic base portion extending inward from the support surface configured to deflect in response to a pressure differential between the chamber and an exterior of the container body. The sidewall portion includes a lower circumferential groove ring and an upper circumferential groove ring, wherein the lower circumferential groove ring has a width W1 and depth D1 in side view, and an outer radius R1 in plan view, the ratio of the width W1 to the outer radius R1 ranges between 0.07 to 0.22, and the ratio of the depth D1 to the outer radius R1 ranges between 0.04 to 0.18. The upper circumferential groove ring has a width W2 and depth D2 in side view, and an outer radius R2 in plan view, the ratio of the width W2 to the outer radius R2 ranges between 0.07 to 0.22, and the ratio of the depth D2 to the outer radius R2 ranges between 0.04 to 0.18. The base portion comprises an inner support wall extending upwardly from the support surface, wherein an upper section of the inner support wall extends inwardly at an angle of between about 15 degrees to about 85 degrees relative to the reference plane.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-In-Part of U.S. patent application Ser. No. 18/134,343 filed Apr. 13, 2023, which is a continuation of U.S. patent application Ser. No. 17/139,719 filed on Dec. 31, 2020, now U.S. Pat. No. 11,661,229, which is a continuation of U.S. patent application Ser. No. 15/856,418, filed on Dec. 28, 2017, now U.S. Pat. No. 10,899,493, which claims priority to U.S. Provisional Patent Application Ser. No. 62/440,267, filed on Dec. 29, 2016, which is hereby incorporated by reference in its entirety.

The present application is also a Continuation-In-Part of U.S. patent application Ser. No. 18/415,182 filed Jan. 17, 2024, which is a continuation of U.S. patent application Ser. No. 17/260,475 filed Jan. 14, 2021 which is a national phase filing of International Patent Application No. PCT/US2019/042754, filed on Jul. 22, 2019, which claims priority to U.S. patent application Ser. No. 16/042,743, filed on Jul. 23, 2018, which issued as U.S. Pat. No. 10,513,364 on Dec. 24, 2019, which is a continuation in part of U.S. patent application Ser. No. 15/048,312, filed on Feb. 19, 2016, which issued as U.S. Pat. No. 10,029,817 on Jul. 24, 2018, the disclosure of each of which is incorporated by reference herein in its entirety.

The present application is also a Continuation-In-Part of U.S. patent application Ser. No. 18/760,474 filed on Jul. 1, 2024, which is a continuation of U.S. patent application Ser. No. 17/703,688 filed on Mar. 24, 2022, which claims the benefit of priority to U.S. Provisional Application No. 63/165,236 filed on Mar. 24, 2021 which are incorporated herein by reference in their entireties.

The present application is also a Continuation-In-Part of U.S. patent application Ser. No. 18/537,501 filed on Dec. 12, 2023, which is a continuation of U.S. patent application Ser. No. 16/901,925 filed on Jun. 15, 2020 which issued as U.S. Pat. No. 11,897,656 on Feb. 13, 2024, which is a continuation of U.S. patent application Ser. No. 15/287,707 filed on Oct. 6, 2016 which issued as U.S. Pat. No. 10,683,127 on Jun. 16, 2020, the disclosure of each of which is incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The disclosed subject matter relates to plastic containers having unique features to sustain hot-filling processes and related pressure differential resulting therefrom.

2. Related Art

Hot-filling is a process of choice for the packaging or bottling of many juice and beverage products. Hot-filling process generally involves filling a suitable container with a beverage or liquid product, such as juices, sauces, teas, flavored waters, nectars, isotonic drinks and sports drinks etc., at a temperature suitable for sterilization, and then sealing and cooling the container to room temperature or below for distribution. During the processes of hot filling, sealing, and cooling, the containers are subject to different thermal and pressure differential scenarios that can cause deformation if made of plastic, which may render the containers visually unappealing or non-functional. Certain containers include functional improvements, such as vacuum panels and bottle bases to accommodate these different thermal and pressure differential scenarios and minimize or eliminate unwanted deformation, making the package both visually appealing and functional for downstream situations.

The consumer beverage market is extremely competitive. Packages that are unique in the market, such as asymmetrical bottle designs, can aesthetically distinguish the products in the marketplace and are highly desirable by manufacturers. However, asymmetrical bottle designs create unique challenges for hot-filling processes.

Conventional hot-fill plastic containers often have sidewall features that are substantially symmetrical about a longitudinal axis. This symmetrical design prevents undesirable tilting or lateral deflection of the container when subject to the thermal and pressure differential conditions associated with the hot-filling processes. A container having asymmetrical sidewall will stress or strain non-uniformly about the sidewall of the container at low pressure differential, and continue to distort the shape as the pressure differential increases, such as when vacuum increases during cooling. As a result, the introduction of stylized container designs into the hot-fill beverage market has been frustrated by this non-uniform distortion issue.

There thus remains a need for a commercially satisfactory asymmetrical plastic container that resists or provides compensation against distortion under hot-filling process.

SUMMARY OF THE INVENTION

The purpose and advantages of the disclosed subject matter will be set forth in and are apparent from the description that follows, as well as will be learned by practice of the disclosed subject matter. Additional advantages of the disclosed subject matter will be realized and attained by the subject matter particularly pointed out in the written description and claims hereof, as well as from the appended drawings.

To achieve these and other advantages and in accordance with the purpose of the disclosed subject matter, as embodied and broadly described, the disclosed subject matter includes a hot-fillable plastic container comprising a container body having a bottom portion, a sidewall portion and an upper portion. The container body has a chamber defined therein. The container body further comprises a finish portion extending from the upper portion and defines a mouth in fluid communication with the chamber. The bottom portion includes a support surface and a variable dynamic base portion configured to deflect in response to a pressure differential between the chamber and an exterior of the container body. The sidewall portion includes a lower circumferential groove ring and an upper circumferential groove ring, and further includes a pair of longitudinal grooves extending longitudinally between the lower and upper circumferential groove rings to define a front sidewall segment on a front side of the sidewall portion between the upper and lower circumferential groove rings and a rear sidewall segment on a rear side of the sidewall portion between the upper and lower circumferential groove rings. The rear sidewall segment comprises a waist groove extending circumferentially between the pair of longitudinal grooves to define an upper rear sidewall segment between the waist groove and the upper circumferential groove ring, and a lower rear sidewall segment between the waist groove and the lower circumferential groove ring, wherein one of the upper rear sidewall segment or the lower rear sidewall segment includes at least one vacuum panel configured to deflect in response to the pressure differential between the chamber and the exterior of the container body. The waist groove can extend about a circumference of about 65% to about 75% of a diameter of the waist groove.

As embodied herein, each of the longitudinal grooves can connect with the lower circumferential groove ring and the upper circumferential groove ring. The front sidewall segment thus can be a front rigid panel bordered by the lower circumferential groove ring, the upper circumferential groove ring and the pair of longitudinal grooves. The front rigid panel can further include a plurality of circumferentially-extending ribs.

In addition, each of the longitudinal grooves can be nonlinear. The hot-fillable plastic container can further comprise a stiffening bead along at least a portion of a length of each longitudinal groove. The stiffening bead can extend from a lower end of each longitudinal groove to about ⅔ of a height of the hot fillable plastic container. The stiffening bead can be disposed along a rear edge of each longitudinal groove.

As embodied herein, the front sidewall segment can have a bow-tie shape defined between the pair of longitudinal grooves, with a maximum circumferential width proximate each of the lower and upper circumferential groove rings and a minimum circumferential width aligned longitudinally along a height of the sidewall portion with the waist groove.

In accordance with another aspect of the disclosed subject matter, the lower rear sidewall segment can include the at least one vacuum panel. Particularly, the lower rear sidewall segment can include two vacuum panels. The lower rear sidewall segment can further include a rigid longitudinal support between the two vacuum panels. Each vacuum panel can be angled inwardly toward the chamber relative to a vertical reference plane perpendicular to the support surface. For example, each vacuum panel can be recessed relative to an outer surface of the rear sidewall portion, wherein an upper recessed depth along an upper edge of the vacuum panel is greater than a lower recessed depth along a lower edge of the vacuum panel.

In accordance with another aspect of the disclosed subject matter, the rigid longitudinal support can be a rigid support panel having a border groove along an edge thereof, wherein the border groove can connect with the lower circumferential groove ring. The rigid support panel can include a plurality of circumferentially-extending ribs.

The rigid support panel can have a partial frustoconical shape tapering inwardly toward the waist groove, and/or the upper rear sidewall segment can have a partial frustoconical or bowl shape, tapering inwardly toward the waist groove.

As embodied herein, the lower circumferential groove ring can have a width W1 and depth D1 in side view, and an outer radius R1 in plan view, wherein the ratio of the width W1 to the outer radius R1 can range between about 0.07 to about 0.22, and the ratio of the depth D1 to the outer radius R1 can range between about 0.04 to about 0.18. The upper circumferential groove ring can have a width W2 and depth D2 in side view, and an outer radius R2 in plan view, wherein the ratio of the width W2 to the outer radius R2 can range between about 0.07 to about 0.22, and the ratio of the depth D2 to the outer radius R2 can range between about 0.04 to about 0.18. The waist groove can have a width W3 and depth D3 in side view, and an inside radius R3 in plan view, wherein the ratio of the width W3 to the inside radius R3 can range between about 0.15 to about 0.46, and the ratio of the depth D3 to the inside radius R3 can range between about 0.10 to about 0.30. The longitudinal groove can have a width W4 and a depth D4 in plan view, and the front sidewall segment can have an outer radius R4 in plan view, wherein the ratio of the width W4 to the outer radius R4 can range between about 0.07 to about 0.18, and the ratio of the depth D4 to the outer radius R4 can range between about 0.02 to about 0.14.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages of the invention will be apparent from the following, more particular description of a preferred embodiment of the invention, as illustrated in the accompanying drawings wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.

FIG. 1A is a front view of an exemplary hot-fillable plastic container in accordance with the disclosed subject matter.

FIG. 1B is a cross-sectional side view taken along the line 1B-1B in FIG. 1A.

FIG. 1C is a cross-sectional plan view taken along the line 1C-1C in FIG. 1A.

FIG. 2A is a rear view of the plastic container illustrated in FIG. 1A.

FIG. 2B is a cross-sectional plan view taken along the line 2B-2B in FIG. 2A.

FIG. 3A is a left-side view of the plastic container illustrated in FIG. 1A.

FIG. 3B is an enlarged detail view of the lower rear sidewall segment with vacuum panel and a portion of the lower front sidewall segment of FIG. 3A.

FIG. 4A is a rear-left view of the plastic container illustrated in FIG. 1A.

FIG. 4B is an enlarged detail view of the vacuum panel and longitudinal support of FIG. 4A.

FIG. 4C is a cross-sectional side view of a plastic container taken along the line 4C-4C in FIG. 4A.

FIG. 4D is a cross-sectional side view of each vacuum panel taken along the line 4D-4D in FIG. 4A.

FIG. 5A is a right-side view of the plastic container illustrated in FIG. 1A.

FIG. 5B is a cross-sectional plan view of the plastic container taken along the line 5B-5B in FIG. 5A.

FIG. 5C is an enlarged detail view of the upper circumferential groove ring of FIG. 5A.

FIG. 5D is an enlarged detail view of the waist groove of FIG. 5A.

FIG. 5E is an enlarged detail view of the lower circumferential groove ring of FIG. 5A.

FIG. 6 is a rear-right side view of the plastic container illustrated in FIG. 1A.

FIG. 7A is a front, cross-sectional schematic view of an exemplary embodiment of the base of the plastic container illustrated in FIG. 1A.

FIG. 7B is a bottom left perspective view of the exemplary embodiment of FIG. 7A.

FIG. 7C is a bottom right perspective view of the exemplary embodiment of FIG. 7D.

FIG. 7D is a bottom plan view of the exemplary embodiment of FIG. 7A.

FIG. 7E is a bottom view of the exemplary embodiment of FIG. 7A, illustrating the thickness of the base at various points.

FIG. 8A is a front, cross-sectional schematic view of another exemplary embodiment of a base in accordance with the disclosed subject matter.

FIG. 8B is a front, cross-sectional schematic view illustrating additional features of the exemplary embodiment of FIG. 8A.

FIG. 8C is a bottom perspective view of the exemplary embodiment of FIG. 8A.

FIG. 9A is a front, cross-sectional schematic view of another exemplary embodiment of a base in accordance with the disclosed subject matter.

FIG. 9B is a front, cross-sectional schematic view illustrating additional features of the exemplary embodiment of FIG. 9A.

FIG. 9C is a bottom perspective view of the exemplary embodiment of FIG. 9A.

FIG. 10 is a front, cross-sectional schematic view of each of the exemplary embodiments of FIGS. 7A-E, 8A-C, and 9A-C overlaid on each other, for purpose of comparison.

FIGS. 11A-11C each is a bottom perspective view of one of the exemplary embodiments of FIGS. 1-9, shown side-by-side for purpose of comparison with: FIG. 11A being a bottom perspective view of the embodiment of FIGS. 7-9; FIG. 11B being a bottom perspective view of the embodiment of FIGS. 4-6; and, FIG. 11C being a bottom perspective view of the embodiment of FIGS. 1-3.

FIG. 12 is a cross-sectional schematic view of a known, current base for a container, for purpose of comparison to the exemplary embodiments of the disclosed subject matter.

FIG. 13 is a cross-sectional schematic view of another known, current base for a container, for purpose of comparison to the exemplary embodiments of the disclosed subject matter.

FIG. 14 is a front, cross-sectional schematic view of another known, competitive base for a container, for purpose of comparison to the exemplary embodiments of the disclosed subject matter.

FIG. 15 is a graph illustrating the volume displacement response over a range of pressures for each of the embodiments of FIG. 1, FIG. 4 and FIG. 7 as compared to the known current base of FIG. 12.

FIG. 16 is a graph illustrating the volume displacement response over a range of pressures for bottles having bases of each of the embodiments of FIG. 1 and FIG. 4 as compared to the known current base of FIG. 12.

FIG. 17 is a graph of the internal vacuum over a range of decreasing temperatures in a container having bases of each of the embodiments of FIG. 1, FIG. 4, and FIG. 7 as compared to the known current base of FIG. 12.

FIG. 18 is a front, cross-sectional schematic view of another exemplary embodiment a base in accordance with the disclosed subject matter.

FIG. 19 is a bottom view of the exemplary embodiment of FIG. 18, illustrating the thickness of the base at various points.

FIG. 20 is a front, cross-sectional schematic view of another exemplary embodiment of a base in accordance with the disclosed subject matter.

FIG. 21 is a front, cross-sectional schematic view of another exemplary embodiment of a base in accordance with the disclosed subject matter.

FIG. 22 is a front, cross-sectional schematic view of each of the exemplary embodiments of FIGS. 18-21 overlaid on each other, for purpose of comparison.

FIGS. 23A-23C each is a bottom perspective view of the exemplary embodiments shown in FIGS. 18-21, shown side-by-side for purpose of comparison with: FIG. 23A being a bottom perspective view of the embodiment of FIG. 21; FIG. 23B being a bottom perspective view of the embodiment of FIG. 20; and, FIG. 23C being a bottom perspective view of the embodiment of FIG. 18.

FIG. 24 is a graph illustrating the volume displacement response over a range of pressures for each of the embodiments of FIG. 18, FIG. 20 and FIG. 21 as compared to the known current base of FIG. 12.

FIG. 25 is a graph of the internal vacuum over a range of decreasing temperatures in a container having bases of each of the embodiments of FIG. 18, FIG. 20, and FIG. 21 as compared to the known current base of FIG. 12.

FIG. 26 is a front, cross-sectional schematic view of exemplary bases illustrating exemplary rib profiles, for purpose of comparison, in accordance with the disclosed subject matter.

FIG. 27 is a front, cross-sectional schematic view of another exemplary embodiment of a base in accordance with the disclosed subject matter.

FIG. 28 is a schematic diagram illustrating additional features of the operation of the exemplary embodiment of FIG. 27.

FIG. 29 is a schematic diagram illustrating additional features of the operation of the exemplary embodiment of FIG. 27.

FIG. 30 is a diagram illustrating the rate of volume decrease associated with the decrease in pressure for the containers having a base of the exemplary embodiment of FIG. 27 compared to a container having a base of the exemplary embodiment of FIG. 1.

FIG. 31 is a front, cross-sectional schematic view of an exemplary embodiment of a base in accordance with another aspect of the disclosed subject matter, including an intermediate surface having a linear portion and an intermediate radiused portion.

FIG. 32A is a bottom left perspective view of the exemplary embodiment of FIG. 31.

FIG. 32B is a bottom plan view of the exemplary embodiment of FIG. 31.

FIGS. 32C-I are additional views of the exemplary embodiment of FIG. 31.

FIG. 33 is a comparative front, cross-sectional schematic view of the exemplary embodiment of FIG. 7A overlaid with two alternative embodiments of a base of the disclosed subject matter including an intermediate surface having a linear portion and an intermediate radiused portion.

FIG. 34 is a comparative graph illustrating the base movement response over a range of pressures for a container having each of the embodiments of FIG. 33.

FIG. 35 shows the electromagnetic spectrum.

FIG. 36 is a block diagram illustrating a method of processing a beverage, constructed and operative in accordance with embodiments of the present invention.

 DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to embodiments of the disclosed subject matter, an example of which is illustrated in the accompanying drawings. The disclosed subject matter will be described in conjunction with the detailed description of the system.

Plastic containers disclosed herein can be used in hot-filling applications for packaging a wide variety of fluid and viscous beverage or liquid products, such as juices, sauces, teas, flavored waters, nectars, isotonic drinks and sports drinks etc. The plastic containers disclosed herein are configured to accommodate an increase in internal container pressure differential when the sealed containers are subject to thermal treatment, and capable of accommodating vacuum during cool down. The unique configuration of the disclosed plastic containers incorporates a number of features that collectively control unwanted deformation during hot-filling processes. Furthermore, the plastic containers disclosed herein have unique asymmetrical designs for hot-fill beverage and food markets.

In accordance with the disclosed subject matter, a plastic container for hot-filling processes is provided. The hot-fillable plastic container comprises a container body having a bottom portion, a sidewall portion and an upper portion. The container body has a chamber defined therein. The container body further comprises a finish portion extending from the upper portion and defines a mouth in fluid communication with the chamber. The bottom portion includes a support surface and a variable dynamic base portion configured to deflect in response to a pressure differential between the chamber and an exterior of the container body. The sidewall portion includes a lower circumferential groove ring and an upper circumferential groove ring, and further includes a pair of longitudinal grooves extending longitudinally between the lower and upper circumferential groove rings to define a front sidewall segment on a front side of the sidewall portion between the upper and lower circumferential groove rings and a rear sidewall segment on a rear side of the sidewall portion between the upper and lower circumferential groove rings. The rear sidewall segment comprises a waist groove extending circumferentially between the pair of longitudinal grooves to define an upper rear sidewall segment between the waist groove and the upper circumferential groove ring, and a lower rear sidewall segment between the waist groove and the lower circumferential groove ring, wherein one of the upper rear sidewall segment or the lower rear sidewall segment includes at least one vacuum panel configured to deflect in response to the pressure differential between the chamber and the exterior of the container body.

The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the disclosed subject matter. Hence, features depicted in the accompanying figures support corresponding features and combinations thereof of the claimed subject matter.

Referring now to an exemplary embodiment as depicted in FIGS. 1A, for purpose of illustration and not limitation, a hot-fillable plastic container comprises a container body 100 having a bottom portion 130, a sidewall portion 120 and an upper portion 110. The container body thus defines a chamber therein for containing liquid products or the like. Additionally, and as illustrated in FIGS. 1A, for example and not limitation, the container body 100 includes a finish portion 140 extending from the upper portion 110 and defining a mouth in fluid communication with the chamber. The finish portion can have a variety of convention configurations, and can include a fastener, such as a thread or flange, for engaging a cap, as well as orientation and capping features as known in the art. Angular design elements on the upper portion 110 of the plastic container can be refined to work in harmony with other portions of the plastic container.

The bottom portion 130, as illustrated in FIGS. 1A-1B, for example and not limitation, can include a cylindrical base wall 135, and a support surface 136 defining a reference plane. The support surface 136 extends radically inward from the cylindrical base wall 135, and is configured for standing the container on a generally plane surface. As depicted in FIGS. 1B, 4C, and 7, the bottom portion 130 further includes a variable dynamic base portion 137 extending inward from the support surface 136. The variable dynamic base 137 is configured to deflect in response to a pressure differential between the chamber and an exterior of the container body. A variety of suitable configurations can be used for the variable dynamic base in accordance with the disclosed subject matter, providing that the structure of the base is capable of accommodating at least a portion of the pressure differential resulting from expected conditions, such as during the processes of hot-filling, cooling and sealing. For example, and not limitation, U.S. Pat. No. 9,296,539 discloses a variable dynamic base that can be used in accordance with the disclosed subject matter, and the content of the forgoing patent is incorporated herein by reference in its entirety.

In accordance with the disclosed subject matter and as illustrated in FIG. 1A, for example and not limitation, the sidewall portion 120 includes and extends longitudinally between a lower circumferential groove ring 121 and an upper circumferential groove ring 122. As embodied herein, each of the lower and upper circumferential groove rings extends about an entire circumference of the container. The lower circumferential groove ring 121 and the upper circumferential groove ring 122 provides structural support to maintain the plastic bottle roughly round in the package.

As illustrated in FIGS. 1A, 2B, and 5E, the lower circumferential groove ring 121 has a width W1 and a depth D1 in side view, each of which can be generally constant as embodied herein, and an outer radius R1 in plan view. Furthermore, and as best depicted in FIG. 5E, the outer radius R1 can be along the lower edge of the lower circumferential groove ring 121 and proximate the bottom portion 130 to define a bumper extending radically outward greater than the sidewall portion 120. In accordance with the disclosed subject matter, the ratio of the width R1 to the outer radius R1 can range between about 0.07 to about 0.22, and the ratio of the depth D1 to the outer radius R1 can range between about 0.04 to about 0.18.

As illustrated in FIGS. 1A and 5C, the upper circumferential groove ring 122 has a width W2 and a depth D2 in side view, each of which can be generally constant as embodied herein, and an outer radius R2 in plan view. Furthermore, and as best depicted in FIG. 5C, the outer radius R2 can be along the upper edge of the upper circumferential groove ring 122 and proximate the upper portion 110 to define a bumper extending radically outward greater than the sidewall portion 120. In accordance with the disclosed subject matter, the ratio of the width W2 to the outer radius R2 can range between about 0.07 to about 0.22, and the ratio of the depth D2 to the outer radius R2 can range between about 0.04 to about 0.18.

Exemplary dimensions of the lower circumferential groove ring 121 and upper circumferential groove ring 122 for an 18.5 oz container are reproduced in detail in Table I for purpose of illustration and not limitation.

In accordance with another aspect of the disclosed subject matter, and as illustrated in FIGS. 3A and 5A, for example and not limitation, the sidewall portion 120 includes a pair of longitudinal grooves 123 extending longitudinally between the upper 122 and lower 121 circumferential groove rings to define a front sidewall segment 200 on a front side of the sidewall portion 120. Each of the longitudinal grooves 123 can extend into and connect with the lower circumferential groove ring 121 and the upper circumferential groove ring 122. As embodied herein, and as illustrated in FIG. 1A, the front sidewall segment 200 can be a front rigid panel 210 bordered by the lower circumferential groove ring 121, the upper circumferential groove ring 122 and the pair of longitudinal grooves 123. These grooves collectively thus structurally isolate the front rigid panel 210 from the rear sidewall segment 220 to protect the front rigid panel 210 from deformation during hot-filling processes. Furthermore, as illustrated in FIGS. 3A-3B and 5A, for example and not limitation, a stiffening bead 124 is provided along at least a portion of a length of each longitudinal groove 123 to isolate the waist groove 225 from the longitudinal grooves 123 and thus the rigid front panel 210. As embodied herein, for illustration and not limitation, the stiffening bead can extend from the lower end of the longitudinal groove 123 to about ⅔ height of the container body 100. For example, and illustrated in FIGS. 5A and SB, the stiffening bead can be disposed along a rear edge of the longitudinal groove 123, physically separating the waist groove 225 from the longitudinal groove 123, as well as structurally reinforce the sidewall to prevent hinge-like movement proximate the waist groove 225.

In addition, as embodied herein and illustrated in FIG. 1A, the front rigid panel 210 can further include a plurality of circumferentially-extending ribs 215 to stiffen the panel area and provide additional protection against deformation during hot-filling and cooling processes. The front rigid panel 210, as embodied herein, is free of any vacuum panel or similar feature. The front rigid panel can have a constant radius in plan view, or as depicted and embodied herein, can flatten along its height.

As shown in FIGS. 1A, 3A, and 5B. the longitudinal groove can have a width W4 and a depth D4 in plan view, and the front sidewall segment can have an outer radius R4 in plan view. The width W4 and depth D4 can be varied along the length of each longitudinal groove. In accordance with the disclosed subject matter, the ratio of the width W4 to the outer radius R4 can range between about 0.07 to about 0.18, and the ratio of the depth D4 to the outer radius R4 can range between about 0.02 to about 0.14. For example, and not limitation, the middle portion of the longitudinal groove can have a greater depth than the upper and lower portions of the longitudinal groove. The exemplary dimensions of the longitudinal groove 123 for an 18.5 oz container are reproduced in detail in Table 1 for purpose of illustration and not limitation.

The pair of longitudinal grooves 123 can be linear to define a generally rectangular panel. Additionally, as embodied herein and illustrated in FIGS. 1A, 3A, and 5A, for example and not limitation, the longitudinal grooves 123 can be nonlinear, such that the front sidewall segment 200, which is defined along opposing sides by each of the longitudinal grooves 123, can be configured with an contoured shape for labeling, aesthetic or ergonomics needs of the disclosed subject matter. As illustrated, for example and not limitation, in FIG. 1A, the front sidewall segment 200 can have a bow-tie shape defined between a pair of nonlinear longitudinal grooves 123. The bow-tie shape front sidewall segment 220 embodied herein thus has a maximum circumferential width proximate each of the lower 121 and upper 122 circumferential groove rings and a minimum circumferential width aligned longitudinally along a height of the sidewall portion with the waist groove 225.

In accordance with another aspect of the disclosed subject matter, and as illustrated in FIGS. 2A, 3A, 4A, 5A, and 6, for example and not limitation, the sidewall portion 120 further includes a rear sidewall segment 220 on a rear side of the sidewall portion 120 between the upper 122 and lower 121 circumferential groove rings, and is defined by the pair of longitudinal grooves 123. As illustrated in FIGS. 2A, 3A, 3B, 4A, 4B, 5A, and 6, for example and not limitation, the rear sidewall segment 220 comprises a waist groove 225 extending circumferentially between the pair of longitudinal groove 123. As embodied herein, the waist groove 225 can extend about a circumference of between about 65% to about 75% of a diameter of the waist groove 225, thus providing a strong structural rigidity for rear sidewall segment 220. As illustrated in FIGS. 1C, 2A, and SD, the waist groove has a width W3 and depth D3 in side view, each of which can be generally constant as embodied herein, and an inside radius R3 in plan view. In accordance with the disclosed subject matter, the ratio of the width W3 to the inside radius R3 can range between about 0.15 to about 0.46, and the ratio of the depth D3 to the inside radius R3 can be about 0.10 to about 0.30. The exemplary dimensions of the waist groove 225 are reproduced in detail in Table 1 for an 18.5 oz container, for purpose of illustration and not limitation.

In accordance with another aspect of the disclosed subject matter, and as illustrated in FIG. 2A, for example not limitation, the rear sidewall segment 220 comprises a lower rear sidewall segment 240 defined between the waist groove 225 and the lower circumferential groove ring 121, and an upper rear sidewall. One of the lower rear sidewall segment 240 or the upper rear sidewall segment 230 includes at least one vacuum panel 245 configured to deflect in response to the pressure differential between the chamber and the exterior of the container body. A variety of suitable configurations can be used for the vacuum panel in accordance with the disclosed subject matter. For example, and not limitation, U.S. Pat. No. 5,971,184 discloses a vacuum panel that can be used in accordance with the disclosed subject matter, and the content of the forgoing patent is incorporated herein by reference in its entirety.

As embodied herein, the lower rear sidewall segment 240 can include the at least one vacuum panel 245. As illustrated, for example and not limitation, in FIGS. 3A, 3B, 4A, 4B, 5A, and 6, the lower rear sidewall segment 240 includes two vacuum panels 245. The vacuum panels and the variable dynamic base together are sized and configured to compensate for a desired range of pressure differentials. As further embodied herein, for additional strength and rigidity, each vacuum panel is angled inwardly toward the chamber relative to a vertical reference plane perpendicular to the support surface 136. For example and as depicted in FIGS. 4A, 4B, and 4D, each vacuum panel 245 is recessed relative an outer surface of the rear sidewall portion 220. A depth of the recess along an upper edge of the vacuum panel, i.e., the upper recessed depth 246, is greater than a depth of the recess along a lower edge of the vacuum panel, i.e., the lower recessed depth 247.

As embodied herein and illustrated in FIGS. 4A and 4B, for example and not limitation, the lower rear sidewall segment 240 further includes a rigid longitudinal support between the two vacuum panels 245. The rigid longitudinal support can be a column feature or other suitable configurations. As illustrated in FIG. 2A, for example and not limitation, the longitudinal support is a rigid support panel 260, which can be free of any vacuum panel. A border groove 265, as shown in FIGS. 4A-4B and 5A-5B, is provided along an edge of the rigid support panel 260. As embodied herein, the border groove 265 can extend into and connect with the lower circumferential groove ring 121.

The border groove 265 together with the lower circumferential grooving ring 121 thus surround the rigid support panel 260 to isolate it from other portions of the container, further structurally protecting the rigid support panel 260 from deformation associated with the hot-filling and cooling processes. Additionally, and as embodied herein, the rigid support panel 260 can include a plurality of circumferentially-extending ribs 266 to stiffen the rigid support panel and provide additional protection against deformation associated with the hot-filling processes. As illustrated in FIG. 2A, for example and not limitation, the rigid support panel 260 can have a partial frustoconical shape, so as to taper inwardly toward the waist groove 225.

As embodied herein, the rear sidewall segment 220 also comprises an upper rear sidewall segment 230 defined between the waist groove 225 and the upper circumferential groove ring 122. As illustrated in FIGS. 3A, 5A, and 6, for example not limitation, the upper rear sidewall segment 230 is bordered by and thus isolated from other portions of the plastic container by the waist groove 225, the upper circumferential groove ring 122 and the pair of longitudinal grooves 123 so as to be structurally protected from deformation during hot-filling and cooling processes. As embodied herein and illustrated in FIGS. 2A, for example not limitation, the upper rear sidewall 230 can include a plurality of angled ribs 235 for stiffening and/or aesthetic purposes, providing additional structural protection to the upper rear sidewall segment 230. As illustrated, for example and not limitation, in FIGS. 1B, 2A, and 5A, the upper rear sidewall segment 230 has a partial bowl shape so as to taper inwardly towards the waist groove 225.

For purpose of illustration and not limitation, reference is now made to an exemplary container in accordance with the disclosed subject matter. The exemplary container is configured to contain approximately 18.5 oz of fluid, and has an overall height of about 8.4 inches and overall maximum diameter at its base of about 2.77 inches. For convenience and illustration, the dimensions of such container for the lower circumferential groove ring 121 depicted in FIGS. 1A and 5E, the upper circumferential groove ring 122 depicted in FIGS. 1A and 5C, the waist groove 225 depicted in FIGS. 2A and SD, and the longitudinal groove 123 depicted in FIGS. 3A and 5B, are reproduced in Table 1 below.

TABLE 1 Exemplary dimensions of lower and upper circumferential groove rings, waist groove, and longitudinal groove. Example (inch) Preferred Ran2e (inch) Lower circumferential Groove ring 121 Width (WI) 0.153 0.100-0.300 Depth (DI) 0.147 0.050-0.250 Outer Radius (RI) 1.383 1.125-2.500 Upper circumferential Groove ring 122 Width (W2) 0.152 0.100-0.300 Depth (D2) 0.142 0.050-0.250 Outer Radius (R2) 1.378 1.125-2.500 Waist Groove 225 Width (W3) 0.254 0.150-0.450 Depth (D3) 0.187 0.100-0.300 Inside Radius (R3) 0.970 0.750-2.000 Longitudinal Groove 123 Width (W4) of lower portion 0.134 0.100-0.250 of longitudinal groove 123 Width (W4) of middle portion 0.178 0.100-0.250 of longitudinal groove 123 Width (W4) of upper portion 0.154 0.100-0.250 of longitudinal groove 123 Depth (D4) of lower portion of 0.050 0.025-0.200 longitudinal groove 123 Depth (D4) of middle portion 0.156 0.025-0.200 of longitudinal groove 123 Depth (D4) of upper portion of 0.052 0.025-0.200 longitudinal groove 123 Outer Radius (R4) 1.383 1.125-2.500

As embodied herein, and for purpose of illustration and not limitation, the plastic containers disclosed herein can be formed using any suitable method as known in the art. For example, the plastic containers can be blow molded from an injection molded preform made from, for example, PET, PEN or blends thereof, or can be extrusion blow molded plastic, for example, polypropylene (PP). The finishes of the containers can be injection molded, i.e., the threaded portion can be formed as part of the preform, or can be blow molded and severed from an accommodation feature formed thereabove, as is known in the art.

In accordance with the disclosed subject matter herein, the disclosed subject matter includes a base for a container having a sidewall including the annular ribs as also disclosed in the present invention. The base includes a support surface defining a reference plane, an inner wall extending upwardly from the support surface, a first radiused portion extending radially inward from the inner wall and concave relative to the reference plane, a second radiused portion extending radially inward from the first radiused portion and convex relative to the reference plane, an intermediate surface extending radially inward from the second radiused portion, a third radiused portion extending radially inward from the inner surface and convex relative to the reference plane, and an inner core disposed proximate the third radiused portion to define a central portion of the base. As discussed further below, at least a portion of the intermediate surface can be linear in cross section. The base can also include an outer support wall, which can be an extension of the container side. In additional embodiments in accordance with the disclosed subject matter, the base further includes a fourth radiused portion disposed between the support surface and the inner support wall, and/or a fifth radiused portion disposed between the support surface and the outer support wall. As described further below, each radiused portion defines a hinge for relative movement therebetween, such that at least a portion of the base acts as a diaphragm.

Reference will now be made in detail to the various exemplary embodiments of the disclosed subject matter, exemplary embodiments of which are illustrated in the accompanying drawings. The structure of the base for the container of the disclosed subject matter will be described in conjunction with the detailed description of the system.

The accompanying figures, where like reference numerals refer to identical or functionally similar elements throughout the separate views, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the disclosed subject matter. For purpose of explanation and illustration, and not limitation, exemplary embodiments of the base and container with the disclosed subject matter are shown in the accompanying figures. The base is suitable for the manufacture of containers such as, bottles, jars and the like. Such containers incorporating the base can be used with a wide variety of perishable and nonperishable goods. However, for purpose of understanding, reference will be made to the use of the base for a container disclosed herein with liquid or semi-liquid products such as sodas, juices, sports drinks, energy drinks, teas, coffees, sauces, dips, jams and the like, wherein the container can be pressure filled with a hot liquid or non-contact (i.e., direct drop) filler, such as a non-pressurized filler, and further used for transporting, serving, storing, and/or re-using such products while maintaining a desired shape, including providing a support surface for standing the container on a table or other substantially flat surface. Containers having a base described herein can be further utilized for sterilization, such as retort sterilization, and pasteurization of products contained therein. As described in further detail below, the container can have a base configuration to provide improved sensitivity and controlled deformation from applied forces, for example resulting from pressurized filling, sterilization or pasteurization and resulting thermal expansion due to hot liquid contents and/or vacuum deformation due to cooling of a liquid product filled therein. The base configuration can influence controlled deformation from positive container pressure, for example resulting from expansion of liquid at increased temperatures or elevations. For purpose of illustration, and not limitation, reference will be made herein to a base and a container incorporating a base that is intended to be hot-filled with a liquid product, such as tea, sports drink, energy drink or other similar liquid product.

FIGS. 1-3 illustrate exemplary embodiments of the disclosed subject matter. With reference to FIG. 7A, the base 100 generally defines a diaphragm including a series of radiused portions. The multiple radiused portions can allow the base 100 to deform in a desired manner from circumferential stress concentrations. As shown in FIG. 7B-E, the base 100 generally can include any number of radial segments between the radiused portions to proportionally distribute the force differential between the inside and outside of the container to provide a low spring rate, that is change in resistance due to pressure change.

As shown for example in FIGS. 7A-E, the base 100 can include an outer support wall 102, a support surface 104 extending inwardly from the outer support wall 102 and defining a reference plane P, and an inner support wall 106 extending upwardly from the support surface 104. In accordance with the disclosed subject matter, a first radiused portion 108 extends radially inward from the inner support wall 106 and concave relative to the reference plane P. A second radiused portion 110 extends radially inward from the first radiused portion 108 and convex relative to the reference plane P. An intermediate surface 112 extends radially inward from the second radiused portion 110 and substantially parallel to the reference plane P. A third internal radiused portion 114 extends radially inward from the intermediate surface 112 and convex to the reference plane P to a central portion 116. The intermediate surface 112 can include at least a portion that is substantially flat or linear in shape, and can extend at an angle substantially parallel (i.e., +/−10 degrees) relative to the reference plane P.

The central portion 116 can be configured to form a variety of suitable shapes and profiles. For example, and as depicted, the central portion 116 can be provided with an inner core 118. The inner core 118 can have a generally frustoconical shape or the like and can be shallow or deep as desired. By way of example, the inner core 118 can comprise a sidewall 120 and a top surface 122 extending from the sidewall 120, the top surface 122 having a convex portion 124 relative to the reference plane P.

As further defined herein, the radiused portions generally function as hinges to control at least in part the dynamic movement of the base 100. For example, the first radiused portion 108 can be configured as a primary contributor to both the ease with which the base 100 deforms and the amount of deformation. With reference to the exemplary embodiments disclosed in FIG. 7A, the second and third radiused portions 110, 114 can cooperate with the first radiused portion 108 and provide for additional deformation, such as approximately 10-20% or more of total base displacement.

Each radiused portion can be configured to deform in conjunction with the other. For example, a change to the geometry and/or relative location of either of the third radiused portion 114 or second radiused portion 110 can affect the deformation response of the first radiused portion 108. As described further below, a transition portion 126 between the third radiused portion 114 and the central portion 116 can also be configured to affect the efficiency or response of the base deformation. Furthermore, the length of the intermediate surface 112 can be selected to affect such deformation based upon its relationship with the second and third radiused portions 110, 114. In this manner a diaphragm can be designed and tailored based upon the interactions of these base portions to provide a desired performance and effect.

In addition to the profile of the base 100 as defined by the radiused portion locations, the radius of the transition portion 126 between the inner core 118 and the third radiused portion 114, as well as the conical shape of the inner core 118, can be modified to increase or decrease the spring rate or response to pressure differentials, which can accommodate a range of thermodynamic environments, such as variations in hot-fill filling lines. The base profile can also allow the base 100 to be scaled to containers of different overall shapes such as oval, square or rectangular shapes and different sizes while maintaining consistent thermal and pressure performance characteristics.

The overall design and contour of the base profile, or a portion thereof, can act as a diaphragm responsive to negative internal pressure or vacuum as well as positive internal pressure. The diaphragm can aid in concentrating and distributing axial stress. With reference to the exemplary embodiment of FIG. 7A-E, the effective area of the diaphragm can be measured as the portion of the base extending diametrically from the top of the inner support wall 106 on one side of the container to the top of the inner support wall 106 on the opposite side. The differential in pressure between the inside of the container and outside of the container can flex the base 100 in a controlled manner. The concentration of stress can be rapidly distributed to radiate outwardly from the center of the base 100 in a uniform circumferential manner. The stress concentrations in the base thus can be directed circumferentially at or around the radiused portions in the diaphragm plane and extend out in a wave manner.

FIGS. 7B-C show a bottom left perspective and bottom right perspective view, respectively, of the exemplary embodiment of FIG. 1. FIG. 2C shows a bottom plan view of the exemplary embodiment of FIG. 1. FIG. 3 shows a bottom view of the exemplary embodiment of FIGS. 1, illustrating the thickness of the base 100 at various points. With reference to FIGS. 2A-3, the base design can further include ribs 128 to form base segments 130 that can cooperate with the radial radiused portions to improve strength and resistance to deformation or roll out from positive pressure. The geometry of the ribs 128 that divide the segments 130 can provide support to the base 100 as it radiates out to the support surface 104. The base 100 can deform more efficiently without the segments 130 when only internal vacuum is considered. However, through testing it was determined that the use of the segments 130 can further prevent the base 100 from deforming in an uncontrolled manner and/or to an unrecoverable state, and thus provides a structural support response to internal positive pressure caused by thermal expansion during the filling and capping process which ultimately results in predicted/controlled and improved response to vacuum. Thus, while typical prior art container base vacuum panel technology focuses on the performance of the panel in response to a vacuum (i.e., negative pressure), embodiments disclosed herein can further address performance of the panel in response to the positive pressure exerted during filling and capping.

Further in accordance with the disclosed subject matter, the base, and thus the container, can be configured with any of a variety of different shapes, such as a faceted shape, a square shape, oval shape (see FIG. 8A) or any other suitable shape. In this manner, each segment 130, if provided, can be formed as a wedge and can serve as a discrete segment of the base. The segment can have a profile that matches the base profile of FIG. 7A when viewed in that direction. When viewing the cross section of the segment as it extends radially out from the center longitudinal axis, each segment can have a convex or concave shape relative to the reference plane P as in FIG. 26. A segment 130 that is convex-shaped when referring to the reference plane P can create small regions that can invert displacing volume in the presence of vacuum. As such, volume displacement can be reduced relative to the entire base or diaphragm structure movement. A segment 130 that is concave-shaped relative to the reference plane P can improve control of deformation from internal pressure. The concave shape can further control total base movement. The ribs 128 dividing the base 100 can further support or tie the base together circumferentially. The ribs 128 can be formed continuously along the base 100 from the inner core 118 to the support surface 104. Alternatively, the ribs 128 can be formed with discontinuities, for example having discontinuities along the base 100 at the points where any or all of the radiused portions are formed. In addition, the rib cross section as viewed in FIG. 26 can have varying shapes and sizes as defined in FIG. 26.

The base segments 130 can each function independently to provide variable movement of the base 100 and can result in displacement in response to small changes in internal or external changes in container pressure. The combined structure of the individual segments 130 and the ribs 128 dividing the segments 130 can reduce the reaction or displacement to positive pressure while increasing or maintaining sensitivity to negative internal pressure. The base segments 130 can move independently in response to the force or rate of pressure change. Thus, each base segment 130 or area within the segment can provide a secondary finite response to vacuum deformation and product displacement. As such, the combination of segments 130 and dividing ribs 128 can adapt or compensate to variations in wall thicknesses and gate locations among containers formed using base 100 that would otherwise cause inconsistent or incomplete base movement as found in the control. The movement of the segments can be secondary to primary movement or deflection of the overall base diaphragm structure, which can be affected by the base geometry and radiused portions, as described herein.

Current and earlier base technologies have also used mechanical actuation as a method to compensate for product contraction. These technologies have incorporated segments or scallops as part of the design of the base, and in these particular instances, the segments—and specifically the area in between the segments—were needed to provide uniform base movement as the base was mechanically inverted. To achieve this, the area between the segments flex or deform to maintain the shape of the segment and maximize the volume displaced by inversion as all the segments around the circumference of the base invert consistently. Without these breaks in the geometry, the base could invert in an uneven and uncontrolled manner. In the case of the present variable displacement base, the segments 130, either concave or convex in shape when viewing the cross section from the central longitudinal axis out to the major diameter, can react individually as a response to either internal positive or negative pressure. The deformation that occurs reacts in the actual segment surface as opposed to the area in between the segment. It is through this action that the segments 130 can respond individually such that base 100 can respond dynamically to multiple forces and maintain consistent total base deformation.

In this manner, base 100 can respond or deform in a controlled manner from the positive internal pressure. The controlled deformation can prevent the base diaphragm region from extending down past the standing ring, which may define reference plane P or support surface 104, while providing a geometry that can respond dynamically to internal vacuum pressure. Base 100 can exhibit a small degree of relaxation or thermal creep due to hot fill temperatures and the resulting positive pressure from thermal expansion within the container. The environmental effect of temperature, pressure and time can interact with base 100 to provide a controlled deformation shape. Due at least in part to the response of the material to heat and pressure, some elastic hysteresis can prevent base 100 from returning to its original molded shape when all forces are removed. It was discovered through analysis and physical testing that the design of the base profile, segments 130 and ribs 128 would lead to an initial surface geometry that, when subjected to the positive pressure of hot filling and capping, results in a shape that also responds efficiently to internal vacuum pressures. Thus, after hot filling and capping, the resulting shape of base 100 can be considered a preloaded condition from which the bottle base can be designed to respond to vacuum deformation from the negative internal pressure created by product contraction during cooling.

Using the base profile as disclosed, a variety of embodiments can be configured as depicted in the figures, for purpose of illustration and not limitation. For example, FIGS. 8A-C illustrate an exemplary embodiment of a base 200 in accordance with the disclosed subject matter, shown without ribs, and having different dimensions. FIGS. 8A and 8B each shows a front, cross-sectional schematic view of the exemplary embodiment of base 200. FIG. 8C shows a bottom perspective view of the exemplary embodiment of base 200.

FIGS. 9A-C illustrate another exemplary embodiment of a base 300 in accordance with the disclosed subject matter having different dimensions. FIGS. 9A and 9B each shows a front, cross-sectional schematic view of the exemplary embodiment of the base 300. FIG. 9C shows a bottom perspective view of the exemplary embodiment of base 300.

FIG. 10 shows front, cross-sectional schematic views of the exemplary embodiments of FIGS. 7A-E, 8A-C, and 9A-C overlaid on each other, for purpose of comparison. FIGS. 11A-11C show bottom perspective views of the exemplary embodiments of FIGS. 7A-E, 8A-C, and 9A-C side-by-side for purpose of comparison. FIG. 11A shows a bottom perspective view of the embodiment of FIGS. 9A-C. FIG. 11B shows a bottom perspective view of the embodiment of FIGS. 8A-C. FIG. 11C shows a bottom perspective view of the embodiment of FIGS. 7A-E.

FIGS. 12 and 13 show cross-sectional schematic views of a known, current base for a container, for purpose of comparison to the exemplary embodiments of the disclosed subject matter. FIG. 14 shows a front, cross-sectional schematic view of a known, competitive base for a container, for purpose of comparison to the exemplary embodiments of the disclosed subject matter.

For purpose of understanding and not limitation, a series of graphs are provided to demonstrate various operational characteristics achieved by the base and container disclosed herein. FIG. 15 shows a graph illustrating the volume displacement response over a range of pressures for the embodiments of FIG. 7A (ref 100), FIG. 8A (ref 200) and FIG. 9A (ref 300) as compared to the known current base of FIG. 12 (ref. Current Production). FIG. 15 illustrates a simulated volume displacement of each base increasing from an initial reference position over a range of applied vacuum pressure. As shown in FIG. 15, the embodiments of the disclosed subject matter exhibit a relatively uniform, linear displacement under applied vacuum pressure compared to the known current base.

FIG. 16 shows a graph illustrating the volume displacement response over a range of pressures for bottles having bases of the embodiments of FIG. 7A (ref 100) and FIG. 8A (ref 200) as compared to the known current base of FIG. 12 (ref. Current Production). FIG. 16 illustrates a simulated volume displacement of each base increasing from an initial reference position over a range of applied vacuum pressure. As shown in FIG. 16, the embodiments of the disclosed subject matter exhibit a relatively uniform, linear displacement under applied vacuum pressure compared to the known current base.

FIG. 17 shows a graph of the internal vacuum over a range of decreasing temperatures in a container having bases of the embodiments of FIG. 7A (refs. 100, 100′), FIG. 8A (ref. 200), and FIG. 9A (ref 300) as compared to the known current base of FIG. 12 (refs. CL, FC1). FIG. 17 illustrates relative internal vacuum pressure data measured over a decreasing range of temperatures of the bottles after being filled with hot water and capped. As shown in FIG. 17, the embodiments of the disclosed subject matter exhibit a lower internal vacuum pressure due to the cooling of the liquid contents compared to the known current bases. As compared to the discontinuity shown in the current base CL at about 115-105 degrees Fahrenheit (F), which can be considered as a base activation point, the embodiments of the disclosed subject matter exhibit a more uniform, linear vacuum pressure in response to the liquid cooling. The base activation points of the exemplary embodiments, shown at about 125 degrees F. in 100 and 100′ and 145 degrees F. in 200, occur at higher temperatures and result in less discontinuity in the vacuum pressure as compared to the known current base. FC1 exhibits a known current base on a production line that did not activate.

FIGS. 18 and 19 illustrate yet another exemplary embodiment in accordance with the disclosed subject matter having different dimensions. FIG. 18 shows a front, cross-sectional schematic view of the exemplary embodiment of a base 400. FIG. 19 shows a bottom view of the exemplary embodiment of FIG. 18, illustrating the thickness of the base at various points.

FIGS. 20 and 21 each shows a front, cross-sectional schematic view of yet another exemplary embodiment of a base 500, 600 in accordance with the disclosed subject matter having different dimensions.

For purpose of illustration and not limitation, exemplary dimensions and angles shown in FIGS. 7A, 8A, 9A, 18, 20 and 21 are provided in Table 1. However, it will be apparent to those skilled in the art that various modifications and variations to the exemplary dimensions and angles can be made without departing from the spirit or scope of the disclosed subject matter.

FIG. 22 shows front, cross-sectional schematic views of the exemplary embodiments of FIGS. 18-21 overlaid on each other, for purpose of comparison. FIGS. 23A-23C show bottom perspective views of the exemplary embodiments shown in FIGS. 18-21, shown side-by-side for purpose of comparison. FIG. 23A shows a bottom perspective view of the embodiment of FIG. 21. FIG. 23B shows a bottom perspective view of the embodiment of FIG. 20. FIG. 23C shows a bottom perspective view of the embodiment of FIG. 18.

FIG. 24 shows a graph illustrating the volume displacement response over a range of pressures for the embodiments of FIG. 18 (ref. 400), FIG. 20 (ref. 500) and FIG. 21 (ref 600) as compared to the known current base of FIG. 12 (ref. Control). FIG. 24 illustrates a simulated volume displacement of each base increasing from an initial reference position over a range of applied vacuum pressure. As shown in FIG. 24, the embodiments of the disclosed subject matter exhibit a relatively uniform, linear displacement under applied vacuum pressure compared to the known current base.

FIG. 25 shows a graph of the internal vacuum over a range of decreasing temperatures in a container having bases of the embodiments of FIG. 18 (ref. 400), FIG. 20 (ref 500), and FIG. 21 (ref. 600) as compared to the known current base of FIG. 12 (ref. Control). FIG. 25 illustrates relative internal vacuum pressure data measured over a decreasing range of temperatures of the bottles after being filled with hot water and capped. As shown in FIG. 25, the embodiments of the disclosed subject matter generally exhibit a lower internal vacuum pressure due to the cooling of the liquid contents compared to the known current bases. As compared to the discontinuity shown in the current base Control at about 90 degrees F., which can be considered as a base activation point, the embodiments of the disclosed subject matter exhibit a more uniform, linear vacuum pressure in response to the liquid cooling. The base activation points of the exemplary embodiments, shown at about 120 degrees F. in base 400, 130 degrees F. in base 500, and 110 degrees F. in base 600, occur at higher temperatures and result in less discontinuity in the vacuum pressure as compared to the known current base.

In accordance with another aspect of the disclosed subject matter, a further modification is provided of the base for a container as defined above. That is, the base generally, comprises an outer support wall, a support surface extending inwardly from the outer support wall and defining a reference plane, an inner support wall extending upwardly from the support surface, a first radiused portion extending radially inward from the inner support wall and concave relative to the reference plane, a second radiused portion extending radially inward from the first radiused portion and convex relative to the reference plane, an intermediate surface extending radially inward from the second radiused portion and substantially parallel to the reference plane, a third radiused portion extending radially inward from the intermediate surface and convex relative to the reference plane, and a central portion disposed proximate the third radiused portion as defined in detail above. As disclosed herein, the base further includes a fourth radiused portion disposed between the support surface and the inner support wall and/or a fifth radiused portion disposed between the support surface and the outer support wall. As with the radiused portions previously defined, the fourth radiused portion and the fifth radiused portion herein each generally functions as a hinge for further deformation of the base. Hence, the portion of the base acting as a diaphragm can extend inwardly from the fourth radiused portion to include the inner support wall or inwardly from the fifth radiused portion to further include the support surface.

For purpose of illustration and not limitation, reference is now made to the exemplary embodiment of FIG. 27. Particularly, FIG. 27 depicts in cross-section the profile of a base 700 having fourth and fifth radiused portions. As depicted in cross-section, the base profile embodied herein generally comprises the various features as described in detail above, including the three radiused portions 708, 710, 714 and intermediate surface 712. Furthermore, a fourth radiused portion 750 is disposed between the support surface 704 and the inner support wall 706 for relative movement therebetween. Additionally or alternatively, a fifth radiused portion 752 can be provided between the support surface 704 and the outer support wall 702. Each of the additional radiused portions can be formed in a variety of ways. As depicted in FIG. 27, the fourth radiused portion 750 is convex when viewed from the bottom, and the inner support wall 706 is configured to extend upward and radially inward from the support surface 704. For example, but not limitation, the inner support wall 706 can be configured such that at least an upper portion thereof extends at an angle of between about 15 degrees and about 85 degrees relative to the reference plane P. Furthermore, and as compared with the embodiment of FIG. 1-3, the support surface 704 can be provided with an increased width in relation to the cross dimension of the base as a whole to enhance the performance of the fifth radiused portion 752 to act as a hinge relative to the outer support wall 702. For example, the support surface 704 can have a width of between about 4% to about 10% of the maximum cross-dimension of the base 700.

In this manner, and as previously described, the radiused portions will function as hinges and can cooperate for dynamic movement of the base as a whole. That is, by providing the fourth radiused portion 750 at the inner edge of the support surface 704, the portion of the base 700 extending inwardly from the fourth radiused portion 750 will act as a diaphragm. Similarly, by providing a fifth radiused portion 752 at the outer support wall 702, the portion of the base 700 extending inwardly from the fifth radiused portion 752 will act as a diaphragm. Depending upon the dimensions of the support surface 704, the diaphragm therefore can comprise at least about 90% of the surface area of the base 700, or even at least about 95% of the surface area.

Furthermore, and as described above, the dimensions and angles of the various features can be selected to tailor the overall performance of the base as desired. For example, the radius and angle of curvature of the various radiused portions, the distances therebetween, and the lengths of the support walls and surfaces can be modified to increase or decrease the spring rate or response to pressure differentials to accommodate a range of thermodynamic environments, such as variations in hot-fill filling lines. Additionally, the angle of curvature of the inner support wall 706 relative to the reference plane P defined by the support surface 704 can be selected for the desired response to pressure differentials to affect the efficiency of the base deformation.

Operation of an exemplary base 700 further having fourth and fifth radiused portions 750, 752 is illustrated schematically with reference to FIGS. 28 and 29. As depicted, operation of base designs having fourth and fifth radiused portions 750, 752 can exhibit base deformation in response to pressure differentials between the container and the environment at the fifth radiused portion 752 proximate the outer wall of the container. Accordingly, in response to a positive pressure differential in the container relative to the environment, the support surface 704 of the base 700 itself can rotate downwards relative to outer support wall 702, and conversely, in response to a negative pressure differential in the container relative to the environment, the support surface 704 can rotate upwards relative to the outer support wall 702.

For example, and as depicted generally in FIG. 28 for purpose of illustration, an increase in pressure within the container will deform the base 700 in a controlled manner such that the fifth radius portion 752 rotates downward relative to the reference plane P (i.e., defined by the support surface when not deflected). That is, and as embodied herein in its initial state, the fifth radiused portion 752 generally defines a right angle or 90 degrees between the support surface 704 and outer support wall 702. Upon an increase in internal pressure, the fifth radiused portion 752 will rotate or open to define an obtuse angle (i.e., greater than 90 degrees). In this manner, as the fifth radiused portion 752 rotates, the standing surface for the container shifts to the inner edge of the support surface 704. As used herein, “standing surface” is the surface that would be in contact with a horizontal surface upon which the base is placed. As shown, however, the radii of the radiused portions 708, 710, 714, 750, 752 and the length of the intermediate surface 712 are selected to cooperate such that the central portion 716 or core does not reside below the standing surface when the maximum desired pressure differential is reached. In a similar fashion, and as shown in FIG. 29, a negative pressure within the container relative the surrounding environment or atmosphere will result in the fifth radiused portion 752 rotating upwardly from the reference plane P to define an acute angle (i.e. less than 90 degrees). As such, the standing surface of the container will shift toward the outer edge of the support surface 704 proximate the outer support wall 702. With reference to the further embodiment disclosed in FIG. 28, the radius portions disposed inwardly of the fifth radius portion 752 can provide additional deformation, which can be approximately 10-20% or more of total base displacement. Hence, and as disclosed herein, the base 700 can be configured such that the support surface 704 can rotate to shift the standing surface toward the inner edge of the support surface 704 proximate the fourth radiused portion 750 when there is a positive pressure differential in the container, and rotate to shift the standing surface to the outer edge of the support surface 704 proximate the fifth radiused portion 752 when there is a negative pressure differential in the container. Throughout operation, the standing surface remains preferably below the remaining portions of the base 700 disposed inwardly of the standing surface.

Particularly, FIGS. 28 and 29 illustrate simulated deformations of base 700 when subject to a range of pressure differentials. FIG. 28 illustrates simulated deformation of base 700 in response to a positive pressure of 1.2 psi. FIG. 29 illustrates simulated deformation of base 700 in response to a negative pressure of 1.8 psi. As shown in FIGS. 28 and 29, the embodiments of the disclosed subject matter exhibit a relatively uniform, linear displacement under applied vacuum pressure compared to the known current base. Additionally, as illustrated, significant displacement occurs at the fifth radiused portion 752, while the portions disposed inwardly of the fourth radiused portion remain 750 above the standing surface.

For purpose of understanding and not limitation, a series of graphs are provided to demonstrate various operational characteristics achieved by the base and container disclosed herein. FIG. 30 shows a graph illustrating the rate of volume decrease associated with the decrease in pressure for the containers having base embodiments as depicted in FIG. 27 compared to a container having a base embodiment as depicted in FIG. 7A. Particularly, it is noted that each of the containers was formed of the same materials, dimensions, and processes, and that only the base profiles differ.

In accordance with another aspect of the disclosed subject matter, an alternative base is disclosed herein to achieve controlled deformation at lower pressure differentials than set forth in the prior embodiments. That is, and as with the embodiments previously disclosed, a base is provided having a support surface defining a reference plane, an inner support wall extending upwardly from the support surface, a first radiused portion extending radially inward toward a central longitudinal axis of the base from the inner support wall and concave relative to the reference plane, a second radiused portion extending radially inward toward the longitudinal axis from the first radiused portion and convex relative to the reference plane, an intermediate surface extending radially inward toward the longitudinal axis from the second radiused portion, a third radiused portion extending radially inward toward the longitudinal axis from the intermediate surface and convex relative to the reference plane, a transition portion extending radially inward toward the longitudinal axis from the third radiused portion and being concave relative to the reference plane, and a central portion disposed proximate the third radiused portion. As disclosed herein, the intermediate surface can comprise a linear portion extending radially from the second radiused portion, and an intermediate radiused portion extending radially inward from the linear portion and concave relative to the reference plane. Furthermore, the linear portion of the intermediate surface can be substantially parallel with the reference plane.

With reference to FIGS. 31-34, for purpose of illustration and not limitation, the base 800 disclosed herein generally defines a diaphragm including a series of radiused portions. For example, and as shown for example in FIG. 31, the base 800 generally can include a support surface 804 extending inwardly from the outer support wall 802 and defining a reference plane P8, and an inner support wall 806 extending upwardly from the support surface 804. In accordance with the disclosed subject matter, a first radiused portion 808 extends radially inward from the inner support wall 806 and concave relative to the reference plane P8. A second radiused portion 810 extends radially inward from the first radiused portion 808 and convex relative to the reference plane P8. An intermediate surface 812 extends radially inward from the second radiused portion 810. A third internal radiused portion 814 extends radially inward from the intermediate surface 812 and convex to the reference plane P8 to a central portion 816. In accordance with the disclosed subject matter, the intermediate surface 812 can comprise a linear portion 811 extending radially from the second radiused portion 810, and an intermediate radiused portion 813 extending radially inward from the linear portion 811 and concave relative to the reference plane. The linear portion 811 of the intermediate surface 812 can extend at an angle substantially parallel, or can extend upwardly or downwardly within a range of about +/−10 degrees and still be subject to movement under internal pressure changes) relative to the reference plane P8. Likewise, the intermediate radiused portion can have a radius between about 0.030 inches and about 0.100 inches.

As described above, the various radiused portions generally function as hinges to control at least in part the dynamic movement of the base 800. For example, the intermediate radiused portion 813 and the third radiused portion 814 can be configured as the primary contributors to the initial deflection of the base, while the first radiused portion 808 can act as the primary contributor to the total amount of base deformation. With reference to the exemplary embodiment disclosed in FIG. 31, and as further shown and described below, the intermediate radiused portion 813 of the intermediate surface 812 can be configured to increase base movement at lower vacuum pressure differentials.

Furthermore, and as previously set forth, each radiused portion can be configured to deform in conjunction with the other. For example, a change to the geometry and/or relative location of the third radiused portion 814 can affect the deformation response of the intermediate radiused portion 813, which can also affect the deformation response of the first radiused portion 808. Additionally, the length and configuration of the linear portion and the intermediate radiused portion of the intermediate surface 812 can be selected to affect such deformation based upon its relationship with the second and the third radiused portions 810, 814. Likewise, the transition portion 826 extending radially inward from the third radiused portion 814 can also be configured to affect the efficiency or response of the base deformation. In this manner, a diaphragm can be designed and tailored based upon these interactions to provide a desired performance and effect, such as by providing increased base movement at lower internal vacuum pressures.

Additionally, and as previously noted, the base 800 can include a central portion. For example, again with reference to FIG. 31, for illustration and not limitation, the central portion 816 can be configured to form a variety of suitable shapes and profiles. For example, and as depicted, the central portion 816 can be provided with an inner core 818. The inner core 818 can have a generally frustoconical shape or the like and can be shallow or deep as desired. By way of example, the inner core 818 can comprise a sidewall 820 and a top surface 822 extending from the sidewall 820, the top surface 822 having a convex portion 824 relative to the reference plane P8. In addition to the profile of the base 800 as defined by the radiused portion locations, the radius of the transition portion 826 between the central portion 816 and the third radiused portion 814, as well as the conical shape of the inner core 818, can be modified to increase or decrease the spring rate or response to pressure differentials, which can accommodate a range of thermodynamic environments, such as variations in hot-fill filling lines. The base profile can also allow the base 800 to be scaled to containers of different overall shapes such as oval, square or rectangular shapes and different sizes while maintaining consistent thermal and pressure performance characteristics.

For example, but not limitation, and again with reference to FIG. 31, as depicted in cross-section, the base generally comprises the various features as described in detail above, including the three radiused portions 808, 810, 814, an intermediate surface, which comprises a linear part 811 and the intermediate radiused portion 813 as further disclosed herein. Furthermore, a fourth radiused portion 850 can be disposed between the support surface 804 and the inner support wall 806 for relative movement therebetween as previously set forth. In addition or alternatively, a fifth radiused portion 852 can be provided between the support surface 804 and the outer support wall 802 as previously set forth. In this manner, and as previously described, the radiused portions will function as hinges and can cooperate for dynamic movement of the base as a whole. That is, by providing the fourth radiused portion 850 at the inner edge of the support surface 804, the portion of the base 800 extending inwardly from the fourth radiused portion 850 will act as a diaphragm. Similarly, by providing a fifth radiused portion 852 at the outer support wall 802, the portion of the base 800 extending inwardly from the fifth radiused portion 852 will act as a diaphragm.

As previously set forth, particularly at lower pressure differentials, the overall design and contour of the base profile, or a portion thereof, can act as a diaphragm responsive to negative internal pressure or vacuum as well as positive internal pressure. The diaphragm can aid in concentrating and distributing axial stress. With reference to the exemplary embodiment of FIG. 31-34, the effective area of the diaphragm can be measured as the portion of the base extending diametrically from the top of the inner support wall 806 on one side of the container to the top of the inner support wall 806 on the opposite side. The differential in pressure between the inside of the container and outside of the container can flex the base 800 in a controlled manner. The concentration of stress can be rapidly distributed to radiate outwardly from the center of the base 800 in a uniform circumferential manner. The stress concentrations in the base thus can be directed circumferentially at or around the radiused portions in the diaphragm plane and extend out in a wave manner.

FIG. 32A shows a bottom right perspective view of the exemplary embodiment of FIG. 31. FIG. 32B shows a bottom plan view of the exemplary embodiment of FIG. 31. With reference to FIGS. 32A-B, the base design 800 can further include ribs 828 to form base segments 830 that can cooperate with the radial radiused portions to improve strength and resistance to deformation or roll out from positive pressure within the container as previously set forth above. In FIGS. 32A-B, the base 800 generally can include any number of radial segments between the radiused portions to proportionally distribute the force differential between the inside and outside of the container to provide a low spring rate.

The geometry of the ribs 828 that define the segments 830 can provide support to the base 800 as it radiates out toward the support surface 804. In this manner, and as described with reference to the other exemplary embodiments above, each segment 830, if provided, can be formed as a wedge and can serve as a discrete segment of the base.

As embodied herein, each segment can have a profile that matches the base profile of FIG. 31 when viewed in corresponding cross-sectional profile. Furthermore, and as previously disclosed, the transverse cross section of each segment as it extends radially out from the center longitudinal axis, can have a convex or concave shape relative to the reference plane P8. A segment 830 that is convex-shaped in transverse cross-section when referring to the reference plane P8 can create small regions that can invert displacing volume in the presence of vacuum. As such, volume displacement can be reduced relative to the entire base or diaphragm structure movement. A segment 830 that is concave-shaped relative to the reference plane P can improve control of deformation from internal pressure. The concave shape can further control total base movement. The ribs 828 dividing the base 800 can further support or tie the base together circumferentially. The ribs 828 can be formed continuously along the base 800 from the inner core 818 to the support surface 804. Alternatively, the ribs 828 can be formed with discontinuities, for example having discontinuities along the base 800 at the points where any or all of the radiused portions are formed. In addition, the rib cross section can have varying shapes and sizes.

The base segments 830 can each function independently to provide variable movement of the base 800 and can result in displacement in response to small changes in internal or external changes in container pressure. The combined structure of the individual segments 830 and the ribs 828 dividing the segments 830 can reduce the reaction or displacement to positive pressure while increasing or maintaining sensitivity to negative internal pressure. The base segments 830 can move independently in response to the force or rate of pressure change. Thus, each base segment 830 or area within the segment can provide a secondary finite response to vacuum deformation and product displacement. As such, the combination of segments 830 and dividing ribs 828 can adapt or compensate to variations in wall thicknesses and gate locations among containers formed using base 800 that would otherwise cause inconsistent or incomplete base movement as found in the control. The movement of the segments can be secondary to primary movement or deflection of the overall base diaphragm structure, which can be affected by the base geometry and radiused portions, as described herein.

For purpose of comparison and not limitation, FIG. 33 shows a front, cross-sectional schematic view of a base having the same configuration as the exemplary embodiment previously described with reference to FIG. 7A (ref. 100′), along with two alternate embodiments (refs. 800, 900) of a base having an intermediate surface including a linear portion and an intermediate radiused portion. That is, each of the embodiments of refs. 800 and 900 respectively include a base having a support surface defining a reference plane, an inner support wall extending upwardly from the support surface, a first radiused portion extending radially inward toward a central longitudinal axis of the base from the inner support wall and concave relative to the reference plane, a second radiused portion extending radially inward toward the longitudinal axis from the first radiused portion and convex relative to the reference plane, an intermediate surface extending radially inward toward the longitudinal axis from the second radiused portion, a third radiused portion extending radially inward toward the longitudinal axis from the intermediate surface and convex relative to the reference plane, a transition portion extending radially inward toward the longitudinal axis from the third radiused portion and being concave relative to the reference plane, and a central portion disposed proximate the third radiused portion. Furthermore, each of the bases shown in cross-sectional schematic view in FIG. 33 (base 100′, base 800, and base 900) was made of the same material, and substantially the same dimensions and weight. However, because of the different base configurations (i.e., intermediate surface configurations), each base has a different response profile as set forth below with reference to FIG. 34.

For purpose of comparison and not limitation, exemplary dimensions and angles of the bases shown in FIG. 33 are provided in Table 2. As shown, the radius of curvature r92 of the third radiused portion of the embodiment of ref. 900 is larger as compared to the radius of curvature r82 of the third radiused portion of the embodiment of ref. 800. Further, the radius of curvature r97 of the intermediate radiused portion of the embodiment of ref. 900 is relatively larger as compared to the radius of curvature r87 of the intermediate radiused portion of the embodiment of ref 800. By comparison, the base 100′ does not include an intermediate radiused portion. As described above, and further shown by the results in FIG. 33, these dimensions can be tailored to provide a desired performance and effect of the base. For example, lighter weight blow molded plastic containers with thinner wall thicknesses can benefit from base configurations similar to ref 800 or 900 due to the greater controlled deformation at lower pressure differentials, as compared to a container of similar size and shape but greater weight and wall thickness.

For purpose of understanding and not limitation, a series of graphs are provided to demonstrate various operational characteristics achieved by the base and container disclosed herein. FIG. 34 shows a graph illustrating the vertical base movement response over a range of pressures for various embodiments of FIG. 33. That is, the graph illustrates the vertical base movement for two alternate embodiments of a base having an intermediate surface with a linear portion and an intermediate radiused portion, as depicted in ref 800 and 900, as compared to the vertical base movement of a base having an intermediate surface as depicted by ref. 100′. Each of the container having base 800, the container having base 900, and the container having base 100′ were formed of the same materials, with substantially the same weights and wall thicknesses, wherein only the base profiles differ as depicted in FIG. 33.

FIG. 34 illustrates a simulated volume displacement of each base increasing from an initial reference position over a range of applied vacuum pressure. As shown by the results of FIG. 34, the embodiments having an intermediate surface with an intermediate radiused portion (ref. 800, ref. 900) exhibit increased volume displacement under lower applied internal vacuum pressure as compared to ref. 100′. This greater response to lower vacuum pressure allows controlled deformation of the base for containers of lower weight before undesirable deformation in other areas of the container (such as the container sidewall). This controlled deformation allows the remaining bottle structure to retain its shape while being subjected to the internal pressures exerted during the hot-fill and capping process, and the cooling process.

It will be apparent to those skilled in the art that various modifications and variations to the exemplary dimensions and angles can be made without departing from the spirit or scope of the disclosed subject matter. For example, and as described above, the specific dimensions and angles of the base configuration disclosed herein can be selected to tailor the overall performance of the base as desired. For example, the radius and angle of curvature of the various radiused portions, the distances therebetween, and the lengths of the support walls and surfaces can be modified to increase or decrease the spring rate or response to pressure differentials to accommodate a range of thermodynamic environments, such as variations in hot-fill filling lines. Additionally, the angle of curvature of the inner support wall 806 relative to the reference plane P8 defined by the support surface 804 can be selected for the desired response to pressure differentials to affect the efficiency of the base deformation.

In accordance with another aspect of the disclosed subject matter, a container is provided having a base as described in detail above. The container generally comprises a sidewall and a base, the base comprising an outer support wall, a support surface extending inwardly from the outer support wall and defining a reference plane, an inner support wall extending upwardly from the support surface, a first radiused portion extending radially inward from the inner support wall and concave relative to the reference plane, a second radiused portion extending radially inward from the first radiused portion and convex relative to the reference plane, an intermediate surface extending radially inward from the second radiused portion, a third radiused portion extending radially inward from the intermediate surface and convex relative to the reference plane, and a central portion disposed proximate the third radiused portion. The intermediate surface can at least include a linear portion extending radially from the second radiused portion. Additionally, and in accordance with another aspect of the disclosed subject matter as set forth above, the intermediate surface can include an intermediate radiused portion extending radially inward from the linear portion and concave relative to the reference plane. As embodied herein, the container sidewall can be coextensive and/or integral with the outer support wall of the base. Other modifications and feature as described in detail above or otherwise known can also be employed.

The various embodiments of the base and of the container as disclosed herein can be formed by conventional molding techniques as known in the industry. For example, the base can be formed by blow-molding with or without a movable cylinder.

In addition to the specific embodiments claimed below, the disclosed subject matter is also directed to other embodiments having any other possible combination of the dependent features claimed below and those disclosed above. As such, the particular features disclosed herein can be combined with each other in other manners within the scope of the disclosed subject matter such that the disclosed subject matter should be recognized as also specifically directed to other embodiments having any other possible combinations. Thus, the foregoing description of specific embodiments of the disclosed subject matter has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosed subject matter to those embodiments disclosed.

It will be apparent to those skilled in the art that various modifications and variations can be made in the method and system of the disclosed subject matter without departing from the spirit or scope of the disclosed subject matter. Thus, it is intended that the disclosed subject matter include modifications and variations that are within the scope of the appended claims and their equivalents.

TABLE 2 Exemplary Dimensions Length in Inches Dimension (Millimeters) h11 0.318 (8.09) h12 0.228 (5.78) h13 0.328 (8.34) w11 0.633 (16.08) w12 0.468 (11.90) w13 0.062 (1.57) w14 2.575 (65.41) w15 0.270 (6.85) h21 0.199 (5.06) h22 0.504 (12.80) h23 0.108 (2.73) h24 0.207 (5.27) w21 0.607 (15.42) w22 0.488 (11.90) w23 0.062 (1.57) w24 0.278 (7.06) w25 2.591 (65.81) h31 0.206 (5.24) h32 0.306 (7.77) w31 0.801 (20.34) w32 0.714 (19.14) w33 0.606 (15.38) w34 0.062 (1.57) w35 0.040 (1.02) w36 0.094 (2.38) w37 0.270 (6.85) w38 0.040 (1.02) w39 0.029 (0.74) w310 0.045 (1.14) w311 2.575 (65.41) h41 0.311 (7.91) h42 0.219 (5.57) h43 0.320 (8.12) w41 0.633 (16.07) w42 0.468 (11.90) w43 0.062 (1.57) w44 2.441 (62.01) w45 0.278 (7.06) h51 0.199 (5.06) h52 0.320 (8.12) w51 0.629 (15.97) w52 0.468 (11.90) w53 0.062 (1.57) w54 2.441 (62.01) w55 0.328 (8.33) h61 0.219 (5.57) h62 0.320 (8.12) w61 0.629 (15.97) w62 0.468 (11.90) w63 0.062 (1.57) w64 2.441 (62.01) w65 0.328 (8.34) Radius of Curvature in Inches Dimension (Millimeters) r11 0.060 (1.52) r12 0.368 (9.36) r13 0.358 (9.09) r14 0.347 (8.81) r15 0.040 (1.02) r16 0.041 (1.03) r21 0.420 (10.68) r22 0.357 (9.08) r23 0.039 (1.00) r24 0.100 (2.54) r25 0.388 (9.35) r26 0.357 (9.08) r27 0.420 (10.68) r28 0.040 (1.02) r31 0.100 (2.54) r32 0.138 (3.51) r33 0.403 (10.23) r34 0.357 (9.08) r35 0.060 (1.52) r36 0.040 (1.02) r41 0.060 (1.52) r42 0.224 (5.70) r43 0.358 (9.09) r44 0.352 (8.94) r45 0.040 (1.02) r46 0.041 (1.03) r51 0.060 (1.52) r52 0.154 (3.90) r53 0.358 (9.09) r54 0.182 (4.61) r55 0.040 (1.02) r56 0.041 (1.03) r61 0.060 (1.52) r62 0.119 (3.03) r63 0.358 (9.09) r64 0.541 (13.75) r65 0.040 (1.02) r66 0.041 (1.03) Angle Degrees ⊖11 90 ⊖12 85 ⊖13 70 ⊖21 90 ⊖22 74 ⊖23 20 ⊖31 90 ⊖32 20 ⊖41 90 ⊖42 85 ⊖43 70 ⊖51 90 ⊖52 85 ⊖53 70 ⊖61 90 ⊖62 85 ⊖63 70

TABLE 3 Exemplary Dimensions of Alternate Embodiments Dimension Length in Inches (Millimeters) h81 0.320 (8.13) h82 0.220 (5.59) w15′ 0.291 (7.39) w81 0.516 (13.12) w82 0.401 (10.19) w83 0.055 (1.40) w84 2.457 (62.40) w85 0.300 (7.62) w95 0.300 (7.62) Radius of Curvature in Inches Dimension (Millimeters) r11′ 0.020 (0.51) r12′ 0.258 (6.55) r13′ 0.358 (9.09) r15′ 0.040 (1.02) r81 0.120 (3.05) r82 0.445 (11.31) r83 0.315 (8.00) r84 0.350 (8.90) r85 0.040 (1.02) r86 0.040 (1.02) r87 0.400 (10.16) r91 0.100 (2.54) r92 0.505 (12.81) r93 0.315 (8.00) r95 0.040 (1.02) r97 0.040 (10.16) Angle Degrees ⊖81 90 ⊖82 85 ⊖83 70

These results indicate that the overall configuration of the disclosed subject matter enables the plastic containers disclosed herein to accommodate different thermal and pressure differential scenarios associated with hot-filling processes, to control and eliminate unwanted deformation, making the package both visually appealing and functional for downstream situations.

A further embodiment of the present invention is described hereinafter, allows packaging, protecting and preserving of various compounds present in both cold and hot fill beverages from the effects of photodegradation. It is particularly advantageous that the method preserves the product flavours, nutrients and other qualities that contribute to the product experience for a longer period of time than is typical in the industry.

Reference is now made to FIG. 36 which illustrates an exemplary method of processing a beverage to be preserved. At step 210, the method may comprise providing a container configured to receive a beverage that may be hot filled. For example, the bottle may be blow molded to form a container that may comprise at least 25% PCR composition and may additionally be primarily red in color, and. In one embodiment, a red colored PET can be used and blow molded to form the container. In another embodiment, a clear, or otherwise near clear PET may be blow molded and then, coated with a red colorant or ink. At the end of step 210, a PET container having a substantially red color primarily transmitting light between about 630 and 700 nm in wavelengths is therefore formed.

The formed primarily red PET container may then be filled at step 220 with a beverage comprising of water and at least one of the following ingredients: Sucrose, Fructose, High Fructose Corn Syrup (HFCS), Sucralose, Stevia, Aspartame, Vitamin A, Vitamin D, Vitamin K and Vitamin B2, Vitamin E, Vitamin C, Vitamin BI, Vitamin B6, Vitamin B12, flavorings, acids or preservatives. The primarily red container formed at step 210 and filled at step 220 allows the ingredients to be protected within by means of filtering the more harmful end of the electromagnetic spectrum and also prevents the damaging light rays within the ultraviolet spectrum from reaching the beverage. By forming and providing a container having a primarily red color, protection and preservation of the contents of the container can be achieved in a superior way to containers currently present in the industry as red is the farthest distance in the electromagnetic spectrum from the ultraviolet wavelengths and therefore offers a superior protection compared to other colored containers.

At step 230, the primarily red container may then be capped or otherwise sealed, whereby the red color present in the PET container filters out a significant amount of the UV light wavelengths that pass through it. This in turn protects the stability of the ingredients of the beverage within from the damaging effects of these Ultraviolet rays.

The formed primarily red PET container may be formed or comprise a significant amount of recycled PET. For example, the container may comprise a particular amount of recycled PET (rPET). The amount of rPET may be equal to or above 25%, but may be anywhere between 50% and 100%, and more preferably between 75% and 100%.

Another advantage of primarily red PET container is that the red color can act as a mask for the yellowing effect that is often prone to occur in the rPET after multiple melts and blow-mold extrusions. As the red segment of the color spectrum is adjacent to the yellow segment, the two colors can mix with little or no noticeable effect on the final color or aesthetic quality of the formed container.

The present invention allows for the use of much lower grade recycled PET to be incorporated back into the freshly produced containers. The lower grade PET that is often removed from the recycling stream(s), those which contain oxygen scavenging or ultraviolet light protecting barrier technologies, or otherwise have multiple recycling melt histories resulting in more visible yellowing. This material can with the application of the invention be used without negative repercussion to the aesthetic quality or consumer perception of the final product. This offers a huge benefit insofar as cheaper and plentiful low-grade PET can be purchased from recycling centres for use as raw material, offering greatly enhanced commercial and ecological potential.

The formed primarily red PET container can also be easily and more clearly identified as its own stream within the recycling systems and therefore the reclamation rate of consistent quality PET can be greatly enhanced. With very few other red containers in the recycling system, the purity of the PET reclaimed will be of a much higher standard than other color streams present in the system that consists of many differing products, producers and plastic compositions.

In the embodiments where the container is formed from clear, or otherwise near clear PET and then colored or tinted red with ink or other coloring method, the PET can be cleaned of its red color during the standard washing, flaking and processing phases during the recycling process. This can then produce high grade clear PET that has been significantly protected from Ultraviolet damage, and can in turn be less yellow than much of the other PET in the system, rendering a higher value recyclable PET.

Another embodiment of the present invention relates to a method of mass producing a plastic container of an uncommon color not presently active in the recycling stream, and then reclaiming said new colored container, thereby ensuring the consistency and purity of all the reclaimed plastic.

Unless the context clearly requires otherwise, throughout the description, the words “comprise”, “comprising”, and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is to say, in the sense of “including, but not limited to”.

Although this invention has been described by way of example and with reference to possible embodiments thereof, it is to be understood that modifications or improvements may be made thereto without departing from the scope of the invention. The invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.

Furthermore, where reference has been made to specific components or integers of the invention having known equivalents, then such equivalents are herein incorporated as if individually set forth.

Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.

Although this invention has been described by way of example and with reference to possible embodiments thereof, it is to be understood that modifications or improvements may be made thereto without departing from the spirit or scope of the appended claims. It is appreciated that various features of the invention which are, for clarity, described in the contexts of separate embodiments may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment may also be provided separately or in any suitable sub-combination.

While the disclosed subject matter is described herein in terms of certain preferred embodiments, those skilled in the art will recognize that various modifications and improvements can be made to the disclosed subject matter without departing from the scope thereof. Moreover, although individual features of one embodiment of the disclosed subject matter can be discussed herein or shown in the drawings of the one embodiment and not in other embodiments, it should be apparent that individual features of one embodiment can be combined with one or more features of another embodiment or features from a plurality of embodiments.

In addition to the various embodiments depicted and claimed, the disclosed subject matter is also directed to other embodiments having any other possible combination of the features disclosed and claimed herein. As such, the particular features presented herein can be combined with each other in other manners within the scope of the disclosed subject matter such that the disclosed subject matter includes any suitable combination of the features disclosed herein. Thus, the foregoing description of specific embodiments of the disclosed subject matter has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosed subject matter to those embodiments disclosed.

It will be apparent to those skilled in the art that various modifications and variations can be made in the devices of the disclosed subject matter without departing from the spirit or scope of the disclosed subject matter. Thus, it is intended that the disclosed subject matter include modifications and variations that are within the scope of the appended claims and their equivalents.

Claims

1. A hot fillable plastic container comprising:

a container body blow molded from a preform comprising at least 25% PCR and having a bottom portion, a sidewall portion and an upper portion;
the bottom portion including a support surface and a variable dynamic base portion extending inward from the support surface configured to deflect in response to a pressure differential between the chamber and an exterior of the container body;
the container body having a chamber defined therein, the container body further comprising a finish portion extending from the upper portion and defining a mouth in fluid communication with the chamber;
the sidewall portion including a lower circumferential groove ring and an upper circumferential groove ring, wherein the lower circumferential groove ring has a width W1 and depth D1 in side view, and an outer radius R1 in plan view, the ratio of the width W1 to the outer radius R1 ranges between 0.07 to 0.22, and the ratio of the depth D1 to the outer radius R1 ranges between 0.04 to 0.18;
wherein the upper circumferential groove ring has a width W2 and depth D2 in side view, and an outer radius R2 in plan view, the ratio of the width W2 to the outer radius R2 ranges between 0.07 to 0.22, and the ratio of the depth D2 to the outer radius R2 ranges between 0.04 to 0.18; and;
the base comprising: a support surface defining a horizontal reference plane; a sidewall having a plurality of horizontally displaced annular ribs; an inner support wall extending upwardly from the support surface,
wherein an upper section of the inner support wall extends inwardly at an angle of between about 15 degrees to about 85 degrees relative to the reference plane; a first radiused portion extending radially inward toward the central longitudinal axis from the inner support wall and concave relative to the reference plane; a second radiused portion extending radially inward toward the longitudinal axis from the first radiused portion and convex relative to the reference plane; an intermediate surface extending radially inward toward the longitudinal axis from the second radiused portion, wherein the intermediate surface comprises an intermediate radiused portion concave relative to the reference plane; a third radiused portion extending radially inward toward the longitudinal axis from the intermediate surface and convex relative to the reference plane; and a central portion disposed proximate the third radiused portion.

2. A hot fillable plastic container comprising:

a container body blow molded from a preform comprising at least 25% PCR and having a bottom portion, a sidewall portion and an upper portion;
the bottom portion including a support surface and a variable dynamic base portion extending inward from the support surface configured to deflect in response to a pressure differential between the chamber and an exterior of the container body;
the container body having a chamber defined therein, the container body further comprising a finish portion extending from the upper portion and defining a mouth in fluid communication with the chamber;
the sidewall portion including a plurality of circumferential groove rings, wherein at least one circumferential groove ring has a width W3 and depth D3 in side view, and an inside radius R3 in plan view, the ratio of the width W3 to the inside radius R3 ranges between about 0.15 to about 0.46, and the ratio of the depth D3 to the inside radius R3 ranges between about 0.10 to about 0.3; and,
the base comprising: a support surface defining a horizontal reference plane; a sidewall having a plurality of horizontally displaced annular ribs; an inner support wall extending upwardly from the support surface,
wherein an upper section of the inner support wall extends inwardly at an angle of between about 15 degrees to about 85 degrees relative to the reference plane; a first radiused portion extending radially inward toward the central longitudinal axis from the inner support wall and concave relative to the reference plane; a second radiused portion extending radially inward toward the longitudinal axis from the first radiused portion and convex relative to the reference plane; an intermediate surface extending radially inward toward the longitudinal axis from the second radiused portion, wherein the intermediate surface comprises an intermediate radiused portion concave relative to the reference plane; a third radiused portion extending radially inward toward the longitudinal axis from the intermediate surface and convex relative to the reference plane; and, a central portion disposed proximate the third radiused portion.
Patent History
Publication number: 20250066062
Type: Application
Filed: Nov 11, 2024
Publication Date: Feb 27, 2025
Inventors: Raymond A. Pritchett, JR. (Mt. Wolf, PA), Justin A. Howell (Mechanicsburg, PA), Shannon K. Sprenkle (York, PA), David M. Melrose (Auckland), Campbell Melrose-Allen (Auckland)
Application Number: 18/943,569
Classifications
International Classification: B65D 1/42 (20060101); B65D 1/02 (20060101); B65D 79/00 (20060101); B65D 85/72 (20060101);