Container structure for removal of vacuum pressure

Abstract

A hot-fill PET container or bottle filling with a liquid at an elevated temperature has a side wall extending to a lower portion including a pressure panel and a base in its unfolded or pre-fill position. The panel is transversely oriented and has a decoupling or hinge structure, an initiator portion and control portion of a steeply angled inverting conical section between 30 and 45 degrees. The control portion enables the inversion of the panel into the container to compensate for vacuum or reduced pressure induced within the container as the liquid cools down. The base can also have a plurality of reinforcing ribs.

Claims

1. A system for handling plastic containers, each said container having a longitudinal axis, an upper portion having an opening into the container, a body portion extending from the upper portion to a lower portion, the lower portion including a base, the base closing off an end of the container and including a standing surface, the container having at least one substantially transversely oriented pressure panel located in the lower portion, an instep recessed from the standing surface to a region of juncture circumscribing the pressure panel, the pressure panel comprising a control portion being inclined downwardly at an angle of more than 100 degrees relative to a plane parallel to the longitudinal axis and the opening into the container, the pressure panel comprising a centrally located push-up portion, the pressure panel comprising a wide diameter adjacent a first juncture with the region of juncture and a narrow diameter, closer to the longitudinal axis than the wide diameter, adjacent a second juncture with the centrally located push-up portion, the centrally located push-up portion being further recessed upwardly relative to the narrow diameter, the pressure panel to be repositioned about the region of juncture, the system comprising: hot filling means for filling the containers with the pressure panel in a first position with a hot or heated product, the product being at an elevated temperature; sealing means for sealing the filled containers using a cap; vacuum creating means for creating a vacuum in each of the filled and sealed containers by cooling; repositioning means to position a mechanical rod or punch-like device for repositioning the pressure panel from the first position to a second position toward the opening into the container to reduce the vacuum, wherein the mechanical rod or punch-like device is configured to engage the centrally located push-up portion closer to the longitudinal axis than the narrow diameter and above a height of the second juncture to reposition the pressure panel from the first position to the second position, and wherein, in the second position: at least a portion of the pressure panel is inclined upwardly relative to the plane parallel to the longitudinal axis and the opening of the container; and, the recessed instep is in an upward position.

2. The system of claim 1, wherein the instep is recessed into the container from the standing surface to such an extent that the entire pressure panel is contained above the standing surface when in the first position, and the pressure panel is connected to the instep by a hinge element provided on the region of juncture.

3. The system of claim 2, comprising means for providing the containers to the hot filling means, the sealing means, the vacuum creating means and the repositioning means and the container is transferred on the standing surface.

4. The system of claim 2, wherein the pressure panel includes a plurality of indentations or flutes to facilitate repositioning thereof, the indentations or flutes being adapted to flex during repositioning of the pressure panel.

5. The system of claim 1, wherein the instep is in an upward position when the pressure panel is in the first position and remains substantially in the same position when the pressure panel is in both the first and second positions.

6. The system of claim 1, wherein the container body includes a portion that is rigidified against vacuum pressure deformation.

7. The system of claim 1, wherein the container body includes a portion that deforms inwardly and reduces a portion of the vacuum pressure created during the cooling of the container.

8. The system of claim 7, wherein repositioning the pressure panel reduces a portion of the vacuum pressure.

9. The system of claim 1, comprising means for providing the containers to the hot filling means, the sealing means, the vacuum creating means and the repositioning means.

10. A system for handling filled plastic containers, each said container including a longitudinal axis and a pressure panel located substantially transversely to the longitudinal axis, wherein the container includes an instep adjacent to an inside border of a standing support, wherein the pressure panel is connected to a hinge element circumscribing a wide diameter of the pressure panel; wherein the pressure panel further comprises a first portion being outwardly inclined at an angle of between about 100 to 135 degrees relative to a plane parallel to the longitudinal axis and a second portion being angled at a lesser angle than the first portion, wherein the pressure panel further comprises a narrow diameter circumscribing a centrally located push-up portion to move in response to a longitudinally directed force, the system comprising: filling means for filling the container with a product, the product being at an elevated temperature; sealing means for sealing the filled container using a cap; vacuum creating means for creating a vacuum in the filled and sealed container by cooling; and repositioning means comprising a mechanical pusher or the like to be located within the centrally located push-up portion closer to the longitudinal axis than the narrow diameter and above a height of the height of the narrow diameter for repositioning the pressure panel of the container from a first position to a second position to reduce at least a portion of the vacuum, and wherein, in the second position, at least a portion of the pressure panel is inclined upwardly relative to the plane parallel to the longitudinal axis, wherein the pressure panel is repositioned about the instep by the hinge element and the instep is an upward position when the pressure panel is in the second position.

11. The system of claim 10, wherein the instep is in an upward position when the pressure panel is in the first position and is recessed to such an extent that the pressure panel is contained entirely above the standing support.

12. The system of claim 10, wherein a body portion of the container further includes at least a portion of a sidewall configured to deform under vacuum forces generated within the container during cooling of the heated liquid prior to the step of repositioning the pressure panel from the first position to the second position.

13. The system of claim 11, wherein the pressure panel includes a plurality of indentations or flutes to facilitate repositioning thereof, the indentations or flutes being adapted to flex during repositioning of the pressure panel.

14. The system of claim 11, further comprising a means for transporting the container from said vacuum creating means to said repositioning means.

15. The system of claim 12, wherein the body portion of the container further includes one or more indentations, the one or more indentations providing structural integrity for the plastic bottle.

16. The system of claim 10, wherein the pressure panel includes a plurality of indentations or flutes to facilitate repositioning thereof, the indentations or flutes being adapted to flex during repositioning of the pressure panel.

17. The system of claim 10, further comprising a means for transporting the container from said vacuum creating means to said repositioning means.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1: shows a cross-sectional view of a hot-fill container according to one possible embodiment of the invention in its pre-collapsed condition;

(2) FIG. 2: shows the container of FIG. 1 in its collapsed position;

(3) FIG. 3: shows the base of FIG. 1 before collapsing;

(4) FIG. 4: shows the base of FIG. 2 following collapsing;

(5) FIG. 5: shows an underneath view of the base of the container of FIG. 1 before collapsing.

(6) FIG. 6: shows the base of FIG. 1 before collapsing;

(7) FIG. 6A: shows a cross sectional view of an alternative container configuration;

(8) FIG. 7: shows the base of FIG. 2 following collapsing;

(9) FIG. 8a: shows a cross-sectional view of a hot-fill container according to an alternative embodiment of the invention in its pre-collapsed condition;

(10) FIG. 8b: shows a side view of the container shown in FIGS. 5b and 9 through line C-C;

(11) FIG. 9: shows an underneath view of the base of the container of FIGS. 8a and 8b and FIG. 10 before collapsing

(12) FIG. 10: shows a cross-sectional view of the container shown in FIG. 9 through line D-D

(13) FIGS. 11a-d: show cross-sectional views of the container according to an alternative embodiment of the invention incorporating a pusher to provide panel folding

(14) FIGS. 12a-d: show cross-sectional views of the container according to a further alternative embodiment of the invention incorporating a pusher to provide panel folding

(15) FIG. 13: shows the base of an alternative embodiment of the invention before collapsing;

(16) FIG. 14: shows the base of FIG. 13 during the initial stages of collapsing;

(17) FIGS. 15a-b: show side and cross-sectional views of the container shown in FIG. 9 including outwardly projecting fluting

(18) FIG. 15c: shows an underneath view of the base of the container of FIGS. 15a and 15b with dotted contour section lines through lines E-E and F-F;

(19) FIG. 15d: shows a perspective view of the base of the container of FIGS. 15a-c;

(20) FIG. 16a: shows a side view of a container of FIG. 16c according to an alternative embodiment including inwardly projecting fluting through Line I-I;

(21) FIG. 16b: shows a cross-sectional view of the base of the container of FIG. 16c through Line J-J;

(22) FIG. 16c: shows an underneath view of the base of the container of FIGS. 16a and 16b with dotted contour section lines through lines G-G and H-H;

(23) FIG. 16d: shows a perspective view of the base of the container of FIGS. 16a-c;

(24) FIGS. 17a-d: show side, side perspective, end perspective and end views respectively of the container of FIG. 15.

(25) FIGS. 18a-d: show side, side perspective, end perspective and end views respectively of the container of FIG. 16;

(26) FIG. 19a: shows a side view of a hot-filled container of an alternative embodiment in its pre-collapsed condition;

(27) FIG. 19b: shows a cross-sectional view of the container of FIG. 19a through the line see-C;

(28) FIG. 20 is a schematic representation of a system for handling plastic containers; and

(29) FIG. 21 is a schematic representation of handling plastic containers.

DETAILED DESCRIPTION

(30) The following description of preferred embodiments is merely exemplary in nature, and is in no way intended to limit the invention or its application or uses.

(31) As discussed above, to accommodate vacuum forces during cooling of the contents within a heat set container, containers have typically been provided with a series of vacuum panels around their sidewalls and an optimized base portion. The vacuum panels deform inwardly, and the base deforms upwardly, under the influence of the vacuum forces. This prevents unwanted distortion elsewhere in the container. However, the container is still subjected to internal vacuum force. The panels and base merely provide a suitably resistant structure against that force. The more resistant the structure the more vacuum force will be present. Additionally, end users can feel the vacuum panels when holding the containers.

(32) Typically at a bottling plant the containers will be filled with a hot liquid, for example by way of hot filling means F (FIGS. 20 and 21), and then capped, for example by way of a sealing means S, before being subjected to a cold water spray, for example by way of a vacuum creating means V, resulting in the formation of a vacuum within the container which the container structure needs to be able to cope with. The present invention relates to hot-fill containers and a structure that provides for the substantial removal or substantial negation of vacuum pressure. This allows much greater design freedom and light weighting opportunities as there is no longer any requirement for the structure to be resistant to vacuum forces which would otherwise mechanically distort the container.

(33) As mentioned above and in the PCT specification, various proposals for hot-fill container designs have been put forward.

(34) Further development of the hot-fill container of the PCT specification has positioned an outwardly inclined and transversely oriented vacuum panel between the lower portion of the side wall and the inwardly domed base region. In this position the container has poor stability, insofar as the base region is very narrow in diameter and does not allow for a good standing ring support. Additionally, there is preferably provided a decoupling structure that provides a hinge joint to the juncture of the vacuum panel and the lower sidewall. This decoupling structure provides for a larger range of longitudinal movement of the vacuum panel than would occur if the panel was coupled to the side wall by way of ribs for example. One side of the decoupling structure remains adjacent the sidewall, allowing the opposite side of the decoupling structure, adjacent to an initiator portion to bend inwardly and upwardly. The decoupling structure therefore provides for increased deflection of the initiator portion, allowing increased movement of the panel portion longitudinally away from the previously outwardly inclined position, enabling the panel portion to fold inwardly relative to the container and upwardly relative to the initial base position. The lower sidewall is therefore subjected to lower force during such inversion. During this action, the base portion is translated longitudinally upward and into the container.

(35) Further, as the panel portion folds inwardly and upwardly, the decoupling structure allows for the vacuum panel to now form part of the container base portion. This development has at least two important advantages.

(36) Firstly, by providing the vacuum panel so as to form part of the base after folding, a mechanical force can now be provided immediately against the panel in order to apply inverting force. This allows much greater control over the action, which may for example be applied by a mechanical pusher, which would engage with the container base in resetting the container shape. This allows increased design options for the initiator portion.

(37) Secondly, the transversely oriented vacuum panel is effectively completely removed from view as it is forced from an outward position to an inward position. This means that there are no visible design features being imposed on the major portion of the side wall of the container in order to incorporate vacuum compensation. If required therefore, the major portion of the side wall of the present invention could have no structural features and the container could, if required, replicate a clear wall glass container. Alternatively, as there will be little or no vacuum remaining in the container after the panel is inverted, any design or shape can now be utilized, without regard for integrity against vacuum forces found in other hot-fill packages.

(38) Such a manoeuvre allows for a wide standing ring to be obtained. The decoupling structure provides for the panel to become displaced longitudinally so that there is no contact between any part of the panel or upwardly domed base portion with the contact surface below. A standing ring is then provided by the lower sidewall immediately adjacent the decoupling structure.

(39) Further, by gaining greater control over the inverting motion and forces, it is possible to allow the initiator portion to share the same steep angle as the control portion. This allows for increased volume displacement during inversion and increased resistance to any reversion back to the original position.

(40) Referring to the accompanying drawings, FIG. 1 shows, by way of example only, and in a diagrammatic cross sectional view, a container in the form of a bottle. This is referenced generally by arrow 10 with a typical neck portion 12 and a side wall 9 extending to a lower portion of the side wall 11 and an underneath base portion 2.

(41) The container 10 will typically be blow moulded from any suitable plastics material but typically this will be polyethylene terephthalate (PET).

(42) The base 2 is shown provided with a plurality of reinforcing ribs 3 so as to form the typical champagne base although this is merely by way of example only.

(43) In FIG. 1 the lower side wall portion 11, which operates as a pressure panel, is shown in its unfolded position so that a ring or annular portion 6 is positioned above the level of the bottom of the base 2 which is forming the standing ring or support 4 for the container 10.

(44) In FIG. 2 the lower side wall portion 11 is shown having folded inwardly so that the ring or annular portion 6 is positioned below the level of the bottom of the base 2 and is forming the new standing ring or support for the container 10.

(45) To assist this occurring, and as will be seen particularly in FIGS. 3 and 4, immediately adjacent the ring or annular portion 6 there may be an instep or recess 8 and decoupling structure 13, in this case a substantially flat, non-ribbed region, which after folding enables the base portion 2 to effectively completely disappear within the bottom of the container and above the line A-A. Many other configurations for the decoupling structure 13 are envisioned, however.

(46) Referring now particularly to FIG. 5, the base 2 with its strengthening ribs 3 is shown surrounded by the bottom annular portion 11 of the side wall 9 and the annular structure 13. The bottom portion 11 is shown in this particular embodiment as having an initiator portion 1 which forms part of the collapsing or inverting section which yields to a longitudinally-directed collapsing force before the rest of the collapsing or folding section. The base 2 is shown provided within the typical base standing ring 4, which will be the first support position for the container 10 prior to the inversion of the folding panel.

(47) Associated with the initiator portion 1 is a control portion 5 which in this embodiment is a more steeply angled inverting section which will resist standing from the collapsed state.

(48) Forming the outer perimeter of the bottom portion 11 of the side wall 9 is shown the side wall standing ring or annular portion 6 which following collapsing of the panel 11 will provide the new container support.

(49) To allow for increased evacuation of vacuum it will be appreciated that it is preferable to provide a steep angle to the control portion 5 of the pressure panel 11. As shown in FIG. 6 the panel control portion 5 is generally set with an angle with respect to a plane orthogonal to the container's longitudinal axis, or using the longitudinal axis as the reference, the angle plus 90 degrees. The panel control portion 5 is generally set with an angle varying between 30 degrees and 45 degrees, or in a range of about 120 degrees to about 135 degrees relative to the longitudinal axis. It is preferable to ensure an angle is set above 10 degrees at least, or above 100 degrees relative to the longitudinal axis. The initiator portion 1 may in this embodiment have a lesser angle of perhaps at least 10 degrees less than the control portion.

(50) By way of example, it will be appreciated that when the panel 11 is inverted by mechanical compression it will undergo an angular change that is double that provided to it. If the conical control portion 5 is set to 10 degrees, or about 100 degrees relative to the longitudinal axis, it will provide a panel change equivalent to 20 degrees. At such a low angle it has been found to provide an inadequate amount of vacuum compensation in a hot-filled container. Therefore it is preferable to provide much steeper angles.

(51) Referring to FIGS. 6 and 7, it will be appreciated that the control portion 5 may be initially set to be outwardly inclined by approximately 35 degrees, or about 125 degrees relative to the longitudinal axis, and will then provide an inversion and angle change of approximately 70 degrees. The initiator portion may in this example be 20 degrees. As a further example referring to FIG. 6A, the base 2 may be recessed to such an extent that the entire lower sidewall portion and base are substantially or completely contained horizontally above the standing ring 6 even prior to folding of the pressure panel 11. Preferably the pressure panel 11 includes a portion inclined outwardly at an angle of greater than 10 degrees relative to a plane orthogonal to a longitudinal axis of the container when the pressure panel is in the initial position, or about 100 degrees relative to the longitudinal axis, and much steeper angles such as those described herein may be used.

(52) Referring to FIGS. 8a and 8b, where the same reference numerals have been used where appropriate as previously, it is envisaged that in possible embodiments of this invention the initiator portion may be reconfigured so that pressure panel 11 would provide essentially a continuous conical area about the base 2.

(53) The initiator portion 1 and the control portion 5 of the embodiment of the preceding figures will now be at a common angle, such that they form a uniformly inclined panel portion. However, initiator portion 1 may still be configured to provide the area of least resistance to inversion, such that although it shares the same angular extent as the control portion 5, it still provides an initial area of collapse or inversion. In this embodiment, initiator portion 1 causes the pressure panel 11 to begin inversion from the widest diameter (i.e., wide diameter 300 of the widest portions 30) adjacent a first juncture with a region of juncture providing the decoupling structure 13 ahead of the narrowest diameter (i.e., narrow diameter of the narrowest portions 31) adjacent a second juncture with the centrally located push-up portion 28. Such an arrangement is shown in FIGS. 19a and 19b.

(54) In the embodiment of FIGS. 8a and 8b the container side walls 9 are glass-like in construction in that there are no additional strengthening ribs or panels as might be typically found in a container, particularly if required to withstand the forces of vacuum pressure. A container side wall can be less glass like, such as is shown in FIGS. 1 and 17a, and may include the structures shown therein, such as ribs or panels if desired, or other structures. Additionally, however, structures may be added to the conical portions of the vacuum panel 11 in order to add further control over the inversion process. For example, the conical portion of the vacuum panel 11 may be divided into fluted regions. Referring to FIGS. 8a and 9 especially, panel portions that are convex outwardly, and evenly distributed around the central axis create regions of greater angular set 19 () and regions of lesser angular set 18 (), may provide for greater control over inversion of the panel. Such geometry provides increased resistance to reversion of the panel, and a more even distribution of forces when in the inverted position.

(55) Referring to FIGS. 15a-c and 17a-d, convex or downwardly outwardly projecting flutes are shown.

(56) Concave or inwardly directed fluting arrangements are also envisioned, in addition to outwardly directed flutes. Inwardly directed flutes offer less resistance to initial inverting forces, coupled with increased resistance to reverting back out to the original position. In this way they behave in much the same manner as ribs to prevent the panel being forced back out to the outwardly inclined position, but allow for hinge movement from the first outwardly inclined position to the inwardly inclined position. Such inwardly or outwardly directed flutes or projections function as ribs to increase the force required to invert the panel. It will be appreciated that the mechanical action applied to invert the panel will be sufficient to overcome any rib-strengthened panel, and when the mechanical action is removed the rib-strengthened panel, for example by strong flutes, will be very resistant to reversion to the original position if the container is dropped or shocked.

(57) Referring to FIGS. 16a-d and 18a-d concave or upwardly inwardly projecting flutes are shown, the contour lines G and H of FIG. 16c illustrating this concavity through two cross-sectional reliefs.

(58) Further embodiments comprising arrays utilizing both concave and convex flutes are also intended within the scope of the invention.

(59) In the embodiment as shown in FIGS. 11a-d the container may be blow moulded with the pressure panel 20 in the inwardly or upwardly inclined position. A force could be imposed on the folding panel 20 such as by means of a mechanical pusher 21 introduced through the neck region and forced downwardly in order to place the panel in the outwardly inclined position prior to use as a vacuum container for example, as shown in FIG. 11d.

(60) In such an embodiment as shown in FIGS. 12a-d, following the filling and capping of the bottle and the use of cold water spray creating the vacuum within the filled bottle, a force, for example by way of repositioning means, could be imposed on the folding panel 20 such as by means of a mechanical pusher 22, received by a centrally located push-up portion 28 in the panel, or the creation of some relative movement of the bottle base relative to a punch or the like, in order to force the panel 20 from an outwardly inclined position to an inwardly inclined position. Any deformation whereby the bottle shape was distorted prior to inversion of the panel 20 would be removed as internal volume is forcibly reduced. The vacuum within the container is removed as the inversion of the panel 20 causes a rise in pressure. Such a rise in pressure reduces vacuum pressure until ambient pressure is reached or even a slightly positive pressure is achieved.

(61) It will be appreciated that in a further embodiment of the invention the panel may be inverted in the manner shown in FIGS. 12a-d in order to provide a panel to accommodate internal force such as is found in pasteurization and the like. In such a way the panel will provide relief against the internal pressure generated and then be capable of accommodating the resulting vacuum force generated when the product cools down.

(62) In this way, the panel will be inverted from an upwardly inclined position FIGS. 11a to 11b to a downwardly inclined position as shown in FIGS. 12a-d, except that the mechanical action is not provided. The force is instead provided by the internal pressure of the contents.

(63) Referring again to FIGS. 12a-d it will be seen that by the provision of the folding portion 20 in the bottom of the side wall 9 of the container 10 the major portion of the side wall 9 could be absent any structural features so that the container 10 could essentially replicate a glass container if this was required.

(64) Although particular structures for the bottom portion of the side wall 9 are shown in the accompanying drawings it will be appreciated that alternative structures could be provided. For example a plurality of folding portions could be incorporated about the base 2 in an alternative embodiment.

(65) There may also be provided many different decoupling or hinge structures 13 without departing from the scope of the invention. With particular reference to FIGS. 6 and 7, it can be seen that the side of the decoupling structure 13 that is provided for the pressure panel 11 may be of an enlarged area to provide for increased longitudinal movement upwards into the container following inversion.

(66) In a further embodiment of the present invention, and referring to FIGS. 13 and 14, it can be seen that the widest diameter (i.e., wide diameter 300 of the widest portions 30) of the pressure panel 11 adjacent a first juncture with the region of juncture providing a hinge element may invert earlier than the narrowest diameter (i.e., narrow diameter of the narrowest portions 31) adjacent a second juncture with the centrally located push-up portion 28. The initiator portion may be constructed with this in mind, to allow for thinner material and so on, to provide for the panel 11 to begin inverting where it has the greater diameter, ahead of the narrower sections of the panel. In this case the portion 30 of the panel, which is radially set more distant from the central axis of the container inverts ahead of portion 31 to act as the initiator portion.

(67) Where in the foregoing description, 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.

(68) 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 as defined in the appended claims.