Pressure container with differential vacuum panels

Abstract

An improved blow molded plastic container having generally rounded sidewalls that are adapted for hot-fill applications has two adjacent sides and two pairs of controlled deflection panels, each pair reacting to vacuum pressure at differing rates of movement, whereby one pair inverts under vacuum pressure and the other pair remains available for increased squeezability or extreme vacuum extraction. The opposing sidewalls are symmetric relative to vacuum panel and rib shape and placement. The ribs and controlled deflection panels cooperate to retain container shape upon filling and cooling and also improves bumper denting resistance, decreases vacuum pressure within the container, and increases light weight capability.

Claims

1. A container comprising a plastic body having a neck portion defining an opening, connected to a shoulder portion extending downward and connecting to a sidewall extending downward and joining a bottom portion forming a base, said sidewall including four panels, wherein said four panels are vacuum panels, and including vertical transitional walls disposed between and joining said panels, wherein said body is adapted to increase volume contraction and reduce pressure, and said panels are adapted to contract inwardly in response to internal negative pressure created during hot-fill processing and subsequent cooling of a hot liquid in said container; and wherein at least one of said panels is adapted for greater uptake of internal negative pressure than one other of said panels, wherein said panels comprise primary panels and secondary panels and wherein said primary panels comprise smaller surface area than said secondary panels; and further wherein the container comprises horizontal transitional walls; wherein the secondary panels are recessed with respect to the horizontal transitional walls; and wherein said secondary panels include horizontal ribbings; wherein said horizontal ribbings are contiguous without being separated by intermediate regions, and further wherein said secondary panels are vertically arced.

2. The container of claim 1, wherein said primary panels and said secondary panels are opposing.

3. The container of claim 2, wherein the panels are convex, substantially flat or concave shaped and become less convex, substantially flat or more concave after contraction.

4. The container of claim 2, wherein the secondary panels are convex and become less convex or substantially flat after contraction.

5. The container of claim 2, wherein the primary panels are substantially flat and become concave after contraction.

6. The container of claim 2, wherein the primary panels are convex and become concave after contraction.

7. The container of claim 2, wherein said primary panels are adapted for greater uptake of internal negative pressure than said secondary panels.

8. The container of claim 2, wherein the primary panels comprise an upper and lower portion.

9. The container of claim 1, wherein the secondary panels comprise upper and lower panel walls.

10. The container of claim 1, further wherein the secondary panels are recessed with respect to the vertical transitional walls.

11. The container of claim 10, wherein an upper and lower bumper walls extend continuously along a circumference of the container.

12. The container of claim 10, wherein an upper and lower portions of said primary panel transition into said upper and lower bumper walls, respectively.

13. The container of claim 2, further comprising horizontal transitional walls defining upper and lower portions of said primary panel.

14. The container of claim 13, wherein said horizontal transitional walls extend continuously along a circumference of the container.

15. The container of claim 9, wherein said secondary panels include at least one horizontal ribbing.

16. A container comprising a plastic body having a neck portion defining an opening, connected to a shoulder portion extending downward and connecting to a sidewall extending downward and joining a bottom portion forming a base, said sidewall including at least a first and second pair of panels, wherein said first and second pair of panels are vacuum panels, and including vertical transitional walls disposed between and joining said first and second pair of panels, wherein said body is adapted to increase volume contraction and reduce pressure, and said first and second pair of panels are adapted to contract inwardly in response to internal negative pressure created during hot-fill processing and subsequent cooling of a hot liquid in said container; and further comprising upper and lower horizontal transitional walls, wherein the second pair of panels are recessed with respect the upper and lower horizontal transitional walls; and wherein said second pair of panels include horizontal ribbings; and further wherein said second pair of panels are vertically concave.

17. The container of claim 1, further comprising at least one recessed rib or groove between said sidewall and said shoulder portion and at least one recessed rib or groove between said sidewall and the bottom portion.

18. The container of claim 17, wherein said recessed rib or groove is continuous along a circumference of the container.

19. The container of claim 1, wherein the container is about an 8 to 64 ounce bottle.

20. The container of claim 1, wherein the shoulder and base are substantially round.

21. The container of claim 1 wherein a size of the secondary panels to the primary panels is selected from the ratio of 3:1, 2:1 or 7:5.

22. The container of claim 1, wherein a size of the secondary panels is 50% larger than the primary panels.

23. The container of claim 16, wherein said second pair of panels include three horizontal ribbings.

24. A container comprising a plastic body having a neck portion defining an opening, connected to a shoulder portion extending downward and connecting to a sidewall extending downward and joining a bottom portion forming a base, said sidewall comprising more than two vacuum panels, and including vertical transitional walls disposed between and joining said more than two panels, wherein said body is adapted to increase volume contraction and reduce pressure, and said panels are adapted to contract inwardly in response to internal negative pressure created during hot-fill processing and subsequent cooling of a hot liquid in said container; and wherein at least two panels of said more than two vacuum panels are adapted for greater uptake of internal negative pressure than one other of said vacuum panels, further wherein said at least two panels are vertically concave.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIGS. 1A and 1B, respectively, show side and front views of a container according to a first embodiment of the present invention;

(2) FIGS. 1C, 1D, 1E, and 1F, respectively, show side, front, orthogonal, and cross-sectional views of a container according to a second embodiment of the present invention, in which the container has vertically straight (i.e., substantially flat) primary panels and secondary panels with horizontal ribbings separated by intermediate regions;

(3) FIGS. 2A, 2B, 2C, and 2D, respectively, show side, front, orthogonal, and cross-sectional views of a container according to a third embodiment of the present invention, in which the container has vertically concave shaped (i.e., arced) primary panels that are horizontally relatively flat/slightly concave and secondary panels with horizontal ribbings separated by intermediate regions;

(4) FIGS. 3A, 3B, and 3C, respectively, show side, front, and orthogonal views of a container according to a fourth embodiment of the present invention, in which the container has concave shaped (i.e., arced) primary panels extending through the upper (i.e., top) and lower (i.e., bottom) bumper walls (i.e., waists) and secondary panels with horizontal ribbings separated by intermediate regions;

(5) FIGS. 4A, 4B, and C, respectively, show side, front, and orthogonal views of a container according to a fifth embodiment of the present invention, in which the container has concave shaped (i.e., arced) primary panels blended into the upper (i.e., top) and lower (i.e., bottom) bumper walls (i.e., major diameters) and secondary panels with horizontal ribbings separated by intermediate regions;

(6) FIGS. 5A, 5B, and 5C, respectively, show side, front, and orthogonal views of a container according to a sixth embodiment of the present invention, in which the container has concave shaped (i.e., arced) primary panels blended into upper (i.e., top) and lower (i.e., bottom) bumper walls, indented recessed rib or groove and secondary panels with horizontal ribbings separated by intermediate regions;

(7) FIGS. 6A, 6B, and 6C, respectively, show side, front, and orthogonal views of a container according to a seventh embodiment of the present invention, in which the container has concave shaped (i.e., arced) primary panels and secondary panels with contiguous (i.e., not separated by intermediate region) horizontal ribbings;

(8) FIGS. 7A, 7B, and 7C, respectively, show side, front, and orthogonal views of a container according to and embodiment of the present invention, in which the container has concave shaped (arced) primary panels blended into the upper (top) and lower (bottom) horizontal transitional walls (major diameters) and secondary panels with contiguous, i.e., not separated by intermediate region, horizontal ribbings;

(9) FIGS. 8A, 8B, and 8C, respectively, show side, front, and orthogonal views of a container according to an embodiment of the present invention, in which the container has concave shaped (arced) and contoured primary panels and secondary panels with contiguous, i.e., not separated by intermediate region, horizontal ribbings;

(10) FIGS. 9A, 9B, 9C, and 9D, respectively, show side, front, orthogonal, and cross-sectional views of a container according to an embodiment of the present invention, in which the container has primary panels and secondary panels similar in size with no ribbings but different geometries;

(11) FIGS. 10A, 10B, and 10C, respectively, show side, front, and orthogonal views of a container according to an embodiment of the present invention, in which the container has vertically straight (substantially flat) primary panels and secondary panels having inwardly directed ribbings separated by intermediate regions;

(12) FIGS. 11A, 11B, and 11C, respectively, show side, front, and orthogonal views of a container according to an embodiment of the present invention, in which the container has vertically straight (substantially flat) primary panels and secondary panels having inwardly horizontal ribbings separated by intermediate regions;

(13) FIGS. 12A, 12B, and 12C, respectively, show side, front, and orthogonal views of a container according to an embodiment of the present invention, in which the container has an alternatively contoured vertically straight (substantially flat) primary panels and secondary panels with horizontal ribbings separated by intermediate regions;

(14) FIGS. 13A, 13B, and 13C, respectively, show side, front, and orthogonal views of a container according to an embodiment of the present invention, in which the container has an alternatively contoured vertically straight (substantially flat) primary panels and secondary panels with contiguous, i.e., not separated by intermediate region, horizontal ribbings;

(15) FIG. 14A shows a Finite Element Analysis (FEA) view of the container shown in FIG. 1A under vacuum pressure of about 0.875 PSI;

(16) FIG. 14B shows an FEA view of the container shown in FIG. 1B under vacuum pressure of about 0.875 PSI;

(17) FIG. 15A shows an FEA view of the container shown in FIG. 1A under vacuum pressure of about 1.000 PSI;

(18) FIG. 15B shows an FEA view of the container shown in FIG. 1B under vacuum pressure of about 1.000 PSI; and

(19) FIGS. 16A-16E show FEA cross-sectional views through line B-B of the container shown in FIG. 1A under vacuum pressure of about 0.250 PSI (FIG. 16A), to about 0.500 PSI (FIG. 16B), to about 0.750 PSI (FIG. 16C), to about 1.000 PSI (FIG. 16D), to about 1.250 PSI (FIG. 16E).

DETAILED DESCRIPTION OF THE INVENTION

(20) A thin-walled container in accordance with the present invention is intended to be filled with a liquid at a temperature above room temperature. According to the invention, a container may be formed from a plastic material such as polyethylene terephthalate (PET) or polyester. Preferably, the container is blow molded. The container can be filled by automated, high speed, hot-fill equipment known in the art.

(21) Referring now to the drawings, a first embodiment of the container of the invention is indicated generally in FIGS. 1A and 1B, as generally having many of the well-known features of hot-fill bottles. The container 101, which is generally round or oval in shape, has a longitudinal axis L when the container is standing upright on its base 126. The container 101 comprises a threaded neck 103 for filling and dispensing fluid through an opening 104. Neck 103 also is sealable with a cap (not shown). The preferred container further comprises a roughly circular base 126 and a bell 130 located below neck 103 and above base 126. The container of the present invention also has a body 102 defined by roughly round sides containing a pair of narrower controlled deflection flex panels 107 and a pair of wider controlled deflection flex panels 108 that connect bell 130 and base 126. A label or labels can easily be applied to the bell area 130 using methods that are well known to those skilled in the art, including shrink wrap labeling and adhesive methods. As applied, the label extends either around the entire bell 130 of the container 101 or extends over a portion of the label mounting area.

(22) Generally, the substantially rectangular flex panels 108 containing one or more ribs 118 are those with a width greater than the pair of flex panels adjacent 107 in the body area 102. The placement of the controlled deflection flex panel 108 and the ribs 118 are such that the opposing sides are generally symmetrical. These flex panels 108 have rounded edges at their upper and lower portions 112, 113. The vacuum panels 108 permit the bottle to flex inwardly upon filling with the hot fluid, sealing, and subsequent cooling. The ribs 118 can have a rounded outer or inner edge, relative to the space defined by the sides of the container. The ribs 118 typically extend most of the width of the side and are parallel with each other and the base. The width of these ribs 118 is selected consistent with the achieving the rib function. The number of ribs 118 on either adjacent side can vary depending on container size, rib number, plastic composition, bottle filling conditions and expected contents. The placement of ribs 118 on a side can also vary so long as the desired goals associated with the interfunctioning of the ribbed flex panels and the non-ribbed flex panels is not lost. The ribs 118 are also spaced apart from the upper and lower edges of the vacuum panels, respectively, and are placed to maximize their function. The ribs 118 of each series are noncontinuous, i.e., they do not touch each other. Nor do they touch a panel edge.

(23) The number of vacuum panels 108 is variable. However, two symmetrical panels 108, each on the opposite sides of the container 101, are preferred. The controlled deflection flex panel 108 is substantially rectangular in shape and has a rounded upper edge 112, and a rounded lower edge 113.

(24) As shown in FIGS. 1A and 1B, the narrower side contains the controlled deflection flex panel 107 that does not have rib strengthening. Of course, the panel 107 may also incorporate a number of ribs (not shown) of varying length and configuration. It is preferred, however, that any ribs positioned on this side correspond in positioning and size to their counterparts on the opposite side of the container.

(25) Each controlled deflection flex panel 107 is generally outwardly curved in cross-section. Further, the amount of outward curvature varies along the longitudinal length of the flex panel, such that response to vacuum pressure varies in different regions of the flex panel 107. FIG. 16A shows the outward curvature in cross-section through Line B-B of FIG. 1A. A cross-section higher through the flex panel region (i.e., closer to the bell) would reveal the outward curvature to be less than through Line B-B, and a cross-section through the flex panel relatively lower on the body 102 and closer to the junction with the base 126 of the container 101 would reveal a greater outward curvature than through Line B-B.

(26) Each controlled deflection flex panel 108 is also generally outwardly curved in cross-section. Similarly, the amount of outward curvature varies along the longitudinal length of the flex panel 108, such that response to vacuum pressure varies in different regions of the flex panel. FIG. 16A shows the outward curvature in cross-section through Line B-B of FIG. 1A. A cross-section higher through the flex panel region (i.e., closer to the bell) would reveal the outward curvature to be less than through Line B-B, and a cross-section through the flex panel 108 relatively lower on the body 102 and closer to the junction with the base 126 of the container 101 would reveal a greater outward curvature than through Line B-B.

(27) In this embodiment, the amount of arc curvature contained within controlled deflection flex panel 107 is different to that contained within controlled deflection flex panel 108. This provides greater control over the movement of the larger flex panels 108 than would be the case if the panels 107 were not present or replaced by strengthened regions, or land areas or posts for example. By separating a pair of flex panels 108, which are disposed opposite each other, by a pair of flex panels 107, the amount of vacuum force generated against flex panels 108 during product contraction can be manipulated. In this way undue distortion of the major panels may be avoided.

(28) In this embodiment, the flex panels 107 provide for earlier response to vacuum pressure, thus removing pressure response necessity from flex panels 108. FIGS. 16A to 16E show gradual increases in vacuum pressure within the container. Flex panels 107 respond earlier and more aggressively than flex panels 108, despite the larger size of flex panels 108 which would normally provide most of the vacuum compensation within the container. Controlled deflection flex panels 107 invert and remain inverted as vacuum pressure increases. This results in full vacuum accommodation being achieved well before full potential is realized from the larger flex panels 108. Controlled deflection flex panels 108 may continue to be drawn inwardly should increased vacuum be experienced under aggressive conditions, such as greatly decreased temperature (e.g., deep refrigeration), or if the product is aged leading to an increased migration of oxygen and other gases through the plastic sidewalls, also causing increased vacuum force.

(29) The improved arrangement of the foregoing and other embodiments of the present invention provides for a greater potential for response to vacuum pressure than that which has been known in the prior art. The container 101 may be squeezed to expel contents as the larger panels 108 are squeezed toward each other, or even if the smaller panels 107 are squeezed toward each other. Release of squeeze pressure results in the container immediately returning to its intended shape rather than remain buckled or distorted. This is a result of having the opposing set of panels having a different response to vacuum pressure levels. In this way, one set of panels will always set the configuration for the container as a whole and not allow any redistribution of panel set that might normally occur otherwise.

(30) Vacuum response is spread circumferentially throughout the container, but allows for efficient contraction of the sidewalls such that each pair of panels may be drawn toward each other without undue force being applied to the posts 109 separating each panel. This overall setup leads to less container distortion at all levels of vacuum pressure than prior art, and less sideways distortion as the larger panels are brought together. Further, a higher level of vacuum compensation is obtained through the employment of smaller vacuum panels set between the larger ones, than would otherwise be obtained by the larger ones alone. Without the smaller panels undue force would be applied to the posts by the contracting larger panels, which would take a less favorable orientation at higher vacuum levels.

(31) The above is offered by way of example only, and the size, shape, and number of the panels 107 and the size, shape, and number of the panels 108, and the size, shape, and number of reinforcement ribs 118 is related to the functional requirements of the size of the container, and could be increased or decreased from the values given.

(32) It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.

(33) The embodiments shown in FIGS. 1A and 1B, as well as those shown in FIGS. 1C, 1D, 1E, and 1F, relate to a container 101, 101 having four controlled deflection flex panels 107 and 108, working in tandem in primary and secondary capacity, thereby reducing the negative internal pressure effects during cooling of a product.

(34) For example, containers 101, 101 are able to withstand the rigors of hot fill processing. In a hot fill process, a product is added to the container at an elevated temperature, about 82 C., which can be near the glass transition temperature of the plastic material, and the container is capped. As container 101, 101 and its contents cool, the contents tend to contract and this volumetric change creates a partial vacuum within the container. Other factors can cause contraction of the container content, creating an internal vacuum that can lead to distortion of the container. For example, internal negative pressure may be created when a packaged product is placed in a cooler environment (e.g., placing a bottle in a refrigerator or a freezer), or from moisture loss within the container during storage.

(35) In the absence of some means for accommodating these internal volumetric and barometric changes, containers tend to deform and/or collapse. For example, a round container 101, 101 can undergo ovalization, or tend to distort and become out of round. Containers of other shapes can become similarly distorted. In addition to these changes that adversely affect the appearance of the container, distortion or deformation can cause the container to lean or become unstable. This is particularly true where deformation of the base region occurs. As supporting structures are removed from the side panels of a container, base distortion can become problematic in the absence of mechanism for accommodating the vacuum. Moreover, configuration of the panels provides additional advantages (e.g., improved top-load performance) allowing the container to be lighter in weight.

(36) The novel design of container 101, 101 increases volume contraction and vacuum uptake, thereby reducing negative internal pressure and unnecessary distortion of the container 101, 101 to provide improved aesthetics, performance and end user handling.

(37) Referring now to FIGS. 1C, 1D, 1E, and 1F, the container 101 may comprise a plastic body 102 suitable for hot-fill application, having a neck portion 103 defining an opening 104, connected to a shoulder portion 105 extending downward and connecting to a sidewall 106 extending downward and joining a bottom portion 122 forming a base 126. The sidewall 106 includes four controlled deflection flex panels 107 and 108 and includes a post or vertical transitional wall 109 disposed between and joining the primary and secondary panels 107 and 108. The body 102 of the container 101 is adapted to increase volume contraction and reduce pressure during hot-fill processing, and the panels 107 and 108 are adapted to contract inward from vacuum forces created from the cooling of a hot liquid during hot-fill application.

(38) The container 101 can be used to package a wide variety of liquid, viscous or solid products including, for example, juices, other beverages, yogurt, sauces, pudding, lotions, soaps in liquid or gel form, and bead shaped objects such as candy.

(39) The present container can be made by conventional blow molding processes including, for example, extrusion blow molding, stretch blow molding and injection blow molding. In extrusion blow molding, a molten tube of thermoplastic material, or plastic parison, is extruded between a pair of open blow mold halves. The blow mold halves close about the parison and cooperate to provide a cavity into which the parison is blown to form the container. As formed, the container can include extra material, or flash, at the region where the molds come together, or extra material, or a moil, intentionally present above the container finish. After the mold halves open, the container drops out and is then sent to a trimmer or cutter where any flash of moil is removed. The finished container may have a visible ridge formed where the two mold halves used to form the container came together. This ridge is often referred to as the parting line.

(40) In stretch blow molding, a preformed parison, or preform, is prepared from a thermoplastic material, typically by an injection molding process. The preform typically includes a threaded end, which becomes the threads of the container. The preform is positioned between two open blow mold halves. The blow mold halves close about the preform and cooperate to provide a cavity into which the preform is blown to form the container. After molding, the mold halves open to release the container. In injection blow molding, a thermoplastic material, is extruded through a rod into an inject mold to form a parison. The parison is positioned between two open blow mold halves. The blow mold halves close about the parison and cooperate to provide a cavity into which the parison is blown to form the container. After molding, the mold halves open to release the container.

(41) In one exemplary embodiment, the container may be in the form of a bottle. The size of the bottle may be from about 8 to 64 ounces, from about 16 to 24 ounces, or either 16 or 20 ounce bottles. The weight of the container may be based on gram weight as a function of surface area (e.g., 4.5 square inches per gram to 2.1 square inches per gram).

(42) The sidewall, as formed, is substantially tubular and can have a variety of cross sectional shapes. Cross sectional shapes include, for example, a generally circular transverse cross section, as illustrated; a substantially square transverse cross section; other substantially polygonal transverse cross sectional shapes such as triangular, pentagonal, etc.; or combinations of curved and arced shapes with linear shapes. As will be understood, when the container has a substantially polygonal transverse cross sectional shape, the corners of the polygon may be typically rounded or chamfered.

(43) In an exemplary embodiment, the shape of container, e.g., the sidewall, the shoulder and/or the base of the container may be substantially round or substantially square shaped. For example, the sidewall can be substantially round (e.g., as in FIGS. 1A-1F) or substantially square shaped (e.g., as in FIG. 9).

(44) The container 101 has a one-piece construction, and can be prepared from a monolayer plastic material, such as a polyamide, for example, nylon; a polyolefin such as polyethylene, for example, low density polyethylene (LDPE) or high density polyethylene (HDPE), or polypropylene; a polyester, for example polyethylene terephthalate (PET), polyethylene naphtalate (PEN); or others, which can also include additives to vary the physical or chemical properties of the material. For example, some plastic resins can be modified to improve the oxygen permeability. Alternatively, the container can be prepared from a multilayer plastic material. The layers can be any plastic material, including virgin, recycled and reground material, and can include plastics or other materials with additives to improve physical properties of the container. In addition to the above-mentioned materials, other materials often used in multilayer plastic containers include, for example, ethylvinyl alcohol (EVOH) and tie layers or binders to hold together materials that are subject to delamination when used in adjacent layers. A coating may be applied over the monolayer or multilayer material, for example to introduce oxygen barrier properties. In an exemplary embodiment, the present container may be made of a generally biaxially oriented polyester material, e.g., polyethylene terephthalate (PET), polypropylene or any other organic blow material which may be suitable to achieve the desired results.

(45) In another embodiment, the shoulder portion, the bottom portion and/or the sidewall may be independently adapted for label application. The container may include a closure 123, 223, 323, 423, 523, 623, 723, 823, 923, 1023, 1123, 1223, 1323 (e.g., FIGS. 1C and 2A-13A) engaging the neck portion and sealing the fluid within the container.

(46) As exemplified in FIGS. 1C-1F, the four panels 107 and 108 may comprise a pair of opposing primary panels 107 and a pair of secondary panels 108, which work in tandem in primary and secondary capacity.

(47) Generally, the primary panels 107 may comprise a smaller surface area and/or have a geometric configuration adapted for greater vacuum uptake than the secondary panels. In an exemplary embodiment, the size of the secondary panel 108 to primary panel 107 may be slightly larger than the primary panel, e.g., at least about 1:1 (e.g., FIG. 9). In another aspect, the size of the secondary panel 108 to primary panel 107 may be in a ratio of about 3:1 or 7:5 or the secondary panel 108 may be at least 70% larger than the primary panel 107, or 2:1 or 50% larger.

(48) Prior to relief of negative internal pressure (e.g., during hot-fill processing), the primary panels 107 and secondary panels 108 may be designed to be convex, straight or concave shaped, and/or combinations thereof, so that after cooling of a closed container or after filling the container with hot product, sealing and cooling, the primary panels and/or secondary panels would decrease in convexity, become vertically straight or increase in concavity. The convexity or concavity of the primary and/or the secondary panels 107, 108 may be in the vertical or horizontal directions (e.g., in the up and down direction or around the circumference or both). In alternative embodiments, the secondary panels 108 may be slightly convex while the primary panels 107 are flat, concave or less convex than their primary panel 108 counterparts. Alternatively, the secondary panels 108 may be substantially flat and the primary panel 107 concave.

(49) The primary and secondary panels 107,108 cooperate to relieve internal negative pressure due to packaging or subsequent handling and storage. Of the pressure relieved, the primary panels 107 may be responsible for greater than 50% of the vacuum relief or uptake. The secondary panels 108 may be responsible for at least a portion (e.g., 15% or more) of the vacuum relief or uptake. For example, the primary panels 107 may absorb greater than 50%, 56% or 85% of a vacuum developed within developed within the container (e.g., upon cooling after hot-filling).

(50) Generally, the primary panels 107 are substantially devoid of structural elements, such as ribs, and are thus more flexible, have less deflection resistance, and therefore have more deflection than secondary panels, although some minimal ribbing may be present as noted above to add structural support to the container overall. The panels 107 may progressively exhibit an increase in deflection resistance as the panels are deflected inward.

(51) In an alternative embodiment, the primary panel 107, secondary panel 108, shoulder portion 105, the bottom portion 122 and/or the sidewall 106 may include an embossed motif or lettering (not shown).

(52) As exemplified in FIGS. 1A-1E, the primary panels 107 may comprise an upper and lower portion, 110 and 111, respectively, and the secondary panels 108 may comprise an upper and lower panel walls, 112 and 113, respectively.

(53) The primary 107 or secondary 108 panels may independently vary in width progressing from top to bottom thereof. For example, the panels may remain similar in width progressing from top to bottom thereof (i.e., they may be generally linear), may have an hourglass shape, may have an oval shape having a wider middle portion than the top and/or bottom, or the top portion of the panels may be wider than the bottom portion of the panel (i.e., narrowing) or vice-a-versa (i.e., broadening).

(54) As shown in the embodiment of FIGS. 1C-1F, the primary panels 107 are vertically straight (e.g., substantially or generally flat) and have an hourglass shape progressing from top to bottom thereof. The secondary panels 108 are vertically concave (e.g., arced inwardly in progressing from top to bottom), and have a generally consistent width progressing from top to bottom thereof, although the width varies slightly with the hourglass shape of the primary panels. In other exemplary embodiments, for example those shown in FIGS. 2-7, the primary panels (e.g., 207) can be vertically concave shaped (e.g., arced moderately in progressing from top to bottom) and have an hourglass shape progressing from top to bottom thereof. In one aspect, the primary panels 107 may be vertically concave shaped (i.e., arced) and horizontally relatively flat/slightly concave (e.g., FIGS. 2C and 2D). The secondary panels in the exemplary embodiments shown in FIGS. 1-8 (e.g., 208) are vertically concave (i.e., arced) and have consistent width progressing from top to bottom thereof. In another embodiment, the primary and/or the secondary panels may have a vertically convex shape with a wider middle section than the top and bottom of the primary panel (not shown). In still other exemplary embodiments, for example as illustrated in FIGS. 8A-8C, the primary panels 807 can be vertically concave shaped (i.e., arced) and become wider progressing from top to bottom thereof. The secondary panels 808 can be vertically concave shaped (i.e., arced) and have consistent width progressing from top to bottom thereof.

(55) In an alternative embodiment, all four panels are similar in size (e.g., d.sub.1 is approximately the same as d.sub.2), as exemplified in FIG. 9D, which is a cross-section of Line 9D-9D of FIG. 9A. The primary panels 907 are vertically concave (e.g., arced inwardly in progressing from top to bottom), and have a generally consistent width progressing from top to bottom thereof, and the secondary panel 908 are vertically straight (e.g., substantially or generally flat), and have a generally consistent width progressing from top to bottom thereof. In such an embodiment, the primary panels are configured in a way to be more responsive to internal vacuum than the secondary panels. For example, the primary panels 907 are horizontally flatter (i.e., less arcuate) than are the secondary panels 908. That is, the radius of curvature (r.sub.1) of the primary panels is greater than the radius of curvature (r.sub.2) of the secondary panels (see, e.g., FIG. 9D). These differences in curvature result in the primary panels having an increased ability for flexure, thus allowing the primary panels to account for the majority (e.g., greater than 50%) of the total vacuum relief accomplished in the container.

(56) In other embodiments, as exemplified in FIGS. 10A-10C, the primary panels (e.g., 1007) can be vertically straight shaped (i.e., substantially flat) and have a consistent width progressing from top to bottom. The secondary panels (e.g., 1008) can be vertically straight shaped (i.e., substantially flat) and have consistent width progressing from top to bottom thereof.

(57) The present invention may include a variety of these combinations and features. For example, as shown in FIGS. 12A-12C and 13A-13C, the primary panels 1207 are vertically straight (e.g., substantially or generally flat) and have a contoured shaped that becomes wider progressing from top to bottom thereof. In other exemplary embodiments (not shown), the secondary panels become progressively wider from top to bottom thereof, so that the upper panel wall is larger than the lower panel wall, and as a result, the upper portion of the secondary panel is more recessed than the lower portion.

(58) The container 101 may also include an upper bumper wall 114 between the shoulder 105 and the sidewall 106 and a lower bumper wall 115 between the sidewall 106 and the bottom portion 122. The upper and/or lower bumper walls may define a maximum diameter of the container, or alternatively may define a second diameter, which may be substantially equal to the maximum diameter.

(59) In the embodiments exemplified in FIGS. 1, 2 and 4-13, the upper bumper wall (e.g., 114), and lower bumper wall (e.g., 115) may extend continuously along the circumference of the container. As exemplified in FIGS. 1, 6 and 8-13, the container may also include horizontal transitional walls 116 and 117 defining the upper portion 110 and lower portion 111 of the primary panel 107 and connecting the primary panel to the bumper wall.

(60) As in FIGS. 9-11, the horizontal transitional walls (e.g., 916 and 917) may extend continuously along the circumference of the container 901. Alternatively, as exemplified in FIGS. 4, 5, and 7, the horizontal transition walls may be absent such that the upper portion (e.g., 410) and lower portion (e.g., 411) of the primary panel (e.g., 407, transition or blend into the upper bumper wall (e.g., 414) and lower bumper wall (e.g., 415), respectively.

(61) In exemplary embodiments having a primary panel that transition into the bumper wall (e.g., as in the embodiment of FIG. 3), the primary panel 307 can lack a horizontal transition wall at the top 310 and/or the bottom 311 of the primary panel 307. As shown in FIG. 3, the upper 310 and lower 311 portion of the primary panel 307 extend through the upper bumper wall 314 and lower bumper wall 315, respectively, so that the upper 314 and lower 315 bumper walls are discontinuous.

(62) In some exemplary embodiments (e.g., FIGS. 1-8 and 10-13), the secondary panels may be contoured to include grip regions, which have anti-slip features projecting inward or outward, while providing secondary means of vacuum uptake, while the primary panels provide the primary means of vacuum uptake. The resultant exemplary design thereby reduces the internal pressure and increasing the amount of vacuum uptake and reduces label distortion, while still providing grippable regions to facilitate end user/consumer handling.

(63) The secondary panels 108 may include at least one horizontal ribbing 118 (e.g., FIGS. 1-8 and 10-11). As exemplified in FIGS. 1-5 and 12, the secondary panels 108 can include, for example, three outwardly projecting horizontal ribbings separated by an intermediate region 119. As exemplified in FIGS. 6-8 and 13, the horizontal ribbings (e.g., 618) can be contiguous (i.e., not separated by intermediate region).

(64) FIGS. 10A-10C illustrate an embodiment having inwardly directed recessed ribbings 1018 separated by intermediate regions 1019 and FIGS. 11A-11C show inwardly recessed ribbings 1118 having a more horizontal transition from the intermediate regions 1119.

(65) As can be seen in FIGS. 1C-1E, the container 101 may include at least one recessed rib or groove 120 between the upper bumper wall 114 and the shoulder portion 105 and/or between the lower bumper wall 115 and the base 126. Alternatively, as exemplified in FIGS. 9, 10 and 11, the container (e.g., 1001) may include at least one recessed rib or groove 1024 between the upper 1014 and/or lower 1015 bumper wall and the primary 1007 and secondary 1008 panels. The recessed rib or groove 120 may be continuous along the circumference of the container 101 (FIGS. 1-4 and 6-11). In another embodiment, the container 101 may contain at least a second recessed rib or groove 121 above the recessed rib or groove 120 above said upper bumper wall (FIGS. 1-3) or two second recessed ribs or grooves 421 (FIGS. 4-11). The second recessed rib or groove (e.g., 121 or 421) may be of lesser or greater height than the recessed rib or groove 120. In yet another embodiment, the recessed rib or groove 520 above the upper bumper wall 514 can comprise an indented portion 522 (FIGS. 5A-5C), such that the rib or groove is discontinuous.

(66) In a further embodiment, the container may be a squeezable container, which delivers or dispenses a product per squeeze. In this embodiment, the container, once opened, may be easily held or gripped and with little resistance, the container may be squeezed along the primary or secondary panels to dispense product there from. Once squeezing pressure is reduced, the container retains its original shape without undue distortion.

(67) Referring again to FIGS. 14A and 14B, it can be seen from finite element analysis (FEA) that the primary panel 107 and second panel 108 reacts to vacuum changes with a differential amount of response. FIG. 14A depicts the container with about 0.875 pounds per square inch (PSI) of vacuum. In the vicinity of the center point of region 1430, the primary panel 107 is displaced inwardly towards the longitudinal axis of the container about 4.67 mm. Lesser amounts of such inward deflection of the primary panel 107 can be seen in the vicinity of region 1405, where there is virtually no inward deflection caused by the vacuum. Region 1410 exhibits an inward deflection of about 0.50 mm; region 1415 exhibits an inward deflection of about 1.00 mm; region 1420 exhibits an inward deflection of about 2.00 mm; and region 1425 exhibits an inward deflection of about 3.75 mm.

(68) Meanwhile, the secondary panel 108 exhibits relatively less inward deflection in the range of about 2.00 mm to about 3.00 mm. FIG. 14B illustrates in greater detail the impact of vacuum upon such secondary panel 108. In the vicinity of the center point of region 1425, the secondary panel 108 is displaced inwardly towards the longitudinal axis of the container about 3.75 mm. Lesser amounts of such inward deflection of the secondary panel 108 can be seen in the vicinity of region 1405, where there is virtually no inward deflection caused by the vacuum. Region 1410 exhibits an inward deflection of about 0.50 mm; region 1415 exhibits an inward deflection of about 1.00 mm; and region 1420 exhibits an inward deflection of about 2.00 mm.

(69) Referring now to FIGS. 15A and 15B, it can be seen from the FEA that the primary panel 107 and second panel 108 continue to react to vacuum changes with a differential amount of response. FIG. 15A depicts the container with about 1.000 pounds per square inch (PSI) of vacuum. In the vicinity of the center point of region 1530, the primary panel 107 is displaced inwardly towards the longitudinal axis of the container about 5.69 mm. Lesser amounts of such inward deflection of the primary panel 107 can be seen in the vicinity of region 1505, where there is virtually no inward deflection caused by the vacuum. Region 1510 exhibits an inward deflection of about 0.50 mm; region 1515 exhibits an inward deflection of about 1.00 mm; region 1520 exhibits an inward deflection of about 2.00 mm; and region 1525 exhibits an inward deflection of about 3.75 mm.

(70) Meanwhile, the secondary panel 108 exhibits relatively less inward deflection, although more so than in FIG. 14A. FIG. 15B illustrates in greater detail the impact of vacuum upon such secondary panel 108 (e.g., there are regions 1525 and 1530 on the secondary panel 108 as shown in FIG. 15A). In the vicinity of the center point of region 1530, for example, the secondary panel 108 is displaced inwardly towards the longitudinal axis of the container about 4.75 mm to about 5.00 mm. Lesser amounts of such inward deflection of the secondary panel 108 can be seen in the vicinity of region 1505, where there is virtually no inward deflection caused by the vacuum. Region 1510 exhibits an inward deflection of about 0.50 mm; region 1515 exhibits an inward deflection of about 1.00 mm; region 1520 exhibits an inward deflection of about 2.00 mm; region 1525 exhibits an inward deflection of about 3.75 mm; and region 1527 exhibits an inward deflection of about 4.25 mm. Referring now to FIGS. 16A-16E, further details of the controlled radial deformation of the primary 107 and secondary 108 panels according to embodiments of the present invention will now be illustrated by way of FEA cross-sectional views through line B-B of the container shown in FIG. 1A under varying degrees of vacuum pressure.

(71) FIG. 16A illustrates the primary 107 and second 108 panels under about 0.250 PSI of vacuum. Both panels 107, 108 exhibit an outward curvature and little inward deflection (i.e., on the order 0.50 mm to about 1.00 mm) even when subjected to this vacuum. As shown in FIG. 16B, however, when the vacuum has increased to about 0.500 PSI, the primary panel 107 begins to exhibit a region 1620 of about 2.00 mm to about 2.50 mm inward deflection, while the secondary panel 108 deflects only 1.25 mm inwardly.

(72) FIG. 16C further illustrates the continued inward deflection of the primary panel 107 under about 0.75 PSI vacuum. Regions 1620, 1625, and 1630 start to appear on the primary panels 107, indicating, respectively, about 2.00 mm to about 2.50 mm, 3.75 mm, and 4.00 mm to about 4.25 mm inward deflection. Meanwhile, the secondary panel 108 continues to exhibit only about 1.00 mm to about 2.00 mm inward deflection.

(73) FIGS. 16D and 16E continue to illustrate the controlled radial deformation of the container under about 1.00 PSI and about 1.25 PSI vacuum, respectively. In FIG. 16D, it can be seen that the primary panel 107 has begun to invert, with regions 1620, 1625, and 1630 illustrating deflection in about the same amounts as shown in FIG. 16C. However, it can also be seen that the secondary panel 108 has begun to deflect inwardly at an increasing rate. Regions 1625 and 1630 start to appear on the secondary panels 108, indicating, respectively, about 3.75 mm, and about 4.00 mm to about 4.25 mm inward deflection. More importantly, it can be seen from FIG. 16E that substantially all of the secondary panels 108 have deflected inwardly about 4.00 mm to about 4.25 mm. The posts or vertical transition walls separating the primary panels 107 from the secondary panels 108 can also be seen to exhibit an inward deflection of about 3.75 mm. Thus, the primary 107 and secondary 108 panels provide flex and create leverage points at the posts or vertical transition walls for the panels 107, 108 to deflect. The primary 107 and secondary 108 panels flex in unison, but at differential rates.

(74) As will be appreciated from the foregoing exemplary FEA, the cage structure comprising the primary 107 and secondary 108 vacuum panels and ribs (if any) cooperate to maintain container shape upon filling and cooling of the container. It also maintains container shape in those instances where the container might not have been hot-filled, bin subjected to vacuum-inducing changes (e.g., refrigeration or vapor loss) during the shelf life of the filled container.

(75) The invention has been disclosed in conjunction with presently contemplated embodiments thereof, and a number of modifications and variations have been discussed. Other modifications and variations will readily suggest themselves to persons of ordinary skill in the art. In particular, various combinations of configurations of the primary and secondary panels have been discussed. Various other container features have also been incorporated with some combinations. The present invention includes combinations of differently configured primary and secondary panels other than those described. The invention also includes alternative configurations with different container features. For example, the indented portion 522 of the upper bumper wall 514 can be incorporated into other embodiments. The invention is intended to embrace all such modifications and variations as fall within the spirit and broad scope of the appended claims.

(76) Unless the context clearly requires otherwise, throughout the description and the claims, the words comprise, comprising and the like are to be considered 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.