Container structure for removal of vacuum pressure

Abstract

A hot-fill PET container or bottle (10) filling with a liquid at an elevated temperature has a side wall (9) extending to a lower portion including a pressure panel (11) and a base (21) in its unfolded or pre-fill position. The panel (11) is transversely oriented and has a decoupling or hinge structure (13), an initiator portion (1) and control portion (5) of a steeply angled inverting conical section between 30 and 45 degrees. The control portion enables the inversion of the panel (11) into the container (10) to compensate for vacuum or reduced pressure induced within the container as the liquid cools down. The base (2) can also have a plurality of reinforcing ribs (3).

Claims

1. A method for handling a container, the container including a longitudinal axis and a pressure panel located substantially transversely to the longitudinal axis, wherein the container includes a recessed instep adjacent to an inside border of a standing support, wherein the pressure panel is connected to a hinge structure; wherein the pressure panel further comprises a first portion being inclined at an angle of more than 100 degrees relative to a plane parallel to the longitudinal axis and a second portion being angled at a lesser angle relative to a plane parallel to the longitudinal axis than the first portion, wherein the pressure panel further comprises a centrally located push-up portion being adapted to move in response to a longitudinally directed force, the method comprising providing the container through the steps of: hot-filling the container with the pressure panel in an initial position, wherein the initial position is longitudinally away from an upper portion of the container; capping the container; creating a vacuum in the container by cooling; repositioning the pressure panel from the initial position to a second position, wherein the second position is longitudinally closer to the upper portion of the container, to reduce at least a portion of the vacuum, wherein the pressure panel remains above the standing support in the second position.

2. The method of claim 1, wherein a body portion of the container includes a sidewall, at least a portion of said 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 initial position to the second position.

3. The method of claim 1, wherein a body portion of the container further includes one or more ribs, the one or more ribs providing structural integrity for the container.

4. The method of claim 1, wherein the pressure panel is adapted to receive a mechanical device, and said repositioning the pressure panel includes operating the mechanical device to apply a force to reposition the pressure panel from the first position to the second position.

5. The method of claim 1, further comprising blow molding the said container and the step of repositioning the pressure panel about the hinge toward the interior of said container relative to the longitudinal axis.

6. The method of claim 5, further comprising the step of configuring the pressure panel to be in the initial position prior to filling the container.

7. The method of claim 1, wherein the instep portion is recessed to such an extent that the pressure panel is contained entirely above the standing support, the method further comprising: repositioning the pressure panel connected to the hinge about the hinge from the initial position to the second position, without repositioning the instep, thereby reducing the internal pressure of the container, wherein prior to repositioning of the pressure panel, the container is adapted to stand upright on a flat surface.

8. The method of claim 1, wherein the pressure panel includes a plurality of flutes, ribs or creases to facilitate repositioning thereof, the flutes, ribs or creases being adapted to flex during said repositioning.

9. The method of claim 1, wherein said providing a container comprises transporting by a conveyor the container with a vacuum created therein between said steps of creating a vacuum and said repositioning.

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 side-elevation view of a hot-fill container according to an alternative embodiment of the invention in its pre-collapsed condition;

(10) FIG. 8b: shows a cross-sectional view of the container shown in FIGS. 8a 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. 10a before collapsing;

(12) FIG. 10a: shows a cross-sectional view of the container shown in FIG. 9 through line D-D prior to movement of the vacuum panel;

(13) FIG. 10b: shows a cross-sectional view of the container shown in FIG. 9 with the pressure panel in a pre-collapsed state recessed to such an extent it is above the standing surface prior to movement of the vacuum panel just as FIG. 10a is prior to movement of the vacuum panel;

(14) FIGS. 11a-d: show cross-sectional views of the container of FIGS. 8a-10a according to an alternative embodiment of the invention incorporating a pusher to provide panel folding;

(15) FIGS. 12a-d: show cross-sectional views of the container of FIGS. 8-10a according to a further alternative embodiment of the invention incorporating a pusher to provide panel folding;

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

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

(18) FIGS. 15a-b: show side and cross-sectional views of portions of the container shown in FIGS. 8-10a including outwardly projecting fluting;

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

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

(21) FIG. 15e: shows a cross-sectional view of a portion of the container shown in FIGS. 8-10a with the pressure panel in a pre-collapsed state recessed to such an extent that it is above the standing surface as is similarly shown in FIG. 10b;

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

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

(24) 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;

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

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

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

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

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

(30) FIG. 20: shows a cross-sectional view of the container shown in FIGS. 8-10a through line D-D with the container sidewall including ribs; and

(31) FIG. 21: shows a cross-sectional view of the container shown in FIG. 10b with the pressure panel in a pre-collapsed state and with the container sidewall including ribs.

DETAILED DESCRIPTION

(32) 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.

(33) 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.

(34) Typically at a bottling plant the containers will be filled with a hot liquid and then capped before being subjected to a cold water spray 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.

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

(36) 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.

(37) 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.

(38) 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.

(39) 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.

(40) 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.

(41) 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.

(42) 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. As will be appreciated by any skilled person, the sidewall 9 may be radially recessed from touch bumper zones 450 that afford protection to the area between upper and lower touch zones during bottle to bottle contact and label zone protection. As will be further appreciated, the container may also comprise a plurality of annular strengthening rings or ribbings. These may be concentric around the container. These may be in the form of a large concave hoop ring 470, or in the form of smaller rib structures 461. Such structures provide strength against vacuum deformation during cooling of hot filled contents. Alternatively, such structures may be avoided altogether as shown in FIG. 8a, where only the upper and lower touch bumper zones 450 are utilized.

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

(44) 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.

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

(46) 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.

(47) 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 a first wall portion or instep or recess 8 and a 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.

(48) 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.

(49) 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.

(50) 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.

(51) 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.

(52) 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.

(53) 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 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.

(54) 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 push-up 28, in this embodiment being an inwardly recessed portion.

(55) 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 adjacent the decoupling structure 13. Such an arrangement is shown in FIGS. 19a and 19b.

(56) 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.

(57) Referring to FIGS. 15a-c and 17a-d, convex or downwardly outwardly projecting flutes 18 are shown, providing inwardly directed creases 19 there between. As discussed above, the creases may comprise a different angulation to the longitudinal axis than other portions of the pressure panel.

(58) 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 creases, flutes or projections function as ribs to increase or decrease 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.

(59) 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. This embodiment provides downwardly or outwardly directed creases 199 between the inwardly directed flutes 188. The outwardly directed creases 199 in this example create regions of lesser angular set than the regions 188.

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

(61) 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.

(62) 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 could be imposed on the folding panel 20 such as by means of engaging a mechanical pusher 22 or the creation of some relative movement of the centrally located push-up portion 28 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.

(63) 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.

(64) 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.

(65) 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.

(66) 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.

(67) 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.

(68) In a further embodiment of the present invention, and referring to FIGS. 13 and 14, it can be seen that the widest portions 30 of the pressure panel 11 may invert earlier than the narrower portion of the control portion 5. 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 5 to act as the initiator portion.

(69) 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.

(70) 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.