U.S. patent application number 10/078931 was filed with the patent office on 2003-08-21 for plastic water bottle.
This patent application is currently assigned to FCI, Inc., an Ohio corporation. Invention is credited to Peronek, Michael H., Sweeny, Kevin.
Application Number | 20030155320 10/078931 |
Document ID | / |
Family ID | 27732942 |
Filed Date | 2003-08-21 |
United States Patent
Application |
20030155320 |
Kind Code |
A1 |
Peronek, Michael H. ; et
al. |
August 21, 2003 |
Plastic water bottle
Abstract
A molded plastic container for carbonated and non-carbonated
beverages. The plastic container includes an upper mouth-forming
portion, a cylindrical sidewall portion and a lower base-forming
portion. The upper mouth-forming portion includes a non-circular
anti-rotation flange adapted to at least partially inhibit full
rotation of the container as a cap is inserted on the container.
The anti-rotation flange typically has an outer perimeter shape of
a heptagon. The lower base-forming portion can include a variety of
different configurations.
Inventors: |
Peronek, Michael H.;
(Brunswick, OH) ; Sweeny, Kevin; (Columbia
Station, OH) |
Correspondence
Address: |
FAY, SHARPE, FAGAN, MINNICH & MCKEE, LLP
1100 SUPERIOR AVENUE
SEVENTH FLOOR
CLEVELAND
OH
44114-2518
US
|
Assignee: |
FCI, Inc., an Ohio
corporation
|
Family ID: |
27732942 |
Appl. No.: |
10/078931 |
Filed: |
February 19, 2002 |
Current U.S.
Class: |
215/46 |
Current CPC
Class: |
B67B 3/2073 20130101;
B67C 3/242 20130101; B67B 3/206 20130101; B65D 1/023 20130101; B67C
2007/0066 20130101; B67B 3/2033 20130101 |
Class at
Publication: |
215/46 |
International
Class: |
B65B 007/28; B65B
043/38 |
Claims
What is claimed is:
1. A molded plastic container for beverages comprising an upper
mouth-forming portion, a cylindrical sidewall portion and a lower
base-forming portion, said upper mouth-forming portion including a
non-circular anti-rotation flange adapted to at least partially
inhibit full rotation of said container as a cap is inserted on
said container.
2. The plastic container as defined in claim 1, wherein said
anti-rotation flange includes at least one substantially straight
surface.
3. The plastic container as defined in claim 2, wherein said
anti-rotation flange includes a plurality of straight surfaces.
4. The plastic container as defined in claim 3, wherein said
anti-rotation flange has an outer perimeter shape of a
pentagon.
5. The plastic container as defined in claim 3, wherein said
anti-rotation flange has an outer perimeter shape of a
heptagon.
6. The plastic container as defined in claim 3, wherein said
anti-rotation flange has an outer perimeter shape of a nonagon.
7. The plastic container as defined in claim 1, wherein said
anti-rotation flange includes at least one notch.
8. The plastic container as defined in claim 7, wherein said notch
has a V-shape.
9. The plastic container as defined in claim 7, wherein said notch
has at least one arcuate surface.
10. The plastic container as defined in claim 1, wherein said lower
base-forming portion includes a plurality of hollow foot-forming
portions extending outwardly from a central portion of the lower
base-forming portion to form a plurality of feet.
11. The plastic container as defined in claim 10, wherein each
foot-forming portion increases circumferentially in size as it
extends radially.
12. The plastic container as defined in claim 1, wherein said lower
base-forming portion has a substantially flat base.
13. The plastic container as defined in claim 1, wherein said lower
base-forming portion has a champagne-type base.
14. The plastic container as defined in claim 1, wherein said
plastic is polyethylene terephthalate.
15. A container comprising an upper mouth-forming portion, a
sidewall portion and a lower base-forming portion, said upper
mouth-forming portion including a non-circular anti-rotation flange
adapted to at least partially inhibit full rotation of said
container as a cap is inserted on said container.
16. The container as defined in claim 15, wherein said container is
a molded plastic container.
17. The container as defined in claim 16, wherein said plastic is
polyethylene terephthalate.
18. The container as defined in claim 15, wherein said container is
for beverages.
19. The container as defined in claim 15, wherein said
anti-rotation flange includes at least one substantially straight
surface.
20. The container as defined in claim 19, wherein said
anti-rotation flange includes a plurality of straight surfaces.
21. The container as defined in claim 20, wherein said
anti-rotation flange has an outer perimeter shape of a
heptagon.
22. The container as defined in claim 15, wherein said
anti-rotation flange includes at least one notch.
23. The container as defined in claim 22, wherein said notch has a
V-shape.
24. The container as defined in claim 22, wherein said notch has at
least one arcuate surface.
25. The container as defined in claim 15, wherein said lower
base-forming portion includes a plurality of hollow foot-forming
portions extending outwardly from a central portion of the lower
base-forming portion to form a plurality of feet.
26. The container as defined in claim 15, wherein said lower
base-forming portion has a substantially flat base.
27. The container as defined in claim 15, wherein said lower
base-forming portion has a champagne-type base.
Description
[0001] The invention relates to containers for fluids, and more
particularly to a plastic bottle for non-carbonated beverages that
resists deformation and damage during the capping process.
BACKGROUND OF THE INVENTION
[0002] Blow-molded plastic bottles for containing liquids at
elevated pressures are known and have found increasing acceptance.
Such containers are accepted particularly in the beverage industry
as disposable containers for use with effervescent or carbonated
beverages, especially carbonated soft drinks. These plastic
containers can reliably contain carbonated beverages generating
internal pressures as high as 100 psi or more and can be
inexpensively manufactured. Typically, these plastic bottles have a
cylindrical shape which reliably contain carbonated beverage
products, can be easily handled, can be inexpensively manufactured,
and have stability when filled and unfilled. Such containers have
most frequently been manufactured from plastic materials such as
polyethylene terephthalate (PET) by, for example, blow molding a
portion of PET into a mold formed in the shape of the container.
The biaxial expansion of PET by blow molding imparts rigidity and
strength to the formed PET material, and blow molded PET can
provide economically acceptable wall thicknesses, with clarity in
relatively intricate designs, sufficient strength to contain
pressures up to 100 psi and more, and resistance to gas passage
that may deplete contained beverages of their carbonation.
[0003] One problem in plastic container design is the propensity of
PET to succumb to the deleterious effects of stress cracking and
crazing, which is manifested as almost imperceptible streaks in the
plastic, but ultimately can become complete cracks due to stress
and other environmental factors. Relatively unstretched portions of
a plastic container that have low degrees of crystallinity due to
the lack of biaxial expansion, such as the central bottom portion,
are particularly susceptible to crazing and stress cracking. The
relatively unstretched central portion of the container bottom is
also frequently provided with a plurality of depending feet that
are formed with distention-resistant but stress concentrating
areas, and the composite effect on such areas of stress and strain
due to the internal pressure of the container and external
environmental factors can lead to crazing, stress cracking and
container bottom failure.
[0004] One commercial cylindrical beverage container that seeks to
avoid such problems is formed with a full hemispherical bottom
portion and provided with a separate plastic base member fastened
over the hemispherical bottom portion to provide a stable base for
the container. Such containers are in common use for large
multi-liter containers for carbonated beverages, even though the
provision of a separate plastic base member imposes increased
container height, and increased manufacturing and material costs
for each container. Another commercial cylindrical beverage
container that seeks to avoid such problems includes a "champagne"
type base having concave, or "domed" eversion-resisting central
bottom portions merging with the cylindrical container sidewalls at
an annular ring which forms a stable base for the container. The
central domed portion of a champagne-based plastic container
generally creates clearance for the gate area of the container
which is intended to resist deformation due to the internal
pressure of the container but is sensitive to stress cracking.
However, containers with champagne bases require a greater wall
thickness in the base portion to resist the distending and everting
forces of the internal pressure and form stress concentrations at
the annular base-forming transition between the concave central
bottom portion and cylindrical sidewall that are prone to stress
cracking and rupture when the container is dropped.
[0005] More recently, hemispherical bottom portions and concave
champagne-like bottom portions have been combined, in which a
plurality of feet are formed in the bottom of a blow molded
container. These designs frequently seek eversion-resistant concave
central bottom portions formed by a plurality of surrounding feet
that are interconnected by a plurality of generally downwardly
convex hemispheric rib portions. Many of such container designs
providing footed bottles are in commercial usage. Such container
designs are still subject, in the absence of relatively thick
bottom wall portions, to distention of their concave central
portions due to high internal pressures that can create "rockers"
and significantly increased interior container volume with lower
fluid levels, all of which are unacceptable to purchasers. Efforts
to increase the eversion and distention resistance of the concave
bottom portions of such footed containers with thinner bottom wall
thicknesses have frequently led to bottom portions including small
radii of curvature and discontinuous and abrupt transitions between
adjoining surfaces that provide stress concentration, crazing and
stress cracking sites. Many of these problems have been overcome by
various bottom configurations such as illustrated in U.S. Pat. Nos.
4,120,135; 4,978,015; 4,939,890; 5,398,485; 5,603,423; 5,816,029;
5,826,400; 5,934,024; and 6,276,546. The bottles disclosed in these
patents are incorporated herein by reference to illustrate some
examples of the type and shape of bottles that can be used in the
present invention.
[0006] Much of the plastic bottle design has been directed to the
carbonated bottle industry. However, the non-carbonated beverage
market such as water, sport drinks, fruit drinks and the like has
continued to grow. It is not uncommon that plastic bottles
originally designed for carbonated beverages are used for
non-carbonated beverages. However, the use of these plastic bottles
has been problematic, especially during the bottling of the
non-carbonated beverage. The gas in carbonated beverage exerts a
force on the interior of the bottle, thus resisting the deformation
or collapse of the base of the bottle during the capping of the
bottle. As a result, the base and walls of the plastic bottle can
be made of a thinner material, which is a significant cost savings
to the manufacturer. The absence of gas in non-carbonated beverages
has resulted in increased deformation and/or damage of base of the
plastic bottle during the bottling process. In order to address
this problem, increased wall thickness for the sidewalls and base
of the plastic bottle has been used. Although the increased wall
thickness of the plastic bottle reduces the incidence of
deformation and/or damage of the base of the plastic bottle during
the bottling process, the increased wall thickness translates into
increased material costs. Plastic bottles or containers that
include a plastic base attachment have also been used to address
this problem. However, the use of the plastic base attachment also
increases the cost of the bottle or container. Bottling
manufactures that bottle both carbonated and non-carbonated
beverages must now maintain additional inventory of various bottle
or container configurations and thicknesses.
[0007] In view of the present state of the art for plastic beverage
bottles, there is a need for a plastic beverage container that can
be used for non-carbonated beverages which resists deformation
and/or damage to the base and/or body of the plastic beverage
container during the bottling process, and which has substantially
the same material cost as standard plastic bottles used for
carbonated beverages.
SUMMARY OF THE INVENTION
[0008] The invention provides an improved container for
non-carbonated beverages that overcomes the past problems
associated with plastic bottles used with non-carbonated beverages.
The improved container is designed to have a low cost and weight,
to be manufacturable from a plastic material by molding with
minimal plastic material in its walls, to have excellent stability
in both filled and unfilled conditions, and to have maximal volumes
with minimal heights in easily handled diameters. The invention
will be described with respect to the containers for non-carbonated
beverages; however, the improved container can be used with
non-carbonated or carbonated beverages. In addition, the present
invention is applicable to containers for the bottling of liquids
other than beverages (e.g., food products other than beverages,
cleaning products, automotive products, paint products, etc.).
Furthermore, the container will be described as being principally
made of plastic material; however, the container can be formed of
other materials (e.g., glass, metal, polymers and/or co-polymers
other than plastic, etc.). The improved plastic container includes
a neck portion, a sidewall portion and a lower bottom-forming
portion. The body and/or base of the improved plastic container can
be formed and/or configured to resemble configurations commonly
used in prior art plastic bottles for carbonated and non-carbonated
beverages. In one embodiment of the invention, the sidewall of the
improved plastic container has a generally cylindrical shape;
however, other shapes can be used. In one aspect of this
embodiment, the sidewall can include one or more ribs to provide
structural rigidity to the sidewall and/or to form a more
aesthetically pleasing container design. In another and/or
alternative aspect of this embodiment, the sidewall can include a
region having a differing diameter than other portions of the
sidewall to accommodate a label, to enhance the ability of a user
to grasp the container, to provide structural rigidity to the
sidewall and/or to form a more aesthetically pleasing container
design. In another and/or alternative embodiment of the invention,
the lower bottom-forming portion of the improved plastic container
can be formed into a variety of configurations such as, but not
limited to, a lower bottom-forming portion having a plurality of
feet, a lower portion bottom-forming having a champagne
configuration, a lower bottom-forming portion having a
substantially flat base, and the like. In one aspect of this
embodiment, the lower bottom-forming portion includes hollow
feet-forming portions and intervening downwardly convex, smoothly
curving bottom segments which can provide, through a plastic
container bottom section of minimal height, substantially maximal
container volume for a given container height, a maximal
cylindrical sidewall labeling height, and a lower center of gravity
and wide foot print for greater container stability, when filled
and unfilled, and with minimal stress concentrations and risk of
stress cracking and/or other types of defects. In one design of
this aspect, the improved plastic container includes a cylindrical
sidewall portion and a lower bottom-forming portion having a
plurality of circumferentially-spaced, downwardly convex segments
extending downwardly from the cylindrical sidewall and a plurality
of intervening, circumferentially-spaced, totally convex, hollow
foot-forming portions that extend radially from the central bottom
portion and downwardly from the downwardly convex segments to form
a clearance for a concave central bottom portion. In another and/or
alternative design of this aspect, the improved plastic container
includes a cylindrical sidewall portion all about a central
longitudinal axis, a lower bottom-forming portion including a
plurality of hollow foot-forming portions extending outwardly from
the central portion of the lower bottom-forming portion to form a
plurality of feet, each foot-forming portion including, between
said central portion of the lower bottom-forming portion and its
foot, a bottom clearance-forming portion including a
compound-curved offset formed by opposing radii of curvature
wherein the compound-curved offset curving downwardly from said
central portion about a radius of curvature below the bottom of the
lower bottom-forming portion before curving about a radius of
curvature above the bottom of the lower bottom-forming portion, and
a plurality of smoothly curved, downwardly convex segments between
adjacent pairs of hollow foot-forming portions, each of said
downwardly convex segments extending upwardly between said adjacent
hollow foot-forming portions and, generally expanding outwardly at
its upper end to merge into said cylindrical sidewall portion. In
another and/or alternative aspect of this embodiment, the lower
bottom-forming portion includes a plurality of ribs extending from
the sidewall to a central portion of the lower bottom-forming
portion where the ribs intersect. The upper curvilinear surface of
the ribs lies on an essentially hemispherical curve in the interior
of the container. In one design of this aspect, the lower
bottom-forming portion includes a plurality of uniquely designed
feet which extend along a curved path from the sidewall, have end
walls connected to adjacent ribs and include a generally horizontal
base surface. This configuration of the lower bottom-forming
portion depicts a pseudo-champagne appearance wherein the feet
contain a substantially vertical inner surface or lip positioned
radially inwardly from the base surface and connected to a second
inner surface which extends from the substantially vertical lip to
the central portion of the bottom structure. Thus, the inner
surfaces of the feet define a pseudo-champagne dome below the
central portion and below the hemispherical bottom contour defined
by the upper rib surfaces. In yet another and/or alternative aspect
of this embodiment, the lower bottom-forming portion includes an
essentially hemispherical curve in the interior of the container.
This configuration of the lower bottom-forming portion depicts a
champagne appearance. In still another and/or alternative
embodiment of the invention, the improved plastic container
includes an upper mouth-forming portion adapted to receive a fluid
and a cap to cover the upper mouth. The design and configuration of
the mouth opening can be generally the same as used in prior art
plastic bottles used for carbonated beverages; however, it can be
different. In one aspect of this embodiment, the opening in the
upper mouth-forming portion is substantially circular. In another
and/or alternative aspect of this embodiment, the upper
mouth-forming portion includes one or more threads that are adapted
to receive a cap. The one or more threads have a configuration that
is generally the same as the threads used on prior art plastic
bottles; however, it can be different. In yet another and/or
alternative embodiment of the invention, the upper mouth-forming
portion includes an anti-rotation flange adapted to inhibit or
prevent the improved plastic container from rotating when a cap is
inserted onto the upper mouth-forming portion. In one aspect of
this embodiment, the anti-rotation flange is also adapted to at
least partially support the improved plastic container as the
improved plastic container is conveyed to and/or from the bottle
filling location.
[0009] In another and/or alternative aspect of the present
invention, the anti-rotation flange on the improved plastic
container includes a non-circular configuration that is at least
partially engagable with one or more components of a capping
machine, and wherein upon at least partial engagement with the one
or more components of the capping machine, the non-circular
configuration resists or prevents rotation of the improved plastic
container when a cap is inserted on the upper mouth-forming portion
of the improved plastic container. In prior bottling operations,
prior art plastic bottles were prevented from rotating during the
capping process by using a sharp implement to engage a portion of
the prior art plastic bottle (e.g. circular flange, bottle base,
etc.) to prevent rotation of the plastic bottle. One such device is
disclosed in U.S. Pat. No. 4,939,890, which is incorporated herein
by reference. The use of the sharp implement typically disfigured
the prior art plastic bottle and made the prior art plastic bottle
less aesthetically pleasing to consumers. The sharp implement could
also damage some prior art plastic bottles during the capping
process, thereby resulting in the bottles having to be destroyed.
Other prior bottling operations used an anti-rotation plate that
engaged the base of the prior art bottle to prevent rotation of the
prior art bottle during capping. Some of these devices are
disclosed in U.S. Pat. Nos. 4,120,135; 4,143,754; 4,280,612;
5,398,485; 5,816,029; 5,826,400; and 5,934,042, which are
incorporated herein by reference. However, for non-carbonated
beverages, the base of the plastic bottle tends to be more
susceptible to deformation or damage by an anti-rotation plate.
This is believed to be the result of the lack of carbonation in the
fluid in the plastic bottle, which carbonation exerts a pressure
force on the inside of the plastic bottle during the capping
process thereby resisting deformation or damage by an anti-rotation
plate. Non-carbonated beverages do not have the carbonated
pressure, thus the prior art plastic bottle is more susceptible to
deformation or damage to the base by an anti-rotation plate. The
use of the anti-rotation flange on the improved plastic container
eliminates the need for use of a sharp implement and/or use of an
anti-rotation plate during the capping process. As such,
deformation and/or damage to the base of the improved plastic
container during the capping process in reduced or eliminated. In
one embodiment of the invention, the anti-rotation flange includes
a plurality of substantially straight surfaces positioned about at
least a portion of the anti-rotation flange. In one aspect of this
embodiment, the anti-rotation flange includes an odd number of
straight surfaces. In one particular, non-limiting design, the
plurality of substantially straight surfaces have substantially the
same length. In another and/or alternative particular, non-limiting
design, the plurality of substantially straight surfaces form a
polygonal shape (e.g. pentagon, heptagon, nonagon, etc.). In
another and/or alternative embodiment of the invention, the
anti-rotation flange includes at least one notch. In one aspect of
this embodiment, one or more sides of at least one notch is a
substantially straight surface. In one particular, non-limiting
design, all the sides of at least one notch are formed by
substantially straight surfaces. In another and/or alternative
aspect of this embodiment, one or more sides of at least one notch
is formed by an arcuate surface. In one particular, non-limiting
design, all the sides of at least one notch are formed by an
arcuate surface. In still another and/or alternative aspect of this
embodiment, the anti-rotation flange includes a plurality of
notches. In one particular, non-limiting design, the plurality of
notches are substantially symmetrically oriented about the
anti-rotation flange. In yet another and/or alternative aspect of
this embodiment, the size and/or shape of two or more of the
notches are substantially the same.
[0010] In still another and/or alternative aspect of the present
invention, the anti-rotation flange on the improved plastic
container includes a non-fully circular configuration that resists
or prevents the improved plastic container from disengaging from a
guide railing as the improved plastic container is conveyed to
and/or from the bottle filling location. During the bottling
process, the empty improved plastic containers are conveyed to a
bottle filling location. The improved plastic containers are
generally conveyed to the bottle filling location by a railing
system wherein the flange on the upper mouth-forming portion of the
improved plastic containers rests on the top of the railing and/or
is at least partially guided by the railing. The improved plastic
containers are typically moved along the railing to the bottle
filling location by blowing air on the improved plastic; however,
other mechanisms can be used to move the improved plastic
containers along the rails. After the improved plastic container
has been filled at the bottle filling location, the flange may be
used to convey and/or at least partially guide the filled improved
plastic container from the bottling location by another rail
system. In prior art plastic bottles, the flange was circular. The
circular flange did not allow the prior art plastic bottle to fall
through the railing even when the plastic bottle rotated as the
plastic bottle was conveyed along the railing. The anti-rotation
flange on the improved plastic container is substituted for the
standard fully circular flange on prior art plastic containers. The
anti-rotation flange is configured to resist or prevent the
improved plastic container from disengaging from or falling through
the rail system as the improved plastic container is conveyed to
and/or from the bottle filling location. As such, the improved
plastic container can be used on existing plastic bottling lines
without having to modify the conveying system for the improved
plastic container to and/or from the bottle filling location.
[0011] In yet another and/or alternative aspect of the present
invention, the anti-rotation flange of the improved plastic
container includes a non-fully circular configuration that enables
the improved plastic bottle to be supported at the bottle filling
location as a cap is inserted onto the mouth of the improved
plastic container. During prior capping processes, the capping
machine exerted a downward force on the cap as the cap was inserted
onto the mouth of the improved plastic container. Typically, the
cap was threaded onto the upper mouth-forming portion of the
improved plastic container as a downward force was being applied to
the cap; however, other techniques were used to insert the cap on
the improved plastic container. This downward force could result in
the base of the improved plastic container becoming deformed and/or
damaged during the capping process. When carbonated beverages were
inserted into the improved plastic container, the carbonated gas
exerted a force on the inside surfaces of the improved plastic
container that reduced or prevented deformation and/or damage to
the base of the improved plastic container during the capping
process. During the bottling of non-carbonated beverages, the lack
of carbonated gas resulted in the base of the improved plastic
container being more susceptible to deformation and/or damage
during the capping process. Some bottle manufactures attempted to
overcome this problem by inserting a protective cap on the base of
prior art plastic bottles. Although the protective cap was
effective in reducing the incidence of deformation and/or damage to
the base of these prior art plastic bottles during the capping
process, the use of the cap increased material costs of the plastic
bottle and typically required some modification to the bottling
line in order to properly convey the plastic bottle to and/or from
the bottle filling location. In one embodiment, the anti-rotation
flange is designed such that a support plate on the capping machine
can be at least partially inserted under the anti-rotation flange
during the capping process such that the downward force applied to
the cap during the capping process is partially or fully countered
by the support plate. As a result, a reduced amount of force is
exerted on the base of the improved plastic container during the
capping process which results in the reduction or elimination of
deformation and/or damage to the base of the improved plastic
container. In one aspect of this embodiment, the support plate is
positioned such that when the anti-rotation flange is supported by
the support plate, the base of the improved plastic container is
suspended as the cap is at least partially inserted on the mouth of
the improved plastic container. As such, prior art anti-rotation
wear plates are not required. In one particular design, the support
plate includes a side face that at least partially engages one or
more side surfaces of the anti-rotation flange so as to at least
partially resist rotation of the improved plastic container while
the cap is at least partially inserted on the improved plastic
container.
[0012] The principal object of the present invention is to provide
an improved plastic container that resists deformation and/or
damage during the capping and/or filling of the improved plastic
container with a fluid.
[0013] Another and/or alternative object of the present invention
is to provide an improved plastic container that can be filled with
non-carbonated fluids and/or carbonated fluids.
[0014] Yet another and/or alternative object of the present
invention is to provide an improved plastic container that includes
an anti-rotation flange.
[0015] Still another and/or alternative object of the present
invention is to provide an improved plastic container that can be
used in standard bottling facilities.
[0016] These and other advantages will become apparent to those
skilled in the art upon the reading and following of this
description taken together with the accompanied drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Reference may now be made to the drawings, which illustrate
various embodiments that the invention may take in physical form
and in certain parts and arrangements of parts wherein:
[0018] FIG. 1 is a partial plan view of a bottling machine
employing the rear container guide assembly of the present
invention;
[0019] FIG. 2 is a cross-sectional elevation view taken along line
2-2 of FIG. 1;
[0020] FIG. 3 is a partial plan view of bottle support plate and
guide rail in accordance with the present invention;
[0021] FIG. 4 is a cross-sectional elevation view taken along line
4-4 of FIG. 3;
[0022] FIG. 5 is an exploded perspective view showing the support
plate, the anti-rotation flange of a bottle and the cap for the
bottle;
[0023] FIGS. 6A and 6B are partial plan views of the position of
the anti-rotation flange of a bottle in the support plate;
[0024] FIG. 7 is a partial plan view of the anti-rotation flange of
two bottle being conveyed along a guide rail; and,
[0025] FIGS. 8A-8E are plan views of various non-limiting
configurations of the anti-rotation flange.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Referring now to the drawings wherein the showing is for the
purpose of illustrating preferred embodiments of the invention only
and not for the purpose of limiting the same, FIGS. 1 and 2 show
various portions of what is defined as a bottling machine 10. The
bottling machine as defined herein includes the filling and/or the
capping bottling equipment. The filling equipment is that which
fills containers with product, such as, but not limited to, a
non-carbonated beverage. The capping equipment is that which
applies a cap, crown or other closure to the container.
[0027] Bottling machine 10 includes a rotatable star wheel 20 and a
rear container guide assembly 40 spaced radially outwardly from
rotatable star wheel 20 for retaining the bottles 160 within
rotatable star wheel 20. Depending upon the application of bottling
machine 10, an additional star wheel (not shown) or conveyor (not
shown) is mated to rotatable star wheel 20 at a fixed entry point
(not shown) on rotatable star wheel 20. Bottles 160 are rotated out
of rotatable star wheel 20 at a fixed exit point 42 to an outfeed
star wheel (not shown) or conveyor (not shown) leading to further
processing or handling equipment.
[0028] FIG. 2 illustrates a capping machine having capper head 150
for placing a closure 180 on bottle 160. Rotatable star wheel 20
essentially comprises a hub 22 secured to a vertically extending
drive shaft 24 which rotates about a drive shaft axis 26.
[0029] Extending radially outwardly from hub 22 are a plurality of
bottle support assemblies 30. As shown, each of bottle support
assemblies 30 is mounted on star wheel 20 at a bottle support
station 32. Each of bottle support assemblies 30 is arranged about
the periphery 28 of rotatable star wheel 20, which is generally
circular. Each bottle support assembly 30 is removable from star
wheel 20 through other embodiments, known in the industry.
[0030] Rear container guide 40 includes an annular rear neck guide
44 secured in a stationary manner by bolts 46 to a frame member 48.
Rear neck guide 44 has a top surface 50, a bottom surface 52 and an
inclined edge surface 54 which extends radially outwardly from top
surface 50 to bottom surface 52. An annular neck block 56 is
secured by fasteners 58 to top surface 50 of rear neck guide 44.
Neck block 56 has a top surface 60 which, as shown in FIG. 2, is
adapted to be in contact with the underside 172 of anti-rotation
flange 170 of bottle 160. Neck block 56 also includes an inclined
edge surface 62 extending radially outward from top surface 60.
Fixed rear guide 40 and specifically annular neck block 56
functions to support anti-rotation flange 170 and bottle 160 by
retaining bottle 160 on rotatable star wheel 20.
[0031] Star wheel 20 extends radially outwardly from hub 22 and has
an annular neck portion 34 secured at its inner end to hub 22.
Specifically, a neck portion top surface 36 extends radially
outwardly to a neck portion edge surface 38 which is generally
coaxial with drive shaft axis 26. Neck portion edge surface 38
terminates at a support plate portion 70 having a support plate top
surface 72 which also extends radially outward from hub 22 and is
generally parallel to top surface 36. Support plate top surface 72
extends radially outwardly to a support plate edge surface 74 which
then extends downwardly to a ledge plate portion 76 having a ledge
plate top surface 78 parallel to both of top surfaces 36 and 72.
Top surface 78 extends radially outwardly to periphery 28 of star
wheel 20.
[0032] As shown, star wheel 20 is used on large capacity bottling
machines. This means that periphery 28 is circular and shaft 24 is
fitted with a single hub 22 and star wheel 20 can be used with many
different sizes of bottles run on the same bottling line. Bottle
support assemblies 30 for each size bottle are provided and are
also capable of being removed and replaced for different size
bottle applications. It will be appreciated that for smaller
capacity machines or for different applications within the same
bottling line, a star wheel may instead comprise a hub and star
wheel portion having individual pockets within the star wheel
itself that serve a function similar to bottle support assembly 30.
In such an instance, individual hubs are designed and removable
when it is desired to convert a line to different size bottles. It
will be appreciated that in this instance, star wheel 20 is split
into two halves 20A and 20B to permit installation and repair
without disturbing, for instance, capper head 150 shown
schematically in FIG. 2, and further to allow ease of assembly and
disassembly by reducing the weight of individual pieces. Such
difference in a hub does not affect the present invention.
[0033] Bottle support assemblies 30 comprise three distinct pieces
including a neck support bracket 80, a neck guide 82 and a bottom
body guide 84. Neck support bracket 80 is attached to star wheel 20
with neck guide 82 attached to a top surface 86 of neck support
bracket 80 and bottom body guide 84 attached to guide support 88 of
neck support bracket 80.
[0034] Neck guide 82 includes a vertical standard 90 extending
upwardly from top surface 86 and a bracket 92 extending
perpendicular from vertical standard 90 radially outwardly. Bracket
92 includes a top surface 94, a bottom surface 96 and an inclined
edge surface 98 which extends radially outwardly from top surface
94 to bottom surface 96. The top surface includes four openings
100. Anti-rotation plate or bottle support plate 102 is secured to
top surface 94 of bracket 92 by hex-screws 104 and pins 106.
Anti-rotation plate 102 includes two openings 108 for screws 104
and two openings 110 for pins 106, which are used to secure and
position the anti-rotation plate to bracket 92. One or more
anti-rotation plates can be removed from bracket 92 and replaced by
simply removing the screws. As can be appreciated, other means for
connecting the anti-rotation plate to the bracket in a removable or
non-removable manner can be used (e.g. bolts, nails, clips,
welding, soldering, rivets, adhesive, clamps, and/or the like).
[0035] Referring now to FIGS. 3-5, anti-rotation plate 102 has a
top surface 112 and a bottom surface 114. Each anti-rotation plate
includes a pocket 116 that is adapted to receive anti-rotation
flange 170 of bottle 160. As shown in FIG. 3, the width of the
anti-rotation plate is greater at the end including the pocket than
at the end including openings 108. The narrowing of the
anti-rotation plate at the connection end facilitates connecting
and orienting multiple anti-rotation plates on bracket 92. As can
be appreciated, other configurations of the anti-rotation plate can
be used to facilitate in connecting and orienting multiple
anti-rotation plates on bracket 92.
[0036] The top surface of the anti-rotation plate includes a
recessed region 118 that surrounds pocket 116. The top surface 120
of recessed region 118 generally lies in the same plane as top
surface 112. End wall 122 is generally perpendicular to top
surfaces 112 and 120. As can be appreciated, end wall 122 can be
oriented non-perpendicular to top surface 120. The recessed region
provides clearance for capper head 150 during the capping process.
As can be appreciated, the recessed region can be eliminated from
the anti-rotation plate.
[0037] Pocket 116 includes a support ledge 124 that is adapted to
partially or fully support bottle 160 during the bottling and/or
capping process. As such, deformation and/or damage to the bottle,
such as plastic bottles, during the bottling and/or capping process
in reduced or eliminated. Support ledge includes a top surface 125
generally lies in the same plane as top surface 112. Support ledge
124 is designed to receive underside 172 of anti-rotation flange
170 of bottle 160. The front face 126 of the support ledge is
semi-circular in configuration and encompasses an angle of up to
about 180.degree.. The semi-circular configuration of the front
face is adapted to receive the circular portion of the neck of the
bottle located below the anti-rotation flange. As can be
appreciated, the shape of the front face can be other than
semi-circular. Extending upwardly from the support ledge and to the
top surface of the recessed region is anti-rotation wall 128. The
plane of the anti-rotation wall is generally perpendicular to top
surface 120 and support ledge 124. As can be appreciated, the plane
of the anti-rotation wall can be oriented so as to form an angle of
between about 90-130.degree. between the anti-rotation wall and
support ledge 124. The top portion of the anti-rotation wall can
abruptly converge with top surface 120 of recessed region 118, or
have a smoother transition in the form of a curved surface.
[0038] Anti-rotation wall 128 includes four walls 130, 132, 134,
136 that are generally straight. Walls 132 and 134 have generally
the same length, as do walls 130 and 136. The angle between the
walls is about 140-143.degree.. Such an angle accommodates a
anti-rotation flange on the bottle having seven equally spaced
sides (e.g. heptagon). As can be appreciated, the configuration of
the anti-rotation wall can include more or less walls, and/or the
one or more walls can have a non-straight surface. The
configuration of the anti-rotation wall is selected so as to
inhibit or prevent rotation of the anti-rotation flange of the
bottle during the capping process when the anti-rotation flange is
positioned in pocket 116.
[0039] When the anti-rotation flange of the bottle is positioned in
pocket 116 of the anti-rotation plate, top surface 60 of neck block
56 is positioned at an area diametrically opposed to pocket 116.
Contact with top surface 60 coacts with anti-rotation plate 102 and
functions to maintain bottle 160 within pocket 116 as star wheel 20
rotates. Pocket 116 inhibits or prevents rotation of bottle 160
when a closure 180 is tightened thereon by capper head 150.
[0040] In one particular non-limiting configuration of the pocket
of the anti-rotation plate, the anti-rotation plate is made of
stainless steel (e.g. 304, 316, etc.). As can be appreciated, the
anti-rotation plate can be made of or include other materials.
Typically the anti-rotation plate is electro-polished. The
thickness of the anti-rotation plate is about 0.1875 inch. As can
be appreciated, other thicknesses can be used. Openings 108 have a
diameter of about 0.28 inch and openings 110 have a diameter of
about 0.19 inch. As can be appreciated, other shapes and sizes of
the openings can be used. Recessed region is recessed about 0.016
inch and has a radius of about 1.125 inch. As can be appreciated,
other depths of the recess can be used. Alternatively, it can be
appreciated that the recess can be eliminated from the
anti-rotation plate. The height of anti-rotation wall is about
0.093 inch. As can be appreciated, other heights can be used. The
anti-rotation wall has four walls having an angle of about
141.43.degree. between the walls. As can be appreciated, other
angles can be used and/or other numbers of walls can be used. The
distance of the center of each wall from the center of pocket 116
is about 0.618 inch. As can be appreciated, other distances can be
used. The front face of support ledge 124 has a radius of curvature
of about 0.531 inch. As can be appreciated, other radii of
curvature can be used. As a result, the width of the support ledge
from the center of each wall 130, 132, 134, 136 to front face 126
is about 0.087 inch.
[0041] As shown in FIG. 2, bottom body guide 84 includes a body
guide bottom surface 85 and a body guide upper surface 87. Bottom
body guide 84 is rigidly attached to neck support bracket 80 and
specifically to guide support 88. It will be appreciated that each
bottom body guide 84 can have a retaining pocket (not shown) having
a semi-circular cross section. As such, bottom body guide 84
contacts the sidewall of bottle 160 at an area vertically downward
from pocket 116 of anti-rotation plate 102 and at an area
diametrically opposed to a sidewall contact established by an
annular sidewall rear guide 64 to retain bottle 160 substantially
vertical while star wheel 20 rotates bottles 160 from a fixed entry
point to fixed exit point 42.
[0042] Annular sidewall rear guide 64 has an inner radial surface
65 and an outer surface 66, the radius of each surface 65 and 66
terminating at drive shaft axis 26. Sidewall rear guide 64 includes
an upper surface 67 and a lower surface 68. A through-sleeve
extends between upper surface 67 and lower surface 68 at at least
one location in sidewall rear guide 64. It will be appreciated that
the relative size and relationship of rear guide 64 can remain
generally constant for many size bottles since, for instance, the
diameter of a one-liter, a 12-ounce and a 20-ounce bottle are
generally the same. It will also be appreciated that the that rear
guide 64 can be completely changed out and replaced with a
different size rear guide 64. Suspended from rear neck guide 44 is
at least one vertical post or positioning rod 69. The positioning
rod can include circumferential concave grooves (not shown) spaced
along a length between the lower end and an upper end of the
vertical post. Vertical post 69 is attached to rear neck guide 44
by the hex head bolts 46. Sidewall rear guide 64 can be attached to
vertical post 69 by various means. One such arrangement is
disclosed in U.S. Pat. No. 5,732,528, which is incorporated herein
by reference.
[0043] Referring now to FIGS. 2-8, bottle 160 is in the form of a
non-carbonated beverage bottle. As can be appreciated, bottle 160
can also be used for carbonated beverages. Bottle 160 includes an
upper neck and mouth-forming portion 162, a cylindrical sidewall
portion 184 extending around the longitudinal axis of the
container, and a lower base-forming portion 190. The upper neck and
mouth-forming portion 162 provides a neck-forming transition 164
leading to the container mouth 166. The transition portion 164 can
take any conveniently usable and moldable shape such as, but not
limited to, a frustoconical shape, hemispherical shape, ogive
shape, or some other shape. A thread 168 positioned adjacent mouth
166 is designed to accept a threaded cap 180 commonly used to close
the beverage bottles; however, the mouth-forming portion of the
containers can be provided with means to accommodate other types of
closures.
[0044] The upper neck and mouth-forming portion 162 also includes
an anti-rotation flange positioned above the transition portion
164. The anti-rotation flange includes an underside surface 172 and
a topside surface 174. Underside surface 172 is adapted to be
partially or fully supported in pocket 116 of anti-rotation plate
during the capping process. Underside surface 172 is also adapted
to be partially or fully supported by guide rails 140, 142 when the
bottle is being conveyed to and/or from the bottling and/or capping
apparatus as illustrated in FIG. 7. As shown in FIGS. 1, 3, 5-7,
the anti-rotation flange has seven sides 176 that form a generally
heptagonal shape. The odd number of sides inhibits or prevents the
anti-rotation flange from disengaging from guide rails 140, 142
when the bottle is being conveyed to and/or from the bottling
and/or capping apparatus. The sides of the anti-rotation flange
also enable one or more sides of the anti-rotation flange to
partially or fully mate with the anti-rotation wall in pocket 116
to inhibit or prevent rotation of the bottle during the capping
process. The mating of the one or more sides of the anti-rotation
flange with the anti-rotation wall in pocket 116 is illustrated in
FIGS. 6A and 6B. As shown in FIGS. 6A and 6B, the anti-rotation
flange is positioned in pocket 116 such that the anti-rotation
flange is not ideally oriented in pocket 116. When the bottles are
conveyed to the bottling and/or capping apparatus, the bottles are
oriented in various positions. However, during the bottle's
movement on the star wheel and/or during the capping process, the
bottle will be rotated as shown by the arrows in FIGS. 6A and 6B,
thereby resulting in the anti-rotation flange becoming properly
oriented with respect to the anti-rotation wall in pocket 116, thus
resulting in the inhibiting or preventing of further rotation of
the bottle during the capping process.
[0045] Referring now to FIGS. 8A-8E, several other non-limiting
configurations of the anti-rotation flange can be used on bottle
160 to inhibit or prevent rotation of the bottle during the capping
process and/or inhibit or prevent the anti-rotation flange from
disengaging from the guide rails when the bottle is being conveyed
to and/or from the bottling and/or capping apparatus. As shown in
FIG. 8A, the anti-rotation flange has five generally equal length
sides 176 thereby forming a pentagon. In FIG. 8B, the anti-rotation
flange has nine generally equal length sides 176 thereby forming a
nonagon. As can be appreciated, the anti-rotation flange can be
formed to have less than five generally equal length sides or more
than nine generally equal length sides. When equal length straight
sides are used, the number of sides typically is an odd number. As
can be appreciated, when non-equal length straight sides are used,
the number of sides on the anti-rotation flange can be an odd or
even number. In FIG. 8C, the anti-rotation flange includes eight
notches 178 having an arcuate shape. Although a plurality of
arcuate notches are shown, the anti-rotation flange can include
only one notch 178 or some number other than eight. In FIG. 8D, the
anti-rotation flange includes a twelve V-shaped notches 200.
Although a plurality of V-shaped notches are shown, the
anti-rotation flange can include only one notch 200 or some number
other than twelve. In FIG. 8E, the anti-rotation flange includes a
eight notches 202 that have a substantially straight surface and an
arcuate surface. Although a plurality of notches 202 are shown, the
anti-rotation flange can include only one notch 202 or some number
other than eight. Many other non-circular anti-rotation flanges can
be used that inhibit or prevent rotation of the bottle during the
capping process and/or inhibit or prevent the anti-rotation flange
from disengaging from the guide rails when the bottle is being
conveyed to and/or from the bottling and/or capping apparatus.
These other configurations fall within the scope of this
invention.
[0046] As shown in FIG. 2, lower base-forming portion 190 of
container 160 includes a central portion 192 having a hemispherical
or champagne-type configuration. As can be appreciated, lower
base-forming portion 190 can have other configurations such as
having a plurality of foot-forming portions (not shown) formed
about the central portion for supporting bottle 160.
[0047] The bottle can be formed into a variety of dimensions to
satisfy a particular use. Typically, the bottle is sized for
16-ounce applications, 20-ounce applications, one-quart
applications, one-liter applications, two-quart applications,
two-liter applications, and one-gallon applications. As can be
appreciated, other sized bottles can be used. For instance, a
bottle for containing 20 ounces can have an overall height of about
7-9 inches, for filling within about 1.25-2 inches of the mouth.
When the bottle is a plastic bottle, the upper neck and
mouth-forming portion can be finished with a threaded opening (e.g.
PCO-28 finish). As can be appreciated, a sports top that allows for
easy opening and closing of the mouth can be additionally or
alternatively inserted in the mouth of the bottle. The cylindrical
sidewall of the bottle can have a maximum diameter of about
2.25-3.5 inches. A reduced label panel diameter 193 on the sidewall
can be used as shown in FIG. 2. If such panel diameter is used, the
diameter can be about 2-3.25 inches. Additionally and/or
alternatively, the sidewall can include one or more ribs 194
extending about the central axis of the bottle. A number of other
configurations can be incorporated on the sidewall for structural
and/or aesthetic purposes. The neck-forming transition between the
cylindrical sidewall and the mouth can be an ogive shape extending
downwardly from about 0.5-1.5 inch below the mouth of to blend into
the cylindrical sidewall approximately 2-3.5 inches below the
mouth. The base of the bottle can be substantially flat, convex,
and/or include a plurality of feet or legs. If the bottle is a
plastic bottle that includes feet or legs, such configuration can
be the same or similar to configurations disclosed in U.S. Pat.
Nos. 4,978,015; 5,603,423; and 6,276,546, which are incorporated
herein by reference.
[0048] In another example, a bottle for containing two liters can
have an overall height of about 10-13 inches, for filling within
about 1-2.25 inches of the mouth. The finish of the bottle, when
made of plastic, can be a threaded opening with a PCO-28 finish.
The cylindrical sidewall of the improved bottle can have a maximum
diameter of about 3.5-5 inches. A reduced label panel diameter on
the sidewall can be used. If such panel diameter is used, the
diameter can be about 3.25-4.75 inches. Additionally and/or
alternatively, the sidewall can include one or more ribs extending
about the central axis of the bottle. A number of other
configurations can be incorporated on the sidewall for structural
and/or aesthetic purposes. The neck-forming transition between the
cylindrical sidewall and the mouth can be an ogive shape extending
downwardly from about 0.5-1.5 inch below the mouth to blend into
the cylindrical sidewall approximately 3-5 inches below the mouth.
The base of the bottle can be substantially flat, convex, and/or
include a plurality of feet or legs. If the improved plastic
container includes feet or legs, such configuration can be the same
or similar to configurations disclosed above.
[0049] Bottle 160 can be formed by a number of standard techniques.
Typically, when the bottle is formed of plastic, the bottle is
formed from PET; however, other plastics can be used. Generally,
the processing of the plastic bottle involves the injection molding
of PET into what is commonly referred to as a "preform" and then
blow-molding such preform into the improved plastic container. PET
is a polymer with a combination of properties that are desirable
for the packaging of carbonated and non-carbonated beverages
including toughness, clarity, creep resistance, strength, and a
high gas barrier. Furthermore, because PET is a thermoplastic, it
can be recycled by the application of heat. Solid PET exists in
three basic forms, namely amorphous, crystalline, and biaxially
oriented. PET in the amorphous state is clear and colorless and is
only moderately strong and tough. This is the state that preforms
are in upon being injection molded. Crystalline PET is formed when
molten PET is cooled slowly to below about 80.degree. C. In the
crystalline state, PET appears opaque, milky-white and is brittle.
Oriented PET is formed by mechanically stretching amorphous PET at
above about 80.degree. C. and then cooling the material. Biaxially
oriented PET is usually very strong, clear, tough, and has good gas
barrier properties. Therefore, in the design of plastic containers
made of PET, it is desirable to obtain as much biaxial orientation
as is possible. Various types of PET material can be used in the
manufacture of the improved plastic container. Typical values of
intrinsic viscosity for PET bottle manufacture are in the range of
about 0.65 to 0.85.
[0050] The bottle, when formed of plastic, can be formed by a
conventional injection-molded preform. As known in the art, various
configurations of preforms for a desired plastic bottle can be used
to make various plastic bottle designs. The use of a particular
preform with a particular plastic bottle design is a matter of
design and the selection criteria. It may be advantageous to alter
the design of the preform to optimize the final plastic bottle
design. For instance, it may be advantageous to taper the bottom of
the preform to allow better orientation and distribution of
material. As can be appreciated, other alterations can be used. The
improved plastic container can be formed by a conventional stretch
blow-molding process. In such a process, biaxial orientation is
introduced into the PET by producing stretch along both the length
of the improved plastic container and the circumference of the
improved plastic container. In stretch blow-molding, a stretch rod
is utilized to elongate the preform, and air or other gas pressure
is used to radially stretch the preform, both of which happen
essentially simultaneously. Prior to blow-molding, the preforms are
preheated to the correct temperature, generally about 100.degree.
C., but this temperature can vary depending upon the particular PET
material used. Once the PET preform is at the desired temperature,
it is typically secured by its neck in a mold which has a cavity of
the desired plastic container shape. A stretch rod is introduced
into the mouth of the improved plastic container to distribute the
material the length of the improved plastic container.
Simultaneously, air can be blown into the improved plastic
container from around the stretch rod to distribute the material
radially to give the radial or hoop orientation. Air pressure
pushes the improved plastic container walls against the mold, which
is generally cooled, causing the PET to cool. After sufficient
cooling has taken place, to avoid plastic bottle shrinkage, the
mold is opened and the improved plastic container is
discharged.
[0051] The invention can thus provide durable bottle for carbonated
and non-carbonated beverages. When the bottle is formed of plastic,
the plastic bottle can be formed at a low cost and low weight
manufacturable from plastic material by molding with minimal
plastic material, with maximal volumes with minimal heights in
easily handled diameters, with maximal height cylindrical sidewall
portions, with excellent stability in both filled and unfilled
conditions.
[0052] The present invention has been described with reference to a
number of different embodiments. It is to be understood that the
invention is not limited to the exact details of construction,
operation, exact materials or embodiments shown and described, as
obvious modifications and equivalents will be apparent to one
skilled in the art. It is believed that many modifications and
alterations to the embodiments disclosed will readily suggest
themselves to those skilled in the art upon reading and
understanding the detailed description of the invention. It is
intended to include all such modifications and alterations insofar
as they come within the scope of the present invention.
* * * * *