Note: Descriptions are shown in the official language in which they were submitted.
- CA 0222~890 1997-12-29
C6453
BOTTLE
Backqround of the Invention
One popular form of laundry detergent is the heavy duty
laundry liquid. Its popularity is due in part to the
convenience of the product form, in particular the ability
to apply the detergent readily to soiled areas of the
clothes. The popularity of laundry liquids has created a
need for more convenient containers for dispensing these
products. Thus, bottles having measuring cups serving as
closures, and fitments incorporating drainage mechanisms and
pouring spouts have appeared on the market.
One type of container is exemplified by that of Barker U.S.
Patent No. 4,550,862 wherein a bottle includes a fitment
having a spout and a structure permitting the product to
drain back into the container. The fitment has internal
threads at its upper aspects which mate with external
threads surrounding the mouth of a bottle closure. The
threads at the mouth of the closure mate with their
counterparts at the upper aspects of the fitment, the cup
does not extend very far into the fitment, and the drainback
region of the fitment can be shallow.
Other containers have been developed using a different
approach. The container disclosed in Davidson et al. U.S.
Patent No. 5,108,009 comprises a spout- and drainback-
including fitment which snaps into the mouth of the bottle.
The closure has internal threads situated within a flange
which surrounds the measuring cup portion of the closure.
The internal threads of the closure mate with external
threads surrounding the neck opening.
CA 0222~890 1997-12-29
C6453
While consumers appreciate the benefits of modern liquid
detergent containers having measuring closures and drainback
fitments, these sophisticated packages are not without their
cost. Many of these containers include three separate
parts, a body, a fitment and a closure. These components
are typically made of plastic and each requires a certain
amount of plastic to perform its structural function.
The amount of plastic material used in making liquid
detergent containers, also should be considered from an
environmental standpoint. It would be desirable to minimize
the amount of such materials so that in those cases where
the package is not recycled a smaller amount of plastic
material reaches the landfill or other disposal area. Also
it is desirable to develop a structure which can utilize a
significant amount of recycled material.
Plysu of Great Britain sells and illustrates in a brochure
ultra light weight bottles under the name Paklite. Its 5
20 liter bottle weights 90 grams (0. 53 g per fluid oz.). The
bottles have a handle, eight panels, include vertical
grooves extending most of the height of the panel at eight
corners and have waffles in the bottom. Plysu also holds
British registered design 2033440 which illustrates their
bottle.
Robbins US Patent No. 4,890,757 discloses an enclosure
having self supporting side walls formed of a plurality of
spaced ribs with non self supporting thin webs therebetween.
Chochran US Patent NO. 4,949,801 discloses a thin wall blow
molded plastic container including a body, a neck support
member 20 and lateral support members 18.
CA 0222~890 l997-l2-29
C6453
NL 9201806 discloses a bottle having a handle, a reinforcing
profiled bottom, and a reinforcing groove ( 14).
GB 2164914 iS directed to a bottle provided with a handle
and a bottom having waffle-like grooves.
German Gebrauchsmuster 9212023 iS directed to a thin walled
bottle having an octagonal shape, a handle and grooves.
0 DE 31 39 083 discloses a bottle having a handle and provided
with various reinforcing grooves.
German Gebrauchsmuster 29503460 discloses a bottle having
grooves running around the top, body and bottom of the
bottle.
EP 624 137 iS directed to a thin walled bottle having side
walls textured to 0. 05 to 0.15 mm. US 5,522,519 appears to
be an equivalent.
GB 2 042 408 discloses a bottle of saturated polyester resin
having an opaque and matt surface.
EP 322 651 iS directed to a bottle having reinforcing
vertically extending ribs (76).
EP 198 587 iS directed to a bottle having various
reinforcing grooves.
Kalkanis US Patent No. 5,469,984 discloses a thermoplastic
container having an anti-bulging base with a flat ring-
shaped section and a central dome-shaped section.
It is known to adhere a bottle label to the bottle in the
mold.
CA 0222~890 l997-l2-29
C6453
Jabarin US Patent No. 4, 567,069 discloses blow molded
polymeric containers said to have good physical properties
and good resistance to envirnomental stress cracking.
The walls and bottom of the container are fabricated from a
multilayer polymeric material. A thin inner wall is
fabricated from a linear low density ethylene polymer. The
thicker outer wall is fabricated from a linear high density
ethylene polymer. The material will generally contain two
layers, but for special applications three or more may be
used. The linear high density ethylene polymers will have a
density of at least about 0.94 gm/ml, preferably at least
0.95 and more especially at least about 0.96 as containers
prepared from such resins are said to have greater
stiffness. It is said that somewhat thinner containers can
be employed with no loss of stiffness.
Strassheimer US Patent No. 4, 785,948 illustrates a container
with a hexagonal section. The patent is directed to bottles
with thickened portions extending completely
circumferentially around the periphery.
Yoshino US 5,080,244 discloses a synthetic resin thin walled
bottle having ribs at least at its bottom portion.
Jakobsen US 4,359,165 discloses a reinforced thermoplastic
container having internal reinforcing ribs.
Yoshino US 4,620,639 discloses synthetic resin, thin walled
bottles having ribs at least at the bottom. Ribs extending
the full axial length of the barrel portion, whereby
buckling strength is said greatly to be increased, are
disclosed in Fig. 6.
CA 0222~890 l997-l2-29
6453
Evers US 3,029,963 discloses a bottle with vertically
extending ribs.
LaFleur US 5,224,623 discloses a fast food container
reinforced by ribs which wrap around the container side
walls.
Other containers are illustrated in Rogler et al.
US Des. 353,541, Ring US Des. 351,347, Ring US Des. 348,612,
Darr et al. US Des. 332,747, Jacobs US Des. 300,005, Visser
US Des. 272,318, Platte US Des. 265,797, Kaplan US
Des. 192,886, Price US Des 195,697, Lyons US Des. 286,379,
Gonda US Des. 305,407, Chambers US Des. 306,410, Davis
US Des. 311,864, Carmine US Des. 312,964,
Fiore et al. US Des. 321,624, Beechuk et al. US Des.
326,052, Baird et al. US 4,846,359, Krall et al.
US 5,232,107, Mallin US 3,385,461 and WO 94/25350.
Summary of the Invention
The present invention is directed to improved packages for
dispensing liquid household products such as liquid
detergents and liquid fabric softeners. The packages are in
the form of a bottle having a drainback fitment.
Advantageously, the bottle is lightweight, thereby
conserving valuable resources and minimizing waste, but at
the same time is functional as a heavy duty liquid detergent
dispenser. In its various embodiments, the octagonal shape,
ribs or grooves and fitment are combined with other features
to form a lightweight bottle suitable for use as a heavy
duty liquid detergent container or as a container for fabric
softener. light duty (eg hand dishwashing) liquids, and
gelled and liquid automatic dishwashing detergents.
CA 0222~890 1997-12-29
C6453
In a first embodiment, the package comprises a finish, a
pour spout having a bottom wall with a product drainage
aperture, a downwardly extending body having from 6-10
axially extending side panels, and grooves or ribs on at
least 50% of the corners where the side panels intersect.
The grooves or ribs extend axially at least 60% of the
distance along the intersection. An optional tapered base
panel extends from the side panels to the bottle base.
The second embodiment is directed to the discovery that the
package is improved by increasing the diameter of the
finish. When a top load is applied the force is more evenly
distributed to the side walls of the mouth. In this second
embodiment, the package comprises a finish having a large
diameter neck, a pour spout having a bottom wall with a
product drainage aperture, a downwardly extending body
having from 6-10 axially extending side panels, and
grooves or ribs on at least 50% of the corners where the
side panels intersect. The grooves or ribs extend axially
at least 60% of the distance along the intersection. An
optional tapered base panel extends from the side panels to
the bottle base. The neck external diameter ranges from
about 50 to about 88 mm, especially from 51 to 77 mm.
In a third embodiment, features of the invention are
combined with an in-mold label. When combined with the
other lightweight features of the third embodiment, a
particularly advantageous lightweight bottle results. Thus,
in the third embodiment, the package comprises a finish, a
pour spout having a bottom wall with a product drainage
aperture, a downwardly extending body having from 6-10
axially extending side panels, grooves or ribs on at least
50% of the corners where the side panels intersect, and an
in-mold label. The grooves or ribs extend axially at least
60% of the distance along the intersection. As in the other
CA 0222~890 1997-12-29
C6453
embodiments, an optional tapered base panel extends from the
side panels to the bottle base.
In the fourth embodiment, the lightweight features of the
invention are advantageously employed in combination with an
off centered neck. Pouring of product from the container is
believed to be faciliated in the present combination of
light weight and off-centered neck. Therefore, the fourth
embodiment includes an off-centered finish, a pour spout
having a bottom wall with a product drainage aperture, a
downwardly extending body having from 6-10 axially extending
side panels, and grooves or ribs on at least 50% of the
corners where the side panels intersect. The grooves or
ribs extend axially at least 60% of the distance along the
intersection. An optional tapered base panel extends from
the side panels to the bottle base.
The lighter weight of the body of the bottle and the finish
make the bottle less expensive and more sparing of valuable
resources. Moreover, less plastic material needs to be
recycled or disposed of in the landfill or otherwise.
Bottles according to the invention preferably weigh
approximately 20-50% less than bottles traditionally used to
contain heavy duty liquids. Preferably the bottle of the
invention (excluding the fitment and closure) weighs less
than 1.2 gram per fluid oz of capacity. Especially
preferred is that the bottle weigh between 1 gram and 0.5
grams per fluid oz.
The bottles of the various embodiments of the invention may
also include an optional handle or other integral gripping
feature.
The invention is further directed to the discovery of a
lightweight bottle suitable for containing heavy duty
CA 0222~890 1997-12-29
C6453
- 8 -
detergents fabricated with certain resins. Especially
preferred is the combination of the above features in a
bottle fabricated from certain resins. Particularly
preferred is a bottle combining one or more of the above
emodiments with a resin structure having one or more of the
following: an outer layer comprised of a high density resin,
an inner stress crack resistant (ESCR) layer, and a layer,
preferably a middle layer, employing at least 25% recycled
resin.
Still more preferred are bottles combining most of the
features of the individual embodiments recited above.
For a more complete understanding of the above and other
features and advantages of the invention, reference should
be made to the following detailed description of preferred
embodiments and to the accompanying drawings.
Brief DescriDtion of the Drawin~s
Figure 1 is a perspective view of a container of the
invention with the closure fastened.
Figure 2 is a section along the lines 2-2 of Figure 1.
Figure 3 is a section along the lines 3-3 of Figure 2.
Figure 4 is a section along the lines 4-4 of Figure 2.
Figure 5 is a bottom plan view along the lines 5-5 of
Figure 2.
Figure 6 is a section along the lines 6-6 of Figure 5.
Figure 7 is a section along the lines 7-7 of Figure 5.
Figure 8 is a perspective view similar to Fig. 1 of a
container of the invention having an in-mold label.
CA 0222~890 l997-l2-29
C6453
Detailed Descri~tion of the Invention
Referring now particularly to Figures 1 and 2, there is
shown a container 2 including a bottle 6 having an integral
handle 8 and a neck 10. The container 2 also includes a
drainback fitment 14. Fastened to the top of the container
2, as viewed in Figure 1, there is a closure or cap 12. A
of the foregoing components are preferably molded from a
resilient flexible plastic material. The materials may be
selected so that the plastic from which the drainback
fitment 14 is molded is softer than the materials from which
the bottle 6 and closure 12 are formed. Alternatively, the
drainback fitment may be made of a material of comparable
hardness to that of which the closure is made, e.g.,
polypropylene or HDPE.
The drainback fitment has an outer, frustoconical wall
portion 16 which gradually tapers downwardly and inwardly
and is received within the neck 10 of the bottle 6. The
wall portion 16 terminates at its upper end in an annular
rim 19. Rim 19 is generally flat.
The surface of the rim turns downwardly and inwardly to form
the outer wall 24 of a circumferential well 26 surrounding a
generally frustoconical, eccentrically positioned (off-
center) spout 36, the lower periphery of which forms the
inner wall 28 of the circumferential well 26. Between the
outer wall 24 and inner wall 28 of the circumferential well
26 there is a sloping floor 30. The outer surface of wall
16 optionally includes a retaining ring which is spaced from
and generally concentric with rim 19. Wall 16 may include a
product exit aperture (or drain port) located above and
spaced from the product drainage aperture 32. The basic
features of the fitment, bottle finish and closure are as
3 5 shown in Fig. 9 of Davidson et al. U.S. Patent No.
CA 0222~890 l997-l2-29
6453
- 10 -
5,108,009, the disclosure of which patent is hereby
incorporated by reference herein. An appropriate product
drainage aperture is illustrated in more detail in Fig. 3 of
Davidson et al.
The product drainage aperture or notch 32 preferably
comprises a substantially rectangular notch formed in the
lowest and widest portion of the floor 30 and is desirably
in alignment with a longitudinal slot 34 which extends from
the top of the rear of the spout. While the longitudinal
slot may extend to the notch 32 and merge therewith (as
shown in Figure 2), of the invention, if desired, the slot
may extend only approximately halfway down the length of the
spout.
The spout may include projections to keep the fitments
separated during stacking. Such projections may also serve
to prevent rotation of the spouts during stacking when
combined with lugs (not shown) depending from the bottom of
the fitment and situated so that they block radial movement
of the stacking projections on the next lower fitment when
the fitments are stacked.
Notch 32 and longitudinal slot 34 provide a path for
residual liquid remaining on the spout 36 or closure 12 to
drain back into the bottle 6 either directly or via the
downwardly sloping floor 30 of the circumferential well 26
under the force of gravity when the container 2 is in an
upright position.
Fitment 14 is secured to bottle finish 68 by a friction fit.
Bottle finish 68 includes an annular mouth 70, and a locking
ridge 72. The finish includes threads 74. The fitment is
inserted into the bottle by forcing it through the opening
at the bottle môuth and pu~hing it until annular rim 19 of
CA 0222~890 1997-12-29
C6453
the fitment is situated upon or above locking ridge 72. If
rim 19 is above locking ridge 72, preferably it is
immediately above. In this position, the distal end of the
annular rim will be adjacent to bottle mouth 70.
Optionally, a retaining ring of the fitment helps to retain
the fitment in position by abutting the lower aspects of
locking ridge 72.
If desired, the spout 36 may be provided with an anti-drip
lip. Also, it may be desirable to provide the spout with a
V-shaped pouring angle for improved control of pouring of
the product.
The drainback fitment 14 may be formed from a thermoplastic
such as high density polyethylene. Or it may be made of a
polyethylene which is a product of a 50:50 blend of a high
density resin and a low density resin. The high density
resin can be U.S.I. LS 506 or a similar resin. The low
density resin can be U.S.I. LS 208 or the like. Instead of
a mix of resins, a low density polyethylene such U.S.I. 241
or even a harder material such as polypropylene may be used
to form the fitment. Other plastic resins having chemical
and physical properties similar to the aforementioned resins
can be used in fabricating the drainback fitment 14.
Preferably, the container of the invention provides the
spout and drainback area in the form of the above described
fitment, separate from the body of the bottle. In the
described preferred embodiment, the fitment snaps into the
container finish so that a friction fit is obtained between
the outer wall of the fitment and a locking ridge on the
inside of the container finish. A fitment may also be
provided in other ways, eg it may be applied by spin
welding, or by hot melt adhesive or by the EMABOND system.
CA 0222~890 1997-12-29
C6453
- 12 -
An internally threaded finish may be combined with an
externally threaded closure.
The EMABOND system employs a thermoplastic gasket
impregnated with metal particles. When the gasket is in
position (between a sealing area ridge of the fitment and
inside bottle neck ledge), a sealing unit with an
electro-magnetic force presses down on the fitment and heats
up the metal particles, thereby melting the plastic gasket,
and the compression welds the two components together with a
leak-proof seal.
Although the fitment would normally be a separate piece, it
may also be formed integral to the bottle. A threaded
collar could then be spin welded onto the exterior of the
bottle to mate with the threads of the closure.
It is also contemplated that some of the embodiments may be
in the form of refill bottles which contain a plain screw
cap and no spout but which are capable of receiving a
transferable spout and self draining closure.
The closure 12 has a closed end 38 at its top which is
merged at its circumference with a downwardly extending
inner circumferential wall 46 having a surface onto which
there are integrally molded gripping teeth 42 biased to
present greater friction to the hand when the closure 12 is
rotated counterclockwise to loosen it than when it is
rotated clockwise for tightening. Alternatively, other
gripping means, such as vertical ribbings may be employed.
The inner circumferential wall 46 is concentric with and
spaced from an outer circumferential wall 40. Inner
circumferential wall 46 extends downwardly beyond the length
of the outer circumferential wall 40. The inner
CA 0222~890 1997-12-29
C6453
circumferential wall 46 and the undersurface of the closed
end 38 form a cup for measuring the contents of the
container 2 as it is poured from the bottle 6. A fill line
can be molded into the inner circumference of the inner wall
if desired. Closely spaced internal vertical ribs can be
used to make the fill line eaier to see.
The outer circumferential wall 40 and inner circumferential
wall 46 are connected by a web 48 so that a downwardly
facing (when the closure 12 is fastened to the bottle 6)
channel is defined between the inner circumferential wall 46
and the outer circumferential wall 40. The channel is
optionally lined with a liner preferably made of a
resilient, polymeric material. However, it is preferred
that the channel be linerless. The channel in cooperation
with the frustoconical wall portion 16 and optional liner
serves as a trap for preventing residual contents of the
container 2 from migrating to the junction of the closure 12
and neck 10 of the bottle 6. If desired the liner may be
omitted.
Complimentary fastener means in the form of threads are
provided on the closure 12 and neck 10 of the bottle 6 at
their juncture. The closure 12 has internal threads 50
which mate with external threads 74 on the finish 68 of the
bottle. As the closure 12 is threaded onto the neck 10 of
the bottle 6, the liner, if present, engages the mouth 70 of
the bottle 6 thereby sealing the bottle to prevent leakage
of the contents from the container. When the liner is
omitted, the top of the channel seals against the mouth 70
of the bottle. The presence of the fitment rim below the
top of the finish permits the closure (or the liner of the
closure) to form a seal at one point at the top of the
finish. If the fitment rim extended over the top of the
fitment there would be two areas for liquid product to
CA 0222~890 l997-l2-29
C6453
- 14 -
escape through the seal, above and below the rim of the
fitment.
The inside of the land of the bottle may be beveled to
assist in sealing. The bevel imparts to the top of the
mouth a sharp point from which the inner wall of the mouth
slants inwardly. The outer wall of the mouth is disposed
generally vertically. Whether the closure is on or off, the
friction fit of fitment 14 against locking ridge 72 within
the bottle finish 68 prevents escape of the product except
through the spout, the drainage aperture or the product exit
aperture. When the closure is screwed closed, product which
has exited bottle 6 through the spout, drainage aperture or
product exit aperture is contained within container 2 by the
closure.
As is apparent from Figure 2, except for the spout, fitment
14 is wholly contained within the bottle 6. The entire
outer wall 16 is situated below the mouth 70 of this bottle.
Although the fitment herein has been described as having a
single product exit aperture, a plurality of apertures may
be utilized.
In addition to serving to permit use of the last portion of
the product, the product drainage aperture also serves as a
vent hole as well. As such, it permits air to enter the
container as product leaves through the spout.
The product exit aperture may assume any shape and size
suitable for permitting exit of at least a portion of the
last fraction of product trapped between the outside of the
fitment and the wall of the bottle, e.g. triangular,
rectangular or square, or may take the form of a slit.
Preferably, the exit aperture is of a size and shape
CA 0222~890 1997-12-29
C6453
- 15 -
suitable for venting, as well. The product exit aperture is
located high enough in the fitment wall such that at least a
portion of liquid trapped when the bottle is turned upside
down can escape. The product exit aperture is described
herein as being positioned approximately halfway down the
wall of the fitment, although it may be located one quarter
of the way down or three quarters of the way down or
elsewhere, depending on the dimensions of the container.
While certain features such as the annular rim and the
retaining ring have been illustrated and/or described as
extending 360 degrees around the circumference of the
fitment, it will be apparent that such will not always be
necessary in order that their functions be fulfilled in
accordance with the invention. For instance, the annular
rim may be replaced by other stopping means and the
retaining rim may be replaced by other retaining means.
Stopping means refers to the annular rim and equivalent
structures even in fitments and containers wherein the
friction fit between the fitment wall 16 and the locking
ridge 72 is sufficient to prevent the entire fitment from
being pushed through and into the bottle.
The closure may be formed of a harder material than that
used in the drainback fitment 14. In the preferred
embodiment of the invention, the plastic material from which
the closure 12 is molded is a homopolymer or copolymer
polypropylene such as that sold by Phillips Petroleum
Company under the designation Phillips HLV 120-01.
The bottle 6 also may be formed of a material that is harder
than the material employed in the drainback fitment 14.
Alternately, the fitment may be formed of a harder material,
as where the fitment is fabricated from polypropylene.
Materials from which the bottle may be fabricated include
CA 0222~890 1997-12-29
C6453
- 16 -
high density polyethylene. Or, another resin sold by U.S.I.
under the designation .955 density, OI-388-2, is a suitable
material. Other materials exhibiting similar chemical and
physical properties can be substituted. Preferably, however
in accordance with certain embodiments of the invention, the
bottle is made from multiple layers.
The bottle of the invention preferably is made of at least
one resin layer, especially the inner layer, which
possesses a good stress crack resistance, as determined
according to ASTM D-1693-95. That is, the layer preferably
has at least 75 hours, and more preferably at least 100
hours, most preferably at least 300 hours stress crack
resistance under that test. Good stress crack resistance is
promoted by the selection of resins having an appropriate
distribution of chain lengths, especially distributions
favoring long chain lengths. Stress crack resistance is
important to the ability of the package to contain
effectively its contents for prolonged periods of time on
the shelf or in the consumer's cupboard. Polymer layers
which have a lower MI (lower melt index) promote stress
crack resistance, since they tend to have longer molecular
chain lengths, and impact resistance, as well.
Preferably, the container also possesses a good drop
strength resistance so that a water filled bottle will
survive at least one 3-foot drop onto its base. The drop
strength can be important to assure that the container can
withstand the travails of packing, shipment, and use and
storage by the consumer.
ASTM D1693-95 ESCR test results are believed to be good
indications of whether a resin has good stress crack
resistance. Resins which are understood to have good ASTM
D1693-95 ESCR test results and which are therefore good
CA 0222~890 1997-12-29
C6453
- 17 -
candidates for the high ESCR layers of the invention
include:
Paxon AC 45-004 (0.945 density); Marlex D252 (0.923
density) (Resin is called "low density, linear polyethylene
on data sheet); Chevron 9503 (0.946 density); Chevron 9346
(0.9455 density) (pipe resin); Exact 3035 (MPE) (0.900
density, melt index of 3.5 dg/min (0.35)); Phillips D252
LLDPE (25% LLDPE/75% HDPE) (density 0.923; melt index 0.25).
Exact 3035 is obtainable from Exxon.
The high stress crack resistant layer may be pigmented or
non-pigmented.
It is further preferred that the density of the outer layer
be higher, eg from 0.948 to 0.964. The optional middle
layer may also be high density. The selection of a resin,
such as a high density polyethylene having a density in the
higher ranges (eg, 0.945 to 0.964 and above) will assist in
making the container more resistant to top load pressure.
Examples of materials which may be used include Paxon AU55-
003, a medium molecular weight distribution high density
polyethylene copolymer available from Paxon Polymer Company
of Baton Rouge, LA, and Paxon AC45-004, a high density
polyethylene copolymer available from Paxon Polymer Company.
Either of the above may advantageously be used in
conjunction with a percentage, say 25% of a recycled resin,
i.e., a post-consumer recycled resin (PCR) such as a high
density polyethylene bottle scrap. More preferred are the
above materials used in conjunction with an inner layer of a
blend such as linear low density polyethylene (LLDPE) and
high density polyethylene (HDPE) at about 25%/75%.
Preferably, the container comprises panels having a
multilayer structure including i) an outer higher density
CA 0222~890 1997-12-29
C6453
- 18 -
material, ii) an optional middle layer comprising a minimum
of 25% recycled resin, and iii) an inner, lower density,
lower MI layer. It is especially preferred that the
features of the individual or combined embodiments of the
invention be present in a bottle fabricated from a
multilayer structure including i) a high stress crack
resistant virgin inner layer, ii) an optional second layer
comprising a minimum of 25% recycled resin, and iii) a
virgin resin outer layer. In accordance with another a
still further aspect of the invention, the bottle is made
from i) an outer higher density material, ii) an optional
middle layer comprising a minimum of 25% recycled resin,
and iii) an inner, lower density, lower MI layer.
Recycled resin is preferably HDPE from used milk or water
bottles and possibly used detergent bottles of about the
same color.
Other advantageous combinations of multiple layers are
possible, including I) i) an outer higher density material,
ii) an optional middle layer which may include 25% or more
recycled resin, and iii) an inner layer selected from the
group consisting of a) high ESCR, virgin resin, b) a blend
including recycled or virgin LLDPE, c) a metallocene
polyethylene (MPE), or d) an MPE/HDPE blend. II.) high
ESCR inner and outer layers, III.) high ESCR inner layer
and outer layers and a foamed inner layer and, IV.) high
ESCR inner and outer layers/rigid resin in outer and/or
middle layer. Ranges of thicknesses preferred in a
multilayer material would be 10-20% outer, 20-80% middle and
10-20% inner. A useful arrangement (percentage thickness)
of layers would be 10% outer layer, 80% middle layer and 10%
inner layer. Thickness may be measured in millimeters or
mils (thousandths of an inch). Other advantageous resins
include (low density linear polyethylene) LDLPE or a blend
of LDLPE and HDPE.
CA 0222~890 1997-12-29
C6453
- 19 -
Preferred multilayer structures also include a) lower
density, high ESCR resins in the inner layer or with b) an
inner layer blend of 75% high ESCR/HDPE with 25% LLDPE.
Containers made with such multilayers have been found to
have advantageous impact resistance and stress crack
resistance characteristics, especially when compared to
typical, current household bottles which use the same resin
for all 3 layers, not including the PCR content.
Especially preferred multilayer structures for the bottles
comprise l) outside layer (20%): Chevron polyethylene 9402;
middle layer (70%): Chevron virgin 9402 PCR polyethylene
homopolymer (employs recyled PE); inner layer (10%): Chevron
9301 polyethylene; or 2) outside layer (20%): Chevron
polyethylene 9503 (20%); middle layer (70%): Chevron virgin
9402 PCR polyethylene homopolymer (employs recyled PE);
inner layer (10%): Chevron 9301 polyethylene.
While trilayer structures (5-30% outer/60-90% middle/5-30%
inner layers, particularly 10-20% outer/70-80% middle/10-20%
inner layers) will generally be preferred, bilayer or
monolayer structures may also be used. While it will
generally be preferred that inner and outer layers be virgin
(ie not recycled, resin), the inner layer may include some
recycled resin. Where the inner layer includes recycled
resin, one candidate will be blends containing LLDPE from
recycled pallet stretch film. Other good candidates for the
inner layer include LLDPE and LLDPE/HDPE blends,
metallocene polyethylene (MPE) (e.g., Exxon's Exact) and
MPE/HDPE blends. It will generally be preferred that middle
layer include at least 25% PCR. A foamed HDPE middle layer
may also be used. Other advantageous resins include (low
density linear polyethylene) LDLPE or a blend of LDLPE and
HDPE.
CA 0222~890 1997-12-29
C6453
- 20 -
In accordance with the invention, the finished end or body
of the bottle is lightweighted. That is, the finished end
or body is made of a material which is lighter in weight
than standard materials from which heavy duty liquid
detergent bottles are made. This permits less material to
be used and results in less material to be disposed of after
the contents of the bottle have been consumed.
Despite the lightweight of the bottle, body and finish, the
bottle enjoys good stress-crack resistance and preferably
also, dent resistance and drop strength and compressive
strength. Numerous features are believed to contribute to
the structural strength of the body despite its lightweight.
On the front and sides of the bottle, finish 10 of the body
of the bottle leads to downwardly sloping shoulder 11. To
the rear of the bottle, integral handle 8 extends backwardly
and then downwardly. Wall 9 extends almost vertically from
the finish behind and to the sides of the handle. Generally
horizontal shoulder 13 is formed as a continuation of wall 9
in front of, and on either side of, the handle.
Extending downwardly from shoulder 11 are medial front panel
230, first and second lateral front panels 232 and 234, and
first and second side panels 236 and 238. Portions of side
panels 236 and 238 also extend from wall 9 and from
horizontal shoulder 13. Extending downwardly from shoulder
13 are first and second lateral rear panels 240 and 242.
Medial rear panel 244 also extends downwardly from shoulder
13, and in addition, from the bottom of handle 8.
Below panels 230, 232, 234, 236, 238, 240, 242 and 244
is an optional bottom wall 250, which slants inwardly from
each of the panels. Bottom wall 250 leads to base 260
(See, especially Figs. 5-7), which comprises a peripheral
CA 0222~890 l997-l2-29
C6453
ring 262 and an interior recessed area 264 within the ring.
Interior recessed area 264 iS divided in half by external
rib 270 which projects outwardly from the surface of area
264. Within recessed area 264 iS a waffle pattern, which
may be in the form of a series of debossments 214 formed in
the bottom panel 216 of the bottle. Alternatively, if
desired, a series of embossments rather than debossments
with respect to the bottom panel may be used. The
embossments or debossments may be in the form of rectangles
as shown in Fig. 5 or may assume another shape.
The described patterns of embossments or debossments provide
enhanced structural strength, particularly for impact
resistance.
As best seen from Figs. 1, 4 and 5, the body of the bottle
has an octagonal cross section formed by panels 230, 232,
234, 236, 238, 240, 242 and 244. At each of the corners
formed by intersection of the panels with each other, a
vertically extending groove 210 is formed in the outer wall
of the bottle. Alternatively, a rib (extending outwardly
with respect to the outer surface of the container as
opposed to the inwardly extending groove) may be employed
in place of the groove. The grooves or ribs disposed at the
panel intersections, in conjunction with the generally
octagonal cross section and the highlight groove, are
believed to increase the rupture resistance of
the bottle. The octagonal shape itself is believed to
contribute importantly to compressive or top load strength.
In addition to vertical grooves 210 at the bottle corners,
optional horizontal grooves 212 and optional vertical
grooves 211 (not disposed at panel intersections), which
connect with some of the horizontal grooves may contribute
to the integrity of the bottle, particularly impact
CA 0222~890 l997-l2-29
C6453
resistance. As seen in part in Fig. 1, these grooves which
also "highlight" certain features of the bottle, extend
horizontally from the base of the handle, across the top of
the rear panel, a corner panel, a portion of the side panel
238, and then upward along the top of the side panel, along
the top of another corner panel, the front panel, a portion
of the second side panel, then downwardly along the top of
the second side panel, along the top of the next corner
panel and then back along the top of the rear panel to
return to the base of the handle. Again, ribs may be used
instead of grooves here, as well. If desired, the bottle
may be stippled, particularly above grooves 212 and 211, as
illustrated in British registered design 2033440.
Another noteworthy advantage comes from the combination of
the lightweight bottles and plastic in-mold labels (IML).
In-mold label 310 on bottle is shown in Fig. 8. Even with
their light weights they did not fail laboratory drop and
ESCR tests. Current bottles at light weights normally fail
at the edge of the labels, which creates an area of stress
in the bottle front/back panels. By "in-mold label" it is
meant that the label is placed in the mold halves before the
mold halves are clamped around the parison and the bottle is
blown against the mold walls. This takes the place of
affixing the label to the bottle after molding.
While this embodiment pertains to the use of an in-mold
label, it will be apparent that other embodiments may also
include this feature. Alternatively, other embodiments may
include a conventional adhesive applied label or, indeed, no
label.
The structure of the bottle of the invention permits use of
lighter weight materials than would otherwise be possible.
For instance, an empty 128 fluid oz heavy duty liquid
CA 0222~890 1997-12-29
C6453
- 23 -
container can be produced having approximately 1/2 the
normal weight for such containers (80 grams vs. the more
usual 160 grams). Bottles according to the invention may
have a gram weight reduction of from 25 to 33% as compared
to bottles typically used for heavy duty liquid detergent
products.
The use of a neck or finish which is displaced from the
center is believed to facilitate pouring of product from the
container. To determine whether a neck finish is off-center
for the purposes of the invention, one measures the distance
from one side to the other of the bottle's length, measured
at the point of maximum length, i.e., the maximum horizontal
dimension when the container is standing on its base. Then
one determines the center point of that distance from one
side to the other. The next step is to ascertain where the
center point of the container finish, ie the center of the
bottle mouth, falls along the line drawn from one side of
the container to the other at its longest length. The
percentage displacement is calculated by subracting the
distance in position between the center point of the finish
and the center of the container length at its widest point
and dividing that figure by the length of the bottle at its
widest point.
An example of the percentage displacement calculation is as
follows. If the container has its maximum length at the
bottom, and the length of the bottom is16 cm, and a vertical
line drawn through the center of the finish intersects the
length line at 10.6 cm, the calculation is as follows: (10.6
minus 8 (the midpoint of the length)), divided by 16. The
result is 16.25%. For the purposes of the invention, a neck
finish is considered off center if the displacement
percentage is greater than 3%. Preferred displacments are
CA 0222~890 1997-12-29
C6453
- 24 -
from 3% through 20%. Especially preferred is if the
percentage is from 5%-20%.
Use of a large diameter neck or finish, eg on the order of
from 50 to 88 mm, minimizes aglugging" of product emerging
from the container and distributes polymer in such a way as
to increase the topload strength of the container.
Advantageously, the bottle of the invention can be made on a
wheel machine, i.e., a high speed production blow molding
apparatus, or a Uniloy brand or other shuttle machine. A
"wheel" machine rotates and clamps around a continuously
extruded parison. Bottles are ejected after forming.
Bottles according to the invention which were 20~ lighter
than current heavy duty liquid bottles sold by a major
detergent manufacturer, were found to be as sturdy, durable
and vigorous as the full weight, current bottles.
It will be apparent that the pouring fitment and container
of the invention may be used for liquid laundry and other
detergents, fabric softeners and many other types of liquid
household and other products.
As used herein, "handle" refers to a structure for holding
the bottle where there is a "hole" through which the human
hand can extend. A gripping feature is a pair of
indentations facilitating the holding of the bottle by a
human hand, but which does not include a "hole."
Examples of multi layer resins which may be used to make the
bottles of the invention, are as follows:
CA 0222~890 1997-12-29
C6453
- 25 -
Variable Inside hayer Middle Layer Outside Layer
1 9503 9503-PCR/Regrind 9503/3% Colorant
3 9503 LX4570/PCR/Regri LX4570/3%
nd Colorant
6 9346T 9602/PCR/Regrind 9602/3% Colorant
Note: 9503 = 0.948 density
LX4570 = 0.955 density
LX4225 = 0.950 density
9602 = 0.964 density
9346T = 0.945 density
It should be understood, of course, that the specific forms
of the invention herein illustrated and described are
intended to be representative only, as certain changes may
be made therein without departing from the clear teachings
of the disclosure. Accordingly, reference should be made to
the following appended claims in determining the full scope
of the invention.
