Note: Descriptions are shown in the official language in which they were submitted.
SWIRL BELL BOTTLE WITH WAVY RIBS
[0001] This application claims priority to U.S. Patent Application
Serial No.
14/610,940, filed January 30, 2015.
FIELD
[0002] This invention relates to plastic bottles and preforms, more
specifically plastic
preforms and bottles blown from such preforms that are suitable for containing
beverages and
utilize less resin such that they are lighter in weight than conventional
bottles.
BACKGROUND
[0003] Plastic containers have been used as a replacement for glass or
metal containers
in the packaging of beverages for several decades. The most common plastic
used in making
beverage containers today is polyethylene terephthalate (PET). Containers made
of PET are
transparent, thin-walled, and have the ability to maintain their shape by
withstanding the force
exerted on the walls of the container by their contents. PET resins are also
reasonably priced
and easy to process. PET bottles generally are made by way of a process that
includes blow-
molding of plastic preforms which have been made by injection molding of PET
resin.
[0004] Advantages of plastic packaging include lighter weight and
decreased breakage
as compared to glass, as well as lower costs overall when taking both
production and
transportation into account. Although plastic packaging is lighter in weight
than glass, there is
still great interest in creating the lightest possible plastic packaging so as
to maximize the
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Date Recue/Date Received 2022-07-15
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cost savings in both transportation and manufacturing by making and using
containers that
contain less plastic.
SUMMARY
[0005] The bottling industry is moving in the direction of removing
auxiliary packaging
from cases or pallets. A case of bottles with film only and no paperboard is
called a "film
only conversion" or "lightweighting" of auxiliary packaging. The removal of
supporting
elements such as paperboard places additional stress on a bottle, which
increases the
structural demands on the bottle. In certain embodiments, a bottle design can
provide one or
more of the benefits of reducing bending and point loading failures. The
disclosed design
embodiments can alleviate the stresses during shipping and handling (including
film only
packaging) while maintaining ease of blow-molding. In certain embodiments, a
bottle design
uses less resin for the same or similar mechanical performance, resulting in a
lightweight
product.
[0006] Embodiments of the bottle disclosed herein may use polyethylene
terephthalate
(PET), which has viscoelastic properties of creep and relaxation. As a
plastic, PET and other
resins tend to relax at temperatures normally seen during use. This relaxation
is a time
dependent stress relieving response to strain. Bending can provide exaggerated
strains over
what would be seen in tensile loading. Due to exaggerated strains, the
relaxation in bending
can be much more severe. Bending happens at multiple length scales. Bending
can happen
at the length scale of the bottle or on a small length scale. An example of
the bottle length
scale bending is a person bending the bottle in his/her hands, or bending
experienced during
packing in a case on a pallet. An example of the small scale is the flexing or
folding of ribs
or other small features on the wall of the bottle. In response to loads at the
first, larger length
scale, ribs flex at the local, smaller length scale. When they are held in
this position with
time, the ribs will permanently deform through relaxation.
[0007] Further, embodiments of the bottles disclosed herein may undergo
pressurization.
Pressure inside a bottle can be due to the bottle containing a carbonated
beverage. Pressure
inside a bottle can be due to pressurization procedures or processes performed
during bottling
and packaging. For example, a bottle can be pressurized to help the bottle
retain its shape.
As another example, the bottle can be pressurized with certain gases to help
preserve a
beverage contained in the bottle.
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[0008] Embodiments of the bottles disclosed herein have varying depth ribs
that achieve
a balance of strength and rigidity to resist the bending described above while
maintaining
hoop strength, such as, for example, when pressure is not used or relieved. A
collection of
flattened and/or shallow depth ribs act as recessed columns in the body of the
bottle that
distribute bending and top load forces along the wall to resist leaning,
stretching, and
crumbling. The collection of flattened and/or shallow depth ribs can help the
bottle retain its
shape during pressurization, such as, for example, help inhibit stretching of
the bottle when
pressurized. Inhibiting stretching of the bottle helps retain desired bottle
shape to aid in
packaging of the bottles as discussed herein by, for example, maintaining a
substantially
constant height of the bottle. Inhibiting stretching of the bottle can help
with applying a label
to a label portion of the bottle. For example, with a label applied to a
bottle, inhibiting
stretching of the bottle helps retain a constant length or height of the
bottle at the label panel
portion, which can help prevent tearing of the label and/or prevent the label
from at least
partially separating from the bottle (i.e., failure of the adhesive between
the bottle and the
label). Further details on the features and functions of varying depth ribs
are disclosed in
U.S. Patent Application Serial No. 13/705,040, entitled "Plastic Container
with Varying
Depth Ribs," filed on December 4, 2012, now U.S. Patent No. 8,556,098,
entitled "Plastic
Container Having Sidewall Ribs with Varying Depth," which claims benefit to
U.S.
Provisional Patent Application Serial No. 61/567,086, entitled "Plastic
Container with
Varying Depth Ribs," filed on December 5, 2011, the entirety of each of which
is
incorporated herein by reference and made a part of this disclosure.
[0009] A balance may be achieved between flattened and/or shallow ribs and
deep ribs to
attain a desired resistance to bending, leaning, and/or stretching while
maintaining stiffness in
a lightweight bottle. In some embodiments, at least some of the aforementioned
desired
qualities may be further achieved through a steeper bell portion of a bottle.
A steeper bell
portion can increase top load performance in a lightweight bell. A lightweight
bottle body
and bell leaves more resin for a thicker base of the bottle, which can
increase stability. A
thicker base may better resist bending and top load forces and benefits
designs with a larger
base diameter with respect to the bottle diameter for tolerance even when the
base is damaged
during packaging, shipping, and/or handling.
[0010] Embodiments disclosed herein have a multiplicity of strap ribs that
can function as
straps from a base to a sidewall of the bottle to the help further achieve
resistance to bending,
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leaning, stretching and/or flexing while maintaining stiffness. A strap rib on
a base helps the
base resist deformation under pressure without necessitating the base being
overly heavy in
weight relative to the lightweight bottle (i.e., relative to wall thickness of
flat foot base that
does not resist pressure as well). The strap base rib can be incorporated into
a flat foot base.
A flat foot base helps retain base foot thickness. Retaining base foot
thickness helps retain
bottle integrity during packaging and handling using lightweight packaging,
such as, for
example, film only packaging that requires the base to directly resist forces,
including
bending and point loading, during packaging, shipping, and/or handling. A flat
foot base
performs well with or without internal pressure due to, for example, the
ability to maintain
relative foot thickness in the base in a lightweight bottle. Without strap
ribs, the base may
have little internal pressure resistance and may rollout (pop out and create a
rocker bottom).
The strap ribs help resist damage and deformation as discussed herein without
requiring a
relatively heavy footed base. Without requiring a relatively heavy footed
base, less material
is needed for the lightweight bottle. Further, the strapped base design may
allow for a
relatively easier blowing process than other known pressure bases. Thus, a
base with strap
ribs as disclosed herein provides for a material efficient, pressure optional
bottle base.
[0011] Incorporating strap ribs into the base with column formations in the
sidewall of
the bottle as discussed herein offers pressure resistance for internally
pressurized bottles
while maintaining strength and performance (i.e., resistance to bending and
leaning) when
without internal pressure (i.e., pressure release' by a user opening a closure
of a bottle). The
strap ribs can cooperate with the column formations on the sidewall of the
bottle to form
straps around the bottle to communicate stresses along the height of the
bottle.
[0012] The base with strap ribs helps maintain strength and performance of
the column
formations for internally pressurized bottles. With strap ribs, resistance to
bending, leaning,
and/or stretching while maintaining stiffness and hoop strength is maintained
without
pressure while enhancing these characteristics when the bottle is pressurized.
For example,
strap ribs allow the utilization of a flat foot base for better base strength
during processing at
a plant (i.e., adding beverage contents), while preventing rollout or popping
out of the base
during pressurization. Rollout of the base of the bottle leads to what may be
called a "rocker
bottom." Preventing rollout of the base helps the bottle stay level when
resting on a surface
and maintains the flat feet as the contact points on the surface. Further,
base rollout can also
occur without pressurization or low pressurization of the bottle, such as, for
example, during
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shipping and handling or filling at high speed. Strap base ribs also help
prevent base rollout
without or low internal pressurization. While the specification herein may
discuss preventing
or inhibiting deformation under external/internal pressures and/or forces, it
is to be
understood that some deformation of a bottle may occur without straying
outside of the scope
of this disclosure. Some deformation of the bottle under external/internal
pressures and/or
forces may occur while retaining excellent structural properties of the
features and functions
disclosed herein.
[0013] Embodiments disclosed herein can be utilized for bottle pressures of
a wide range.
The strap base rib can help resist pressurization pressures in the bottle of
up to 3 bars,
including up to 2.5, up to 2, up to 1.5, up to 1, up to 0.5 bars, and up to
0.3 bars, including
ranges bordered and including the foregoing values. The preform design also
plays a role in
resisting pressures such that much higher pressures than already demonstrated
can be resisted
with greater strap thickness available from the preform. The strap design
provides a more
efficient way of resisting the pressure in a bottle that also performs well
without pressure.
[0014] Embodiments disclosed herein can be utilized in bottle volumes of a
wide range.
For example, features and functions disclosed herein can be utilized with a 3
ounce bottle up
to a multiple gallon bottle. As another example, features and functions
disclosed herein can
be utilized with an 8 ounce (0.24 liter/0.15 liter) bottle up to a 3 liter
bottle, including 12
ounces (0.35 liters) to 2 liters, 16 (0.47 liters) ounces to 1 liter, 18
ounces (0.53 liters) to 0.75
liters, and 0.5 liters, including ranges bordered and including the foregoing
values.
[0015] Further, a new approach which relies on a general change in preform
design,
which significantly improves the ability to blow efficient, lightweight
bottles is disclosed
herein. The design elegantly incorporates =features for protecting critical
dimensions of the
bottle and stabilizing the production blowing process. These features may also
utilize less
resin while achieving suitable mechanical performance resulting in a reduction
in the use of
petroleum products by the industry.
[0016] In an exemplary embodiment, a container comprises a base, a bell, a
sidewall
between the base and the bell, a neck and a finish which define an opening to
an interior of
the container, and a shoulder between the sidewall and the bell. The container
further
comprises a grip portion of the sidewall comprising a multiplicity of
circumferentially
positioned grip portion ribs; a label portion of the sidewall comprising a
multiplicity of
CA 02918903 2016-01-26
circumferentially positioned label portion ribs; a plurality of strap ribs,
wherein each of the
strap ribs extends substantially from a central portion of the base and
terminates at a sidewall
end in the grip portion, and wherein the strap ribs cooperate with a plurality
of vertically
aligned recessed columns of the sidewall so as to resist at least one of
bending, leaning,
crumbling, or stretching along the sidewall and the base; a plurality of
inwardly offset
portions of the sidewall configured to resist outward bowing of the sidewall
due to internal
pressure of contents in the interior of the container, each of the plurality
of inwardly offset
portions being disposed between each pair of adjacent vertically aligned
recessed columns; a
plurality of load ribs spaced equally between adjacent strap ribs, wherein the
load ribs are
configured to resist deformation of the base; and a plurality of feet formed
between the strap
ribs and the load ribs, wherein the plurality of feet comprises a resting
surface of the
container.
[0017] In another exemplary embodiment, the plurality of vertically aligned
recessed
columns comprises three recessed columns equally spaced around the perimeter
of the
sidewall, such that the sidewall comprises a circumference which is offset
from a generally
circular cross-sectional shape to a substantially triangular cross-sectional
shape. In another
exemplary embodiment, each of the plurality of inwardly offset portions is
offset from 0 to 30
degrees from the circular cross-sectional shape. In another exemplary
embodiment, the
plurality of inwardly offset portions is configured to counteract outward-
directed forces on
the sidewall of the container due to internal pressure, such that the
pressurized container
assumes a substantially circular cross-sectional shape.
[0018] In another exemplary embodiment, the base comprises a diameter which
is larger
than a diameter of the shoulder, such that the base creates a single point of
contact with other
substantially similar containers in a production line, or in packaging. In
another exemplary
embodiment, the diameter of the base is larger than the diameter of the
shoulder by 0.5 to 4
millimeters. In another exemplary embodiment, the diameter of the base is
larger than the
diameter of the shoulder by 1 to 2 millimeters.
[0019] In another exemplary embodiment, the plurality of strap ribs
comprises three strap
ribs equally spaced around the circumference of the base, and wherein the
plurality of load
ribs comprises six load ribs, such that two load ribs are equally spaced
between each pair of
adjacent strap ribs. In another exemplary embodiment, the base further
comprises a gate
centered on a longitudinal axis of the container, a wall extending from the
gate toward the
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resting surface of the container, and a dome immediately surrounding the gate,
wherein the
dome is a portion of the wall of the base that slopes more steeply toward the
resting surface
of the container. In another exemplary embodiment, each of the strap ribs has
a base end
which terminates in the dome, near the periphery of the gate. In another
exemplary
embodiment, each of the strap ribs begins at the base end substantially
parallel to the resting
surface of the container and then extends along an upward curved path, a first
portion of the
upward curved path comprising a first radius, a second portion of the upward
curved path
comprising a second radius, and a third portion of the upward curved path
comprising a
straight portion, wherein at a first height the first radius terminates and
the second radius
begins, and at a second height the straight portion connects to the sidewall
end of the strap
rib, and wherein the first radius and the second radius cooperate to give the
strap rib and the
base a spherical configuration, such that the container better accommodates
internal pressure.
In another exemplary embodiment, each of the strap ribs further comprises two
rib side walls
that connect the strap rib to portions of the base and the feet, the rib side
walls comprising
smooth and gradual transitions into the base and the feet, such that the
transitions comprise
spherical features of the container.
[0020] In an exemplary embodiment, a container configured to substantially
reduce
triangulation of the container due to internal pressure of contents within the
container,
comprises a base which extends upward to a sidewall of the container; a
shoulder connected
between the sidewall and a bell, a diameter of the bell decreasing as the bell
extends upward
to a neck of the container; a finish connected to the neck, the finish
configured to receive a
closure and defining an opening to an interior of the container; and a
plurality of inwardly
offset portions of the sidewall configured to resist outward bowing of the
sidewall due to the
internal pressure of the contents.
[0021] In another exemplary embodiment, the sidewall comprises a plurality
of vertically
aligned recessed columns configured to resist the internal pressure of the
contents. In another
exemplary embodiment, the plurality of vertically aligned recessed columns
comprises three
recessed columns disposed uniformly around the circumference of the sidewall,
and wherein
one inwardly offset portion is disposed between each pair of adjacent recessed
columns, such
that the circumference of the sidewall is offset from a generally circular
cross-sectional shape
to a substantially triangular cross-sectional shape. In another exemplary
embodiment, each of
the inwardly offset portions is offset from 0 to 30 degrees from the circular
cross-sectional
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shape. In another exemplary embodiment, the inwardly offset portions are
configured to
counteract outward-directed forces on the sidewall of the container due to
internal pressure,
such that the pressurized container assumes a substantially circular cross-
sectional shape.
[0022] In another exemplary embodiment, the base comprises a diameter which
is larger
than a diameter of the shoulder, such that the base creates a single point of
contact with other
substantially similar containers in a production line, or in packaging. In
another exemplary
embodiment, the diameter of the base is larger than the diameter of the
shoulder by 0.5 to 4
millimeters. In another exemplary embodiment, the diameter of the base is
larger than the
diameter of the shoulder by 1 to 2 millimeters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The drawings refer to embodiments of the present invention in which:
[0024] Figure 1 illustrates a lower perspective view of an exemplary
embodiment of a
container in accordance with the present disclosure;
[0025] Figure 2 illustrates a front elevation view of an exemplary
embodiment of a
container, according to the present disclosure;
[0026] Figure 3 illustrates a rear elevation view of an exemplary
embodiment of a
container in accordance with the present disclosure;
[0027] Figure 4 illustrates a right side elevation view of an exemplary
embodiment of a
container, according to the present disclosure;
[0028] Figure 5 illustrates a left side elevation view of an exemplary
embodiment of a
container in accordance with the present disclosure;
[0029] Figure 6 illustrates a top plan view of an exemplary embodiment of a
container,
according to the present disclosure;
[0030] Figure 7 illustrates a bottom plan view of an exemplary embodiment
of a
container in accordance with the present disclosure;
[0031] Figure 8 illustrates a cross-sectional view along a longitudinal
axis of an
exemplary embodiment of a base of a container, according to the present
disclosure;
CA 02918903 2016-01-26
[0032] Figure 9 illustrates an exemplary embodiment of a preform which may
be blow-
molded to form a container in accordance with the present disclosure;
[0033] Figure 10 illustrates a cross-sectional view of an exemplary
embodiment of a
preform, according to the present disclosure;
[0034] Figure 11 illustrates a cross-sectional view of a preform in a
cavity of an
exemplary embodiment of a blow-molding apparatus that may be used to make a
bottle or
container; and
[0035] Figure 12 illustrates an exemplary embodiment of a container formed
by way of
stretch blow-molding in accordance with the present disclosure.
[0036] While the present invention is subject to various modifications and
alternative
forms, specific embodiments thereof have been shown by way of example in the
drawings
and will herein be described in detail. The invention should be understood to
not be limited
to the particular forms disclosed, but on the contrary, the intention is to
cover all
modifications, equivalents, and alternatives falling within the spirit and
scope of the present
invention.
DETAILED DESCRIPTION
[0037] In the following description, numerous specific details are set
forth in order to
provide a thorough understanding of the present invention. It will be
apparent, however, to
one of ordinary skill in the art that the present invention may be practiced
without these
specific details. In other instances, specific numeric references such as
"first load rib," may
be made. However, the specific numeric reference should not be interpreted as
a literal
sequential order but rather interpreted that the "first load rib" is different
than a "second load
rib." Thus, the specific details set forth are merely exemplary. The specific
details may be
varied from and still be contemplated to be within the spirit and scope of the
present
invention. The term "coupled" is defined as meaning connected either directly
to the
component or indirectly to the component through another component. Further,
as used
herein, the terms "about," "approximately," or "substantially" for any
numerical values or
ranges indicate a suitable dimensional tolerance that allows the part or
collection of
components to function for its intended purpose as described herein.
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[0038] In general, the present disclosure provides an apparatus for a
container comprising
a base, a bell, a sidewall between the base and the bell, a neck and a finish
which define an
opening to an interior of the container, and a shoulder between the sidewall
and the bell. In
one embodiment, the base comprises a diameter which is larger than a diameter
of the
shoulder, such that the base creates a single point of contact with other
substantially similar
containers in a production line, or in packaging. In some embodiments, the
diameter of the
base is larger than the diameter of the shoulder by 0.5 to 4 millimeters, and
preferably by 1 to
2 millimeters. Strap ribs extend from a central portion of the base and
terminate at the
sidewall. The strap ribs cooperate with vertically aligned recessed columns of
the sidewall to
resist bending, leaning, crumbling, or stretching along the sidewall and the
base. An
inwardly offset portion of the sidewall is disposed between each pair of
adjacent recessed
columns. In one embodiment, three recessed columns are equally spaced around
the
perimeter of the sidewall, such that the sidewall comprises a circumference
which is offset
from a generally circular cross-sectional shape to a substantially triangular
cross-sectional
shape. In one embodiment, each of the inwardly offset portions is offset from
0 to 30 degrees
from the circular cross-sectional shape. The inwardly offset portions of the
sidewall are
configured to resist outward bowing of the sidewall due to internal pressure
of contents
within the container.
[0039] Figure 1 illustrates a bottom perspective view of an exemplary
embodiment of a
container 100 in accordance with the present disclosure. The container 100
comprises a base
104 that extends up to a grip portion 108. The grip portion 108 comprises a
plurality of grip
portion ribs 112 (i.e., sidewall ribs). As illustrated in Fig. 1, the
plurality of grip portion ribs
112 generally vary in depth, and swirl or angulate around the grip portion
108. A label
portion 116 is connected to the grip portion 108 and comprises one or more
label panel ribs
120 (i.e., sidewall ribs). The label panel portion 116 transitions into a
shoulder 124, which
connects to a bell 128. In the embodiment illustrated in Fig. 1, the bell 128
comprises a
plurality of design features 132. In other embodiments, however, the bell 128
may include
various other design features, or may be smooth and generally unornamented.
The bell 128
connects to a neck 136, which connects to a finish 140. As shown in Fig. 1,
the bell 128
comprises a diameter that generally decreases as the bell 128 extends upward
from the
shoulder 124 to the neck 136 and the finish 140. The finish 140 is adapted to
receive a
closure, such as by way of non-limiting example, a container cap or bottle
cap, so as to seal
contents within the container 100. The finish 140 generally defines an opening
144 that leads
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to an interior of the container 100 for containing a beverage, or other
contents, such as any of
a variety of carbonated soft drinks.
[0040] A substantially vertical sidewall comprising the grip portion 108
and the label
portion 116 between the base 104 and the bell 128, extending substantially
along a
longitudinal axis of the container 100, and defines at least part of the
interior of the container
100. In some embodiments, the sidewall may include the bell 128, the shoulder
124, and/or
the base 104. A perimeter (i.e., periphery) of the sidewall is substantially
perpendicular to
the longitudinal axis of the container 100. The finish 140, the neck 136, the
bell 128, the
shoulder 124, the label portion 116, the grip portion 108, and the base 104
each comprises a
respective perimeter (i.e., periphery) which is substantially perpendicular to
the longitudinal
axis of the container 100. For example, the label portion 116 comprises a
label portion
perimeter, whereas the grip portion 108 comprises a grip portion perimeter,
both of which
perimeters being substantially perpendicular to the longitudinal axis of the
container 100.
[0041] In the embodiment illustrated in Figs. 1-5, each grip portion rib
112 comprises a
deep rib portion 148 transitioning to a middle rib portion 152 and then
transitioning to a
shallow rib portion 156. Similarly, each label portion rib 120 comprises a
deep rib portion
160 transitioning to a middle rib portion 164 and then transitioning to a
shallow rib portion
168. The deep, middle, and shallow rib portions may also be referred to as
deep, middle, and
shallow ribs as a shorthand, but it is to be understood that these terms are
intended to define
portions of each rib in the grip portion 108 and the label portion 116. In the
embodiment
illustrated in Figs. 1-5, the shallow rib portions 156, 168 are vertically
aligned with the
longitudinal axis of the container 100. As best illustrated in Fig. 3, the
shallow rib portions
156, 168 form an equivalent of recessed columns 172 at portions where the
shallow rib
portions 156, 168 substantially vertically line up along the longitudinal axis
of the container
100. Further, the deep rib portions 148, 160 are substantially vertically
aligned along the
vertical or longitudinal axis of the container 100. Thus, the embodiment
illustrated in Figs. 1-
comprises three recessed columns 172 and three portions where the deep rib
portion 148,
160 are substantially vertically aligned.
[0042] In some embodiments, the shallow rib portions 168 of the label
portion 116 may
be vertically misaligned with the shallow rib portions 156 of the grip portion
108, such that
the label portion 116 has a first set of recessed columns and the grip portion
108 has a second
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set of recessed columns. In some embodiments, the container 100 may have
recessed
columns solely in the grip portion 108 or solely in the label panel portion
116.
[00431 In the illustrated embodiment of Figs. 1-5, the three recessed
columns 172 are
equally spaced apart around the perimeter of the container 100 and located on
an opposite
sides of the container perimeter from the deep rib portions 148, 160. It will
be appreciated
that with three equally spaced recessed columns 172, the recessed columns 172
are spaced
substantially every 120 degrees around the circumference of the container 100.
Any number
of recessed columns 172 may be incorporated into a design of the container 100
by either
increasing or decreasing the number of shallow rib portions 156, 168 that are
substantially
vertically aligned along the longitudinal axis of the container 100. For
instance, other
embodiments of the container 100 may comprise a number of the recessed columns
172
ranging between 1 and 10 recessed columns.
[0044] In some embodiments, the label portion 116 may comprise a different
number of
recessed columns 172 than the grip portion 108. For example, the label portion
116 may
comprise six equally spaced recessed columns, wherein three are vertically
aligned with the
recessed columns 172 of the grip portion 108 while the remaining three
recessed columns are
limited to the label portion 116. With six equally spaced recessed columns
around the
perimeter of the label portion 116, the recessed columns are positioned every
60 degrees
around the circumference of the container 100. More recessed columns can help
prevent
triangulation of the label portion 116. As will be appreciated, shallow rib
portions coupled
with recessed columns better resists radial outward flexing, at least
partially because the
shallow rib portions possess a relatively smaller radial depth available for
flexing.
Correspondingly, shallow rib portions coupled with recessed columns provides a
greater
resistance to internal pressure relative to deep rib portions. Thus,
incorporating more
frequent shallow rib portions and/or recessed columns around the circumference
of the
container 100 helps inhibit outward triangulation of the container due to
internal pressure of
contents within the container.
[0045] The vertical alignment of the shallow rib portions 156, 168 that
form the recessed
columns 172 provides resistance to leaning, load crushing, and/or stretching
of the container
100. Leaning can occur when, during and/or after bottle packaging, a bottle,
such as the
container 100, experiences top load forces (tangential forces or otherwise)
from other bottles
and/or other objects stacked on top of the container. Similarly, top load
crushing can occur
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due to vertical compression (or otherwise) forces from bottles and/or other
objects stacked on
top. Stretching can occur when the container is pressurized. The recessed
columns 172
transfer the resulting forces along the sidewall of the container 100 to the
base 104 and thus
increase rigidity of the container 100. The deep rib portions 148, 160 of the
grip portion ribs
112 and label panel ribs 120, respectively, provide a hoop strength that can
be equivalent to
the hoop strength imparted by ribs comprising a uniform depth. The number of
ribs,
including the grip portion ribs 112, and/or the label panel ribs 120 may vary
between 1 and
30 ribs positioned, for example, every 10 centimeters along any rib-containing
portion of the
container 100, such as, but not necessarily limited to the grip portion 108
and/or the label
portion 116. It should be understood that the aforementioned 10-centimeters
that is used to
measure the number of ribs in a portion of the container need not be actually
10 centimeters
in length, but rather the 10-centimeters is used illustratively to provide a
relationship between
the number of ribs incorporated into a given length of a portion of the
container.
[0046] As discussed above, the three recessed columns 172 operate to
prevent outward
triangulation of the sidewall of the container 100, wherein the shallow rib
portions 156, 168
coupled with the recessed columns 172 better resists radial outward flexing of
the sidewall of
the container 100. Preferably, the portions of the sidewall between the
recessed columns 172
are bowed inward, or offset, toward the interior of the container 100, such
that the perimeter
of the sidewall is offset from a generally circular cross-sectional shape to a
substantially
inwardly triangular cross-sectional shape. In some embodiments, the offset
portions of the
sidewall may be offset from 0 to 30 degrees from the circular cross-sectional
shape. The
offset portions of the sidewall are configured to resist outward bowing of the
sidewall due to
internal pressure when the container 100 is filled with contents, particularly
carbonated
contents. It is envisioned that outward-directed forces on the sidewall of the
container 100
due to internal pressure are counteracted by inward-directed resistance forces
produced by the
offset portions, such that the pressurized container assumes a substantially
circular cross-
sectional shape rather than becoming outwardly triangulated, as discussed
herein. Thus,
incorporating inwardly offset portions between the recessed columns 172 around
the
perimeter of the container 100 further inhibits outward triangulation of the
container.
[0047] With reference to Fig. 1, the base 104 comprises three strap ribs
176. Each of the
strap ribs 176 comprises a sidewall end 180 that terminates along the sidewall
of the
container 100, as discussed herein. Further, the base 104 comprises six load
ribs 184. As
13
CA 02918903 2016-01-26
illustrated in Fig. 1, two load ribs 184 are positioned between two strap ribs
176. In some
embodiments, the base 104 may comprise a number of load ribs 184 ranging
between 1 and 5
load ribs positioned between two strap ribs 176. Each of the load ribs 184 has
a sidewall end
188 that terminates along the base 104 at a transition from the base 104 to
the sidewall of the
container 100. As illustrated in Fig. 1, the sidewall end 188 of the load rib
184 is vertically
lower than the sidewall end 180 of the strap rib 176 along the longitudinal
axis of the
container 100. In some embodiments, the sidewall end 188 of the load rib 184
may terminate
along the sidewall of the container 100 at a height which is substantially
similar to the height
of the sidewall end 180 of the strap rib 176. As further illustrated in Fig.
1, the base 104
comprises feet 192 formed between the strap ribs 176 and the load ribs 184.
[0048] The strap rib 176 is relatively larger and deeper than the load rib
184, as discussed
herein. As illustrated in Figs. 1-5, each of the strap ribs 176 is vertically
aligned with one of
the recessed columns 172, and thus the strap ribs 176 are spaced equally
around the
circumference of the container 100. It will be recognized that with three
equally spaced strap
ribs 176, the strap ribs 176 are positioned every 120 degrees around the
container
circumference. The load ribs 184 are vertically aligned with the grip portion
ribs 112
between the recessed columns 172. In some embodiments, the strap ribs 176 may
be
vertically misaligned with the recessed columns 172. In some embodiments, the
strap ribs
176 may be spaced unequally around the circumference of the container 100. In
some
embodiments, the base 104 may comprise more or less strap ribs 176 than the
number of
recessed columns 172. In some embodiments, the strap rib 176 may be vertically
aligned
with the deep rib portions 148, 160 and may terminate into a first deep rib
portion 148 (first
from the base 104). In some embodiments, the strap rib 176 may have a sidewall
end 180
that terminates past the first shallow rib portion 156 and/or the first deep
rib portion 148, such
as for example at the second, third, and/or fourth grip portion ribs 112.
[0049] Figure 3 illustrates a rear elevation view of the container 100. As
shown in Fig. 3,
the sidewall end 180 of the strap rib 176 vertically aligns with, or points to
substantially the
center of the recessed column 172, which is coincident with the center point
of the shallow
rib portion 156. As further illustrated in Fig. 3, the strap rib 176 forms a
recess 196, which is
relatively a small area in comparison to the contact area of the feet 192 with
a resting surface.
Utilizing a small recess 196 aids in distributing more resin toward the feet
192 during the
blowing process, which generally increases the abrasion resistance and
strength of the feet
14
CA 02918903 2016-01-26
192. Thus, the strap ribs 176 operate to provide internal pressure resistance
while leaving
enough resin for the feet 192 to achieve the benefits of a flat foot base
(i.e., thicker resin feet
192 for greater abrasion, deformation, and/or stress resistance; and/or
greater foot contact
area for stability and load distribution).
[0050] As best illustrated in Fig. 7, the strap ribs 176 extend
substantially from a central
portion of the base 104, coinciding with the longitudinal axis of the
container 100, as
discussed herein. As will be appreciated by those skilled in the art, the
strap ribs 176 operate
as a straps extending between the recessed columns 172 of the sidewall to the
central portion
of the base 104. As shown in Fig. 1, the strap rib 176 provides a more direct
and shorter path
from the center of the base 104 to the sidewall of the container 100 without
proceeding to the
vertical level of the feet 192. As discussed herein, the strap ribs 176 thus
provide a relatively
more pressure resistant base 104. Each of the strap ribs 176 provides a link
for forces and
stresses between the sidewall, including the recessed column 172, and the
central portion of
the base 104.
[0051] Figure 8 illustrates a cross-sectional view along the longitudinal
axis of the base
104 of the container 100. As shown in Fig. 8, the strap rib 176 of the base
104 begins at a
base end 212 substantially parallel to a resting surface of the base 104 and
then extends along
a curved path, having a first radius Rid, with an increasingly positive slope.
At a height Hid,
the radius of the curved path of the strap rib 176 changes to a second radius
R2d with an
increasingly positive slope before extending into a straight portion 220. At a
height H2d, the
straight portion 220 connects to the sidewall end 180 as discussed herein. The
first and
second radii Rid, R2d, as well as the corresponding positive slopes and the
heights Hid and
H2d, may have dimensional values falling within any of the appropriate ranges
of values
discussed in detail in U.S. Patent Application Serial No. 14/157,400, entitled
"Plastic
Container With Strapped Base," filed on January 16, 2014, the entirety of
which is
incorporated herein by reference and forms a part of the present disclosure.
Preferably,
however, the combination of the radii Rid and R2d cooperate to give the strap
rib 176, and
thus the base 104, a smooth and gradual, spherical configuration. As discussed
herein,
spherical features of the container 100 better accommodate internal pressure.
Experimentation has demonstrated that the spherical configuration of the base
104 depicted in
Fig. 1-5 is capable of withstanding an internal pressure at least twice the
internal pressure
tolerable by conventional base configurations.
CA 02918903 2016-01-26
[00521 It will be recognized that the strap rib 176 illustrated in Fig. 8
does not include a
transition curve between the first radius Rid and the second radius R2d, nor
between the
second radius R2d and the straight portion 220. In other embodiments, however,
a transition
curve having a radius other than Rid and R2d may be positioned between the
curved portions
of the strap rib 176 having radii Rid and R2d. In still other embodiments, a
transition curve
may be positioned between the curved portion of the strap rib 176 having the
second radius
R2d and the straight portion 220. It is envisioned that the transition curves
may have
dimensional values that further produce a spherical configuration of the strap
rib 176, and
thus the base 104.
[0053] As illustrated in Fig. 7, the base 104 comprises a gate 200
surrounded by a dome
204. The dome 204 comprises a portion of a wall of the base 104 which slopes
more steeply
toward a resting surface when the bottle is placed on the resting surface
relative to the rest of
the wall of the base 104 leading to the feet 192. The strap rib 176 comprises
a base end 208
that terminates substantially at a periphery of the dome 204. In some
embodiments, the base
end 208 of each strap rib 176 may be positioned outside of the dome 204
similarly to base
ends 212 of the load ribs 184. Each of the strap ribs 176 comprises a pair of
rib side walls
216 that connect the strap rib 176 to portions of the base 104 and the feet
192. The rib side
wall 216 smoothly and gradually transitions into the base 104 and the feet
192. The smooth
and gradual transition provides internal pressure resistance at and near the
rib side wall 216
since more spherical features of the container 100 better accommodate internal
pressure. The
strap rib 176 is relatively deeper in the base 104 than the load rib 184 so as
to provide stress
transfer and pressure resistance, as discussed herein.
[0054] As mentioned above, each of the load ribs 184 comprises a base end
212 that
terminates at, or near the dome 204. In the embodiment illustrated in Fig. 7,
the base ends
212 of the load ribs 184 terminate before the base ends 180 of the strap ribs
176. Further, the
load ribs 184 are shallow relative to the strap ribs 176. Accordingly, the
load ribs 184 each
comprises rib side walls that are relatively smaller than the rib side walls
216, and thus the
transition from the load ribs 184 to the base 104 and the feet 192 is more
abrupt, or sharper,
than in the case of the rib side walls 216. It will be appreciated that when
the container 100 is
top loaded during packaging, shipping, and/or handling, the sharper
transitions of the load
ribs 184 resist bending and/or leaning as discussed herein by, for example,
maintaining the
integrity and shape of the base 104. Moreover, the sharper transitions of the
load ribs 184
16
CA 02918903 2016-01-26
provide more area of the base 104 being available for relatively larger feet
192. It will be
further appreciated that larger feet 192 of a flat-foot base, such as the base
104 discussed
herein and as illustrated in Fig. 7, provide more resin contact area with a
resting surface, and
thus provide better abrasion resistance and stability of the base. As further
illustrated in Fig.
7, the rib side walls 216 generally transition into the strap ribs 176 more
abruptly, or sharply,
relative to the transition from the rib side walls 216 to the feet 192. The
sharper transitions to
the strap ribs 176 provide more rigidity to the strap ribs so as to resist, or
inhibit, flexing due
to internal pressures.
[0055] In the embodiment of Fig. 7, the base ends 208 of the strap ribs 176
terminate
substantially near the gate 200, and the base ends 212 of the load ribs 184
terminate near the
periphery of the dome 204. It will be appreciated that terminating the base
ends 208 of the
strap ribs 176 and/or the base ends 212 of the load ribs 184 substantially
near, or at the gate
200 provides greater internal pressure resistance to the base 104, as
discussed herein,
preventing, for example, base rollout. Moreover, terminating each of the base
ends 208
substantially near, or at the gate 200 provides strap ribs 176 that are
substantially continuous
from (or near) the gate 200 to the sidewall ends 180. As shown in Figs 1-5,
the sidewall ends
180 terminate at the first shallow rib portion 156 and communicate directly
with the recessed
columns 172. The continuity from the recessed columns 172 to the gate 200
provides
substantially continuous pressure resistance bands, or straps, from a top of
the label portion
116 to the gate 200. Pressure resistance straps that are substantially
continuous provide
greater resistance to internal pressure, as discussed herein.
[0056] Figure 6 illustrates a top plan view of the container 100, showing
the shoulder
124, the bell 128 with the design features 132, the finish 140, and the
opening 144 to the
interior of the container. As illustrated in Fig. 6, the shoulder 124
comprises a diameter Ds.
Similarly, in the embodiment of the base 104 illustrated in Fig. 7, the base
104 comprises a
diameter DB. The diameter DB of the base 104 preferably is larger than the
diameter Ds of
the shoulder 124, such that the base 104 creates a single point of contact
with other
substantially similar containers in a production line, or in packaging. In
some embodiments,
the diameter DB of the base 104 is larger by 0.5 to 4 millimeters than any
other diameter of
the container 100, including the diameter Ds of the shoulder 124. It will be
appreciated that
the larger base 104 diameter DB advantageously improves conveying a
multiplicity of the
container 100 in a production line. Further, the larger base 104 diameter DB
advantageously
17
CA 02918903 2016-01-26
improves stability when there is any damage to the base 104. In some
embodiments, the
diameter Ds of the shoulder 124 may be equal to the diameter DB of the base
104, thereby
providing two points of contact, at the shoulder 124 and the base 104, with
other substantially
similar bottles in a production line, or in packaging. It will be appreciated
that where the
diameter(s) of any portion of the container 100 varies, the largest diameters
create points of
contact with other substantially similar containers in a production line, or
in packaging.
Thus, the containers generally may have either a single point of contact or
multiple points of
contact.
[0057] Figure 4 illustrates a right side elevation view of container 100,
which shows a
plan view of the shallow rib portions 156, 168 along the right-hand side of
the container 100
and a plan view of the deep rib portions 148, 160 along the left-hand side of
the container
100. Figure 5 illustrates a left side elevation view of container 100, which
shows the shallow
rib portions 156, 168 along the left-hand side of the container 100 and the
deep rib portions
148, 160 along the right-hand side of the container 100. As discussed above in
connection
with Fig. 1, the deep rib portions 148, 160 comprise a depth which is larger
than a depth of
the middle rib portions 152, 164 which is larger than a depth of the shallow
rib portions 156,
168. In some embodiments, a depth of the deep rib portions 148 may range from
1 to 10
millimeters. In some embodiments, a depth of the deep rib portions 160 may
range from 0.5
to 10 millimeters. In some embodiments, a depth of the middle rib portions 152
may range
from 0 to 5 millimeters. In some embodiments, a ratio of the depth of the deep
rib portions
148 to the depth of the middle rib portions 152 may vary from 1:1 to 20:1.
[0058] In some embodiments, a depth of the shallow rib portions 156 may
range from 0
to 2.5 millimeters. In some embodiments, a ratio of the depth of the deep rib
portions 148 to
the depth of the shallow rib portions 156 may vary from 1:1 to 100:1,
including where the
shallow rib portions 156 have zero depth, resulting in substantially an
infinite ratio. In some
embodiments, a ratio of the depth of the middle rib portions 152 to the depth
of the shallow
rib portions 156 may vary from 1:1 to 50:1, including where shallow rib
portions 156 have
zero depth, resulting in substantially an infinite ratio.
[0059] In some embodiments, a depth of the shallow rib portions 168 may
vary from 0 to
2.5 millimeters. In some embodiments, a ratio of the depth of the deep rib
portions 148 to the
depth of the shallow rib portions 168 may vary from 1:1 to 100:1, including
where the
shallow rib portions 168 have zero depth, resulting in substantially an
infinite ratio. In some
18
CA 02918903 2016-01-26
embodiments, a ratio of the depth of the deep rib portions 160 to the depth of
the shallow rib
portions 168 may range from 1:1 to 100:1, including where the shallow rib
portions 168 have
zero depth, resulting in substantially an infinite ratio. In some embodiments,
a ratio of the
depth of the middle rib portions 152, 164 to the depth of the shallow rib
portions 168 may
vary from 1:1 to 50:1, including where the depth of the shallow rib portions
168 is zero,
resulting in substantially an infinite ratio. In some embodiments, a ratio of
the depth of the
deep rib portions 160 to the depth of the shallow rib portions 168 may vary
from 1:1 to 100:1,
including a substantially infinite ratio arising when the shallow rib portions
168 have zero
depth.
[0060] Transitions between the various depths of the rib portions are
smooth, as
illustrated in Figs. 1-5. In some embodiments, however, the transitions may
comprise other
forms, such as by way of non-limiting example, a step-change connecting the
varying depth
portions. Moreover, some embodiments may minimize the shallow rib portions
156, 168 to
20-30% of the circumference of the container 100, thereby resulting in a
respective 70-80%,
of the container circumference comprising the deep rib portions 148, 160 and
the middle rib
portions 152, 164. However, any ratio of shallow rib portions to deep rib
portions and middle
rib portions may be utilized.
[0061] Figure 9 illustrates an exemplary embodiment of a preform 230 which
may be
blow-molded to form the container 100. The preform 230 preferably is made of
material
approved for contact with food and beverages, such as virgin PET, and may be
of any of a
wide variety of shapes and sizes. The preform 230 comprises a neck portion 232
and a body
portion 234, formed monolithically (i.e., as a single, or unitary, structure).
Advantageously,
the monolithic arrangement of the preform 230, when blow-molded into a bottle,
such as
container 100, provides greater dimensional stability and improved physical
properties in
comparison to a preform comprising separate neck and body portions, which are
bonded
together. The preform 230 illustrated in Fig. 9 generally is of a type which
will form a 12-16
oz. beverage bottle, but as will be understood by those skilled in the art,
other preform
configurations may be used depending upon the desired configuration,
characteristics and use
of the final article. The preform 230 may be made by injection molding methods
including
those that are well known in the art.
[0062] Figure 10 illustrates a cross-sectional view of an exemplary
embodiment of the
preform 230 which may be used to form the container 100. The neck portion 232
of the
19
CA 02918903 2016-01-26
preform 230 begins at an opening 236 to an interior of the preform 230 and
extends to and
includes a support ring 238. The neck portion 232 is further characterized by
the presence of
a structure for engaging a closure. In the illustrated embodiment, the
structure includes
threads 240, which provide a means to fasten a cap to the container 100
produced from the
preform 230. It will be appreciated that the illustrated preform 230 comprises
a shorter
overall neck portion than most conventional preforms. Further, the neck
portion 232 of the
preform 230 comprises a wall thickness 252 which is generally thinner than in
conventional
preforms, wherein the wall thickness 252 of the neck portion 232 is measured
at the very top
or between the threads 240, or between any other protruding structures.
[0063] The body portion 234 is an elongated structure extending down from
the neck
portion 232 and culminating in an end cap 242. In some embodiments, the body
portion 234
is generally cylindrical, and the end cap 242 is conical or frustoconical, and
may also be
hemispherical, and the very terminus of the end cap 242 may be flattened or
rounded. The
preform 230 comprises a wall thickness 244 throughout most of the body portion
234 which
depends upon an overall size of the preform 230, as well as a predetermined
wall thickness
and overall size of the resulting container 100. As illustrated in Fig. 10,
the wall thickness
244 tapers, between 250 and 248, to a wall thickness 246 immediately below the
support ring
238. In some embodiments, the wall thickness between 244 and 250 may further
comprise a
slight taper so as to facilitates a release of the preform 230 from a core
during the injection
molding process. Specific dimensions of the wall thickness, as well as
dimensions of various
other features of the preform 230 are discussed in detail in U.S. Patent
Application Serial No.
13/295,699, entitled "Preform Extended Finish for Processing Light Weight
Ecologically
Beneficial Bottles," filed on November 14, 2011, the entirety of which is
incorporated herein
by reference and forms a part of the present disclosure.
[0064] Once the preform 230 has been prepared by way of injection molding,
or other
equivalent process, the preform 230 may be subjected to a stretch blow-molding
process. As
illustrated in Fig. 11, the preform 230 is placed in a mold 260 'comprising a
cavity
corresponding to the desired container shape. The preform 230 is then heated
and expanded
by stretching such as by way of a stretch rod inserted into the center of the
preform 230 to
push it to the end of the mold 260 and by way of air forced into the interior
of the preform
230 to fill the cavity within the mold 260, creating a container 264, as shown
in Fig. 12. As
illustrated in Fig. 12, the container 264 comprises a neck portion 232 and a
body portion 234
CA 02918903 2016-01-26
corresponding to the neck and body portions of the preform 230 of Fig. 11. The
neck portion
232 is further characterized by the presence of the threads 240 or other
closure engagement
means that provides a way to fasten a cap onto the container 264. Thus, the
blow-molding
process normally is restricted to the body portion 234 of the preform 230 with
the neck
portion 232, including the threads 240 and the support ring 238, retaining the
original
configuration of the preform 230.
[0065]
In some embodiments, the containers 100, 264 described herein may be made
from any suitable thermoplastic material, such as polyesters including
polyethylene
terephthalate (PET), polyolefins, including polypropylene and polyethylene,
polycarbonate,
polyamides, including nylons (e.g. Nylon 6, Nylon 66, MXD6), polystyrenes,
epoxies,
acrylics, copolymers, blends, grafted polymers, and/or modified polymers
(monomers or
portion thereof having another group as a side group, e.g. olefin-modified
polyesters). These
materials may be used alone or in conjunction with each other. More specific
material
examples include, but are not limited to, ethylene vinyl alcohol copolymer
("EVOH"),
ethylene vinyl acetate ("EVA"), ethylene acrylic acid ("EAA"), linear low
density
polyethylene ("LLDPE"), polyethylene 2,6- and 1,5-naphthalate (PEN),
polyethylene
terephthalate glycol (PETG), poly( cyclohexylenedimethylene terephthalate ),
polystryrene,
cycloolefin, copolymer, poly-4-methylpentene-1, poly( methyl methacrylate),
acrylonitrile,
polyvinyl chloride, polyvinylidine chloride, styrene acrylonitrile,
acrylonitrile-butadiene-
styrene, polyacetal, polybutylene terephthalate, ionomer, polysulfone,
polytetra-
fluoroethylene, polytetramethylene 1,2-dioxybenzoate and copolymers of
ethylene
terephthalate and ethylene isophthalate. In certain embodiments, preferred
materials may be
virgin, pre-consumer, post-consumer, regrind, recycled, and/or combinations
thereof.
[0066]
In some embodiments, polypropylene also refers to clarified polypropylene. As
used herein, the term "clarified polypropylene" is a broad term and is used in
accordance with
its ordinary meaning and may include, without limitation, a polypropylene that
includes
nucleation inhibitors and/or clarifying additives. Clarified polypropylene is
a generally
transparent material as compared to the homopolymer or block copolymer of
polypropylene.
The inclusion of nucleation inhibitors helps prevent and/or reduce
crystallinity, which
contributes to the haziness of polypropylene, within the polypropylene.
Clarified
polypropylene may be purchased from various sources such as Dow Chemical Co.
Alternatively, nucleation inhibitors may be added to polypropylene.
21
CA 02918903 2016-01-26
[0067] As used herein, "PET" includes, but is not limited to, modified PET
as well as
PET blended with other materials. One example of a modified PET is IF A-
modified PET,
which refers to PET in which the IPA content is preferably more than about 2%
by weight,
including about 2-10% IP A by weight, also including about 5-10% IP A by
weight. In
another modified PET, an additional comonomer, cylohexane dimethanol (CHDM) is
added
in significant amounts (e.g. approximately 40% by weight or more) to the PET
mixture
during manufacture of the resin. Additional techniques for forming the
container 264,
including additional materials, properties of the materials, as well as
various advantageous
additives are discussed in detail in U.S. Patent Application Serial No.
13/295,699, entitled
"Preform Extended Finish for Processing Light Weight Ecologically Beneficial
Bottles,"
filed on November 14, 2011, the entirety of which is incorporated herein by
reference and
forms a part of the present disclosure.
[0068] While the invention has been described in terms of particular
variations and
illustrative figures, those of ordinary skill in the art will recognize that
the invention is not
limited to the variations or figures described. In addition, where methods and
steps described
above indicate certain events occurring in certain order, those of ordinary
skill in the art will
recognize that the ordering of certain steps may be modified and that such
modifications are
in accordance with the variations of the invention. Additionally, certain of
the steps may be
performed concurrently in a parallel process when possible, as well as
performed sequentially
as described above. To the extent there are variations of the invention, which
are within the
spirit of the disclosure or equivalent to the inventions found in the claims,
it is the intent that
this patent will cover those variations as well. Therefore, the present
invention is to be
understood as not limited by the specific embodiments described herein, but
only by scope of
the appended claims.
22
