A method for making polymer containers with inner patterns and designs

Abstract

A method for making a PET container (400) including steps for melting a polymer resin (202) and flowing it through one or more conduits (206); applying stress over the molten resin in controlled manner before feeding it into forming chambers (208); allowing punch and a die of forming chamber for opening and closing and the punch to form one or more designs into inner surface of preform; passing stress-treated molten polymer into forming chamber (208) to form the preform (210); transferring the preform (210) to blowing chamber (212) for injection stretch blow molding process; blowing compressed air for giving final shape and size to the container (400); and collecting the container (400). The punch is a specially designed with one or more designs (D1, D2, Dn) to provide impressions on inner surface (406) of the container (400) in the form of embossed, debossed design, or a combination of both.

Description

A METHOD FOR MAKING POLYMER CONTAINERS WITH INNER PATTERNS AND DESIGNSTECHNICAL FIELD

[0001] The present disclosure relates generally to the field of packaging. More particularly, the proposed disclosure relates to a method for manufacturing a polymer container with unique features of patterns and design including embossing / debossing or both on inner surface to avoid counterfeiting activities of the filled product.BACKGROUND

[0002] Packaging, the fifth pillar of marketing playing a prominent role for the industries to sell their products. The packaging, supported by the technology playing such unimaginable roles where consumer is attracted by the packaging and not merely by the product it contains. Many consumers retain the packaging as a show piece within their collections. Conventionally, containers used for holding liquid or beverages used by the bottling industry, are made of glass but due to their breaking properties, weight, and difficulty in forming in desirable shape and size proved costly.

[0003] Later, the glass has been replaced by the various plastic polymers having advantage of light weight, low cost, and low breakage properties. But inception of Polyethylene Terephthalate (PET) has changed the complete scenario for such containers, supported by the technology of ‘Injection Stretch Blow Molding” (ISBM). With the combination of PET and the ISBM, it is possible to make lightest possible container with less materials, and required stiffness.

[0004] FIG. 1 depicts an existing art where a side view of a PET bottle 100 with body 102 is shown. The bottle 100 is made through a preform using injection stretch blow molding process. The bottle comprises a neck 104 portions, threaded portion 106 to place a lid, a plurality of ribs in two parts 108A and 108B with a separation of flat middle section 110 depicting uneven outer and inner surfaces and a flattened and / or shallow rib 112 extended vertically. The ribs 108A and 108B provide grip to hold the bottle as well as stiffening along with the flattened vertical rib 112.

[0005] However, disposal of such plastic materials is the great problem and their long degradation cycle is barrier to their eco-friendly uses. This can be minimise by reducing weight of the similar container to decrease the per container weight. Further, copycatting, a known phenomenon and creates problems for genuine manufacturers of products. While copysame label and same type of container, a consumer is easily deceived and not able to differentiate between the original and duped product. Hence, there is a requirement for such container which can meet above-mentioned shortcomings and limitations.

[0006] There are many prior arts disclosing formation of plastic polymer bottles and containers with PET using injection stretch blow molding (ISBM) technology. Patent document US5158817A discloses a method for forming the base section of oblong oval containers and a preform for affecting same using the ISBM. The container sides are much wider than ends; there is an uneven stretching and distribution of the material of the preform. This particularly relates to a preform having a modified container base forming portion which is of a reduced wall thickness and which includes as intermediate conical part. By so shaping the base forming portion of the preform, correct amounts of material are provided for forming the base construction of a container.

[0007] Another Patent document WO2017155712A1 discloses an injection stretch blow molded container prepared by way of injection molding a tubular preform followed by reheating and accurately stretching and blow molding the heated preform in the container. The container and preform comprises from 70wt. % to 97.5 wt. % of a semi-crystalline polyolefin composition comprising one or polymers selected from polyethylene polymers and polypropylene polymers from 2.5wt. % to 30wt. % of an alicyclic polyolefin composition, wherein the alicyclic polyolefin composition has a glass transition temperature from 80°C to 145°C.

[0008] While the cited references discloses forming of polymer bottles applying injection stretch blow molding (ISBM) technology with outer wall of the body having ribs or embossing / debossing, allowing uneven outer surface for label, which poses a drawbacks. Also, there is no teaching of configuring ribs or designs on the inner wall keeping surface of the outer wall even. Therefore, to address the abovementioned drawbacks and limitation, it would be better to provide a solution to the problem by configuring ribs / desired designs on the inner wall to avoid copycatting, and keeping surface of the outer wall even.

[0009] There is, therefore, a need in the art to provide improved tactile features, simple, cost-efficient method for manufacturing polymer containers with unique features of patterns and design including embossing / debossing or both on inner surface to avoid counterfeiting activities of the filled product.OBJECTS OF THE INVENTION

[0010] A general object of the present disclosure is to provide a method for manufacturing containers with unique features of embossed / debossed patterns and designs on the inner surface to avoid counterfeiting activities of the filled product.

[0011] An object of the present disclosure is to provide a method with improved tactile features, simple, and cost-efficient.

[0012] Another object of the present disclosure is to provide the unique visual effects where user feels effervesces properties of the filled beverages while consuming in such types of containers.

[0013] Another object of the present disclosure is to provide method for sustainable packaging solution by reducing weight of the container without compromising original features including stiffness.

[0014] Another object of the present disclosure is to provide scope for post-consumer recycling process that reduces energy consumption and greenhouse gas emissions.

[0015] Another object of the present disclosure is to provide outer wall of the container as plain surface for eco-friendly printing and labelling.

[0016] Another object of the present disclosure is to provide recycled polymer without cross-contamination by using paper labelling, and food-grade chemical for printing, those are removable before recycling process.

[0017] Yet another object of the disclosure is to provide a method that reduced emission of greenhouse gases and helping environment by consuming fewer polymers.SUMMARY

[0018] Aspects of the present disclosure relates generally to the field of packaging. More particularly, the proposed disclosure relates to a method for manufacturing a polymer container with unique features of patterns and design including embossing / debossing or both on inner surface to avoid counterfeiting activities of the filled product.

[0019] In an aspect, the disclosure is about a method for making a polymer container including steps for melting a polymer resin using at least one heating process and flowing molten polymer through one or more conduits; applying stress over the molten resin for stress treatment before feeding it into one or more forming chambers; allowing simultaneous movement of a specially designed punch and a die of each forming chamber for the punch to form one or more designs into inner surface of preform; passing stress-treated molten polymer resin into each forming chamber to form the preform; transferring the preform fromforming chamber to blowing chamber for performing injection stretch blow molding process; creating cast transition temperature regions for maintaining temperature variation in the mold for forming embossing / debossing of one or more designs formed by the punch on the inner surface of the preform; blowing compressed air for longitudinal stretching and latitudinal expansion of the preform for giving final shape and size to obtain the container; and removing and collecting the container after releasing from the injection stretch blow molding process.

[0020] In an embodiment, the preform is configured with a side wall extending around a first axis, a bottom wall extending to a second axis transverse to the first axis, a neck portion with a plurality of threads, and a support ring; and the side wall has a predefined thickness.

[0021] In an embodiment, the punch is a specially designed punch configured with one or more designs to provide impressions on inner surface of the preform, and the designs and patterns is selected from one or more alphabets, one or more numerals, and one or more drawings including a geometrical drawing.

[0022] In an embodiment, the designs configured over the punch provide impressions selected as an embossed design, a debossed design, and a combination of both.

[0023] In an embodiment, the one or more alphabets, one or more numerals, and other designs are arranged in a meaningful sequence to represent name of an entity, logo, and patterns.

[0024] In an embodiment, the stress is applied in a controlled manner to the molten polymer resin flowing in the one or more conduits to increase molecular orientation of the molded polymer.

[0025] In an embodiment, during the injection stretch blow molding process, cast transition temperature regions are marked, wherein the all designs for embossed and debossed regions are kept in a low temperature zone and remaining regions in a higher temperature zone and vice-versa, and depends on the size and thickness of the container.

[0026] In an embodiment, the heating temperature is provided by at least one heating source based on conduction model, and wherein the heating source is selected as the infrared beam, electrical heating and the like applied for heating the polymer resin, air, and for the cast temperature regions.

[0027] In an embodiment, the compressed air is blown to stretch and expand the preform in such a way that it avoid non-uniform stretch and expansion of the one or more designs and do not distort and de-shape the design patterns embossed / debossed on the inner surface of the container.

[0028] In an embodiment, the polymer resin used to make the container (400) is selected at least one from a polyester polymer, homopolymer, a co-polyester polymer, and postconsumer recycled (PCR) material.

[0029] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure.

[0031] FIG. 1 illustrates a PET bottle comprising one or more features disclosed in prior art.

[0032] FIG. 2 illustrates an exemplary block diagram depicting process flow of the injection stretch blow molding for making containers of plastic polymers, in accordance with embodiments of the present disclosure.

[0033] FIG. 3 illustrates a schematic view of a preform used to make final container using injection stretch blow molding process, in accordance with embodiments of the present disclosure.

[0034] FIG. 4 illustrates an exemplary schematic view of a container with embossed designs on inner surface made through injection stretch blow molding process, in accordance with embodiments of the present disclosure.

[0035] FIG. 5 illustrates a method block diagram for making a container with embossed designs on inner surface made through injection stretch blow molding process, in accordance with embodiments of the present disclosure.DETAILED DESCRIPTION

[0036] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0037] Embodiments explained herein relate generally to the field of packaging. More particularly, the proposed disclosure relates to a method for manufacturing a polymer container with unique features of patterns and design including embossing / debossing or both on inner surface to avoid counterfeiting activities of the filled product.

[0038] In an embodiment, the disclosure is about a method for making a polymer container including steps for melting a polymer resin and flowing it through one or more conduits; applying stress over the molten resin in controlled manner before feeding it into forming chambers; allowing punch and a die of forming chamber for opening and closing and the punch to form one or more designs into inner surface of preform; passing stress-treated molten polymer into forming chamber to form the preform; transferring the preform to blowing chamber for injection stretch blow molding process; blowing compressed air for giving final shape and size to the container; and collecting the container. The punch is a specially designed with one or more designs to provide impressions on inner surface of the container in the form of embossed, debossed design, or a combination of both. Infrared beam heating process is applied during the method.

[0039] In an embodiment, during the injection stretch blow molding process, cast transition temperature regions are marked, wherein the all designs for embossed and debossed regions are kept in a low temperature zone and remaining regions in a higher temperature zone and the temperature variation depends on the size and thickness of the container.

[0040] In an embodiment, the compressed air is blown to stretch and expand the preform in such a way that it avoid non-uniform stretch and expansion of the one or more designs and do not distort and de-shape the design patterns embossed / debossed on the inner surface of the container.

[0041] Referring to FIG. 2 where an exemplary block diagram 200 depicting process flow of the injection stretch blow molding for making containers 400 of plastic polymers is shown.

[0042] In an aspect, the containers 400 can be prepared from a homopolymer plastic material such as polyamide (nylon), polyolefin (polyethylene) like high density polyethylene (HDPE), low density polyethylene (LDPE), polyester like polyethylene terephthalate (PET), polyethylene napthalate (PEN) or others, with or without additive. The disclosure is for the container 400, which is formed using polyethylene terephthalate (PET) (hereinafter called tobe collectively PET). Due to excellent properties PET is used extensively in the packaging industry especially in medicine and food particularly for packing of beverage, using injection stretched blow molding process on preform.

[0043] In an aspect, the injection stretched blow molding process can be done in a single- stage process or a two-stage process. In single-stage process, the preform obtained directly from the injection phase is stretched and blown straightway after a short conditioning phase, whereas in two-stage process, the preform which is obtained from the injection stage is stored until required, and heated up to a predefined temperature, and then stretched and blown with high pressure air to take the final shape of the container.

[0044] In an embodiment, the polymer resin 202 used to make the container 400 is selected at least one from a polyester polymer, a homopolymer, and a co-polyester polymer having thermoplastic properties. In a simple process, when the polymer resin 202 is melted, preform 210 is made using forming chambers 208 or cavities having predefined size and shape. The preform 210 is further fed to injection stretched blow molding (ISBM) (hereinafter called to be collectively ISBM) process, where the preform 210 is blown with compressed air in biaxial manner for stretching and widening of the preform 210 to form the container 400.

[0045] In an embodiment, the polymer resin 202 is taken which is PET polymer. The PET is optimally, added with additives, which depends on the requirements of the final container 400. The polymer resin 202 is transferred through a conveyor / hooper process to the heating chamber 204. The heating of the polymer resin 202 is carried out till it transform into liquid. The temperature applied to melt is predefined so that the crystalline properties of the PET should not affect. The molten polymer is then fed through the conduits 206 and to the forming chamber 208 for forming the preform 210.

[0046] In an embodiment, the controlled stress is applied to the molten polymer by means of conduit 206. Generally, the conditions for flowing of the molten polymer is manipulated within all or a portion of the conduits 206 to increase molecular orientation of the molded preform 210. Also, it is subjected to very high shear stress, due to which the molecules are oriented parallel to each other. High aspect ratio conduits 206 built directly into or onto the hot conduit 206 of the injection molder are employed such that a moderate amount of shear is used for pre-organised, oriented preform 210.

[0047] In an embodiment, in the forming chamber 208, a plurality of cavities, the stressed-molten polymer is injected through specially designed injectors. Here, allowingsimultaneous movement of specially designed punch and a die configured with each forming chamber 206 for the punch to form one or more designs into inner surface of preform.

[0048] In an embodiment, the punch is a specially designed punch configured with one or more designs to provide impressions on inner surface of the preform 210, and the design can be selected from one or more alphabets, one or more numerals, and one or more drawings including a geometrical drawing. The designs configured over the punch provide impressions selected as an embossed design, a debossed design, and a combination of both. This is configured in a reverse manner that is if the embossing required on the inner wall of the container 400, the punch is debossed and vice versa. The one or more alphabets, one or more numerals, and other designs are arranged in a meaningful sequence to represent name of an entity, logo, and patterns of the art.

[0049] In an embodiment, the punch and die move in relation to one another to reach the open position as they are mutually movable between a closed position and an open position. In the closed position, between the punch and die, the forming chamber 206 is defined in which the preform 210 is shaped. In open position, the punch and die are spaced apart from one another so that the preform 210 is extracted from the mold.

[0050] In an embodiment, the designs are configured on the punch in such a way that it does not obstruct ejection process of the punch from the preform 210. This is based on the angles decided for the designs over the inner wall of the container 400.

[0051] In an embodiment, the die comprises an injecting conduit through which, in closed position, the molten polymer is injected into the mold. The injecting conduit leads into the forming chamber 206 at an injection point arranged in a central region of the bottom wall of the container 400.

[0052] In an embodiment, after a suitable cooling time, during which the shape of the preform 210 stabilises, the mold can be opened and the preform 210 that has just been formed can be removed. If the mold is open before the preform 210 is cooled, the preform 210 may deform and damage.

[0053] In an embodiment, as the disclosure employ the single-stage process, therefore, the hot preform 210 is further taken for the ISBM process after the conditioning of the preform 210 to bring it to a required temperature sufficient for stretching and blowing process in biaxial manner.

[0054] In an embodiment, when the preform 210 is stretched, the PET material exhibits strain-hardening properties, which are temperature and strain-rate dependent. This provides a self-levelling effect on the stretching preform 210, which is important for forming uniformwall thickness of the container 400. The temperature and strain-rate are dependent in a manner that, at any given strain, increasing the temperature reduces the strain hardening properties and vice-versa. In contrast, at fixed temperature, increasing the strain-rate causes the PET to strain harden, above all at large strain values. Therefore, the operating temperature conditions during the blow molding, and when the container 400 and preform 210 design, need to be considered to obtain desired quality and shape.

[0055] In an aspect, the PET is a semi-crystalline thermoplastic material with a glass transition temperature Tg of 79°C. Above this temperature, the polymer chains gain mobility in amorphous part and a s a result, soften the material. This rubbery behaviour above Tg makes it possible to shape it in a container, specially a bottle using injection stretch blow molding process. The other temperatures related with the process are external temperature Te, internal temperature Ti, and crystallisation temperature Tc.

[0056] In an embodiment, the different conditions for temperature variation when heating the preform 210 for making the container 400 are (i) while entering the mold Ti > Te, (ii) at just before entering the mold Ti & Te > Tg, (iii) at least in percentage of the duration between the beginning of the heating and the entering into the mold, and thereafter in increasing order in percentage preference, (iv) during a part of the blow molding the mold temperature is kept less or equal to the glass transition temperature, and (v) during process Tg < Ti < Tc.

[0057] In an embodiment, the compressed air is blown to stretch and expand the preform 210 in such a way that it avoid non-uniform stretch and expansion of the one or more designs and do not distort and de-shape the design patterns embossed / debossed on the inner surface of the container 400. During the injection stretch blow molding process, temperature distribution technique that is cast transition temperature based on two regions. The regions are marked on the blowing chamber such that the all designed regions marked for embossing or debossing are kept at one separate temperature zones, and kept in a low temperature zone, and remaining or the second regions in a higher temperature zone. However, the condition can be reversed as per the requirements. The temperature variation depends on the size and thickness of the container 400. Also, the internal pressure and the enclosed volume of the preform 210 are fully coupled, and applying the air pressure directly as a boundary condition may leads to unrealistic results.

[0058] In an embodiment, the biaxial stretching employed in the ISBM process which is very good for PET materials used in this process. This is due to the fact that biaxial deformation is the most important mode of the deformation in this process.

[0059] In an embodiment, when the container is ready, the blowing chambers are cooled for proper time and open to eject the container 400 which are further collected for ultimate use after finishing process.

[0060] In an embodiment, the heating temperature is provided by at least one heating source based on conduction model, and can be selected as the infrared beam heating, electrical heating and the like.

[0061] FIG. 3 illustrates a schematic view of a preform 210 used to make final container 400 using injection stretch blow molding process.

[0062] In an embodiment, the preform 210 made in the first phase of the single-stage process for ISBM has an outer wall 302 in a cylindrical shape extending around a first axis Y-Yl, a pushed-up bottom wall 304 that closes an end of the bottom extending to a second axis X-Xl transverse to the first axis Y-Yl, neck portion 306 along with a plurality of threads 308 and a support ring 310 for resting of a lid that is used to close the container 400 using threads 308. The wall has a predefined thickness T.

[0063] In an embodiment, the preform 210 is made through injection molding. The mold comprises a punch that decides the internal dimensions of the preform 210, and a die suitable for shaping the preform 210 externally.

[0064] In an embodiment, any adverse variation in the temperature regulation or the stress feeding, undesirable crystalline zones may form that have the appearance of clearly distinguishable opaque zones in the normally transparent preform known as stress whitening.

[0065] In an embodiment, the conditioning time of the preform 210 is relevant with respect to the shape and size. It is therefore desirable to adjust temperature accordingly. The thickness of wall of the preform 210 is depends on the size and weight of the final container 400.

[0066] FIG. 4 illustrates an exemplary schematic view of disclosed container 400 with embossed designs ‘D’ on inner surface made through injection stretch blow molding process.

[0067] In an embodiment, the disclosed container 400 is a bottle made from PET polymer. The container 400 is shaped to the size and volume from the preform 210, previously molded during the single-stage process. The size, weight, and volume of the container 400 to be filled are based on the quantity / volume of the product to be filled in the container 400, and are predefined.

[0068] In an embodiment, the container 400 can include a neck 402 including a plurality of threads 410 and a support ring 412, a body including outer wall 404 and inner wall 406 where the thickness is the difference between the outer diameter and the inner diameter and isgenerally, kept minimum to keep the weight of the container 400 minimum, but predefined, and a base 408. The base 408 is not a flat surface but for stability, is a push-up based is configured. The container 400 is configured with the wall extending around a first axis Y-Yl, the bottom wall 408 extending to a second axis X-Xl transverse to the first axis Y-Yl.

[0069] In an embodiment, the method for making the container 400 is a continuous process by ISBM process. The blowing device is to supply the chamber with a blowing pressure.

[0070] In an embodiment, the inner wall 406 of the container 400 is embossed with a plurality of designs DI, D2,... ,Dn to provide impressions on inner surface of the container 400. The embossed pair of dotted line DI running parallel from the bottom of the neck 402 to the bottom 408. The user entity name ABC is shown as D2 and the associated numeral as D3. The next D4 design is a plurality of circles embossed near the base 408 of the container 400 running down in successive manner with gradually increasing in size, and in same manner D5, a plurality of drop-shaped design placed similar to the circles. This is to disclose that all designs from DI to D5 are in embossed manner on the inner wall of the container 400.

[0071] In an embodiment, the first feature of the container 400 is the outer wall is perfectly even surface with equal diameter for compete outer wall 404 unlike other bottles made in prior arts. This area, which can be used as label area, is free from ribs / extemal protrusions and very suitable for the labelling / printing. The labelling can be done with paper instead of shrinkable plastics, and also printing with food grade colouring chemicals, which is recyclable. This particular aspect will help to achieve almost nil contamination with respect to chrome contamination and different grade polymers labelling during post-consumer recycling (PCR) process. By adhering to these practices, the disclosure can contribute to optimise recycling process, reducing cross-contamination, and preventing valuable materials from ending up in landfills by allowing them to re-enter the recycling cycle.

[0072] Furthermore, 100% PCR can be used by increasing inner strength of the container 400. This will promote making of different shapes and sizes of the container 400 that further accommodate more number of containers 400 within a given area of transportation means, reducing logistics costs. Therefore, saving resources in terms of material will save time, energy, manpower, logistic costs adding viability, sustainability in phasing out problematic single use of plastic due to packaging and printing.

[0073] The findings of a survey done by McKinsey & Company for “Sustainability in packaging: inside the minds of US consumers” reveals that 55% of US survey respondent reports that they are extremely or very concerned about the environmental impact of theproduct packaging, and 38% say that the importance of sustainable packaging when they purchase products for various end-use areas is very important and 60-70% are ready to pay more on sustainable packaging. The US Plastic Pact abides by the ISO definition for PCR includes returns of material from the distribution chain for recycling. Various studies show that PCR reduces energy consumption by at least 79% and reduces greenhouse gas emissions by at least 67%.

[0074] Another aspect of the PCR is reducing greenhouse emissions, which posing a very adverse effect on environment. The emissions are reduced by the sustainable use of the material. Further, this will reduce the carbon footprint by reducing emissions of greenhouse gasses.

[0075] In an embodiment, the second feature configured is the embossing of the designs D on the inner wall 406 of the container 400. The second feature is very difficult to copy, thus it will be very effective against the counterfeiting activities by the rival entity against the original user entity and will benefit the user entity.

[0076] In an embodiment, the compressed air is blown to stretch and expand the preform 210 in such a way that it avoid non-uniform stretch and expansion of the one or more designs D and do not distort and de-shape the design patterns embossed on the inner surface of the container 400.

[0077] FIG. 5 illustrates a method 500 block diagram for making a container 400 with embossed designs ‘D’ on inner surface 312 made through injection stretch blow molding process. The method 500 for making a polymer container 400 including step 502 for melting a polymer resin 202 using at least one heating process and flowing molten polymer through one or more conduits 206.

[0078] In an embodiment, step 504 define applying stress over the molten resin for stress treatment before feeding it into one or more forming chambers 208; and as per step 506, allowing simultaneous movement of a specially designed punch and a die of each forming chamber for the punch to form one or more designs into inner surface of preform.

[0079] In an embodiment, according to step 510, passing stress-treated molten polymer resin into each forming chamber 208 to form the preform 210; and as per step 512, transferring the preform 210 from forming chamber 208 to blowing chamber 212 for performing injection stretch blow molding process.

[0080] In an embodiment, step 514 define, creating cast transition temperature regions for maintaining temperature variation in the mold for forming embossing / debossing of one or more designs formed by the punch on the inner surface of the preform 210; and step 516 forblowing compressed air for longitudinal stretching and latitudinal expansion of the preform 210 for giving final shape and size to obtain the container 400; and according to step 518 removing and collecting the container 400 after releasing from the injection stretch blow molding process 212.

[0081] Thus the several embodiment of the process to form complexly shaped designs on the inner wall of the container 400 is unique. The weight reduction during preform forming phase will reduce the consumption of the PET polymer for saving millions of tons of polymer helping to reduce greenhouse gases. The method 500 can be applied to make containers with viable size, designs and weight. More specifically, all embodiment sufficiently made to make the container 400 are unique and very difficult to copy as such coping require huge cost and not beneficial as investment vis-a-vis gain obtained from the counterfeiting, will be a lose- lose situation.

[0082] While the foregoing describes various embodiments of the invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof. The scope of the invention is determined by the claims that follow. The invention is not limited to the described embodiments, versions, or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.ADVANTAGES OF THE INVENTION

[0083] The present disclosure provides a method for manufacturing containers with unique features of embossed / debossed patterns and designs on the inner surface to avoid counterfeiting activities of the filled product.

[0084] The present disclosure provides a method with improved tactile features, simple, and cost-efficient.

[0085] The present disclosure provides the unique visual effects where user feels effervesces properties of the filled beverages while consuming in such types of containers.

[0086] The present disclosure provides method for sustainable packaging solution by reducing weight of the container without compromising original features including stiffness.

[0087] The present disclosure provides scope for post-consumer recycling process that reduces energy consumption and greenhouse gas emissions.

[0088] The present disclosure provides outer wall of the container as plain surface for eco-friendly printing and labelling.

[0089] The present disclosure provides recycled polymer without cross-contamination by using paper labelling, and food-grade chemical for printing, those are removable before recycling process.

[0090] The present disclosure provides a method that reduced emission of greenhouse gases and helping environment by consuming fewer polymers.

Claims

We Claim:

1. A method (500) for making a polymer container (400), the method (500) comprising steps for: melting a polymer resin (202) using at least one heating process and flowing molten polymer through one or more conduits (206); applying stress over the molten resin for stress treatment before feeding it into one or more forming chambers (208); allowing simultaneous movement of a specially designed punch and a die of each forming chamber for the punch to form one or more designs into inner surface of preform; passing stress-treated molten polymer resin into each forming chamber (208) to form the preform (210); transferring the preform (210) from forming chamber (208) to blowing chamber (212) for performing injection stretch blow molding process; creating cast transition temperature regions for maintaining temperature variation in the mold for forming embossing / debossing of one or more designs formed by the punch on the inner surface of the preform (210); blowing compressed air for longitudinal stretching and latitudinal expansion of the preform (210) for giving final shape and size to obtain the container (400); and removing and collecting the container (400) after releasing from the injection stretch blow molding process (212).

2. The method as claimed in claim 1, wherein the preform (210) is configured with a side wall (302) extending around a first axis (Y-Yl), a bottom wall (304) extending to a second axis (X-Xl) transverse to the first axis (Y -Yl), and a neck portion (306) with a plurality of threads (308) and a support ring (310), wherein the side wall (302) has a predefined thickness (T).

3. The method as claimed in claim 1, wherein the punch is a specially designed punch configured with one or more designs (DI, D2,...,Dn) and patterns to provide impressions on inner surface (312) of the preform (210), wherein the design (D) is selected from one or more alphabets (D2), one or more numerals (D3), and one or more drawings including a geometrical drawing (D4, D5).

4. The method as claimed in claim 3, wherein the designs (D) configured over the punch provide impressions selected as an embossed design, a debossed design, and a combination of both.

5. The method as claimed in claim 3, wherein the one or more alphabets (D2), one or more numerals (D3), and other designs (D4, ... ,Dn) are arranged in a meaningful sequence to represent name of an entity, logo, and patterns.

6. The method as claimed in claim 1, wherein the stress is applied in a controlled manner to the molten polymer resin flowing in the one or more conduits (206) to increase molecular orientation of the molded polymer.

7. The method as claimed in claim 1, wherein during the injection stretch blow molding process, cast transition temperature regions are marked, wherein the all designs (D) for embossed and debossed regions are kept in a low temperature zone and remaining regions in a higher temperature zone and vice-versa, and depends on the size and thickness of the container (400).

8. The method as claimed in claim 1, wherein the heating temperature is provided by at least one heating source based on conduction model, and wherein the heating source is selected as the infrared beam, electrical heating and the like applied for heating the polymer resin, air, and for the cast temperature regions.

9. The method as claimed in claim 1, wherein the compressed air is blown to stretch and expand the preform (210) in such a way that it avoid non-uniform stretch and expansion of the one or more designs (D) and do not distort and de-shape the design patterns embossed / debossed on the inner surface of the container (400).

10. The method as claimed in claim 1 , wherein the polymer resin (202) used to make the container (400) is selected at least one from a polyester polymer, homopolymer, a copolyester polymer, and post-consumer recycled (PCR) material.

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