PCR Hot-Fill Container Channels and Moveable Base for Shape Stability
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Solution Overview
Problem
Hot-fill containers made with increased recycled content (PCR) face challenges in maintaining structural integrity and stability due to variable thermal and mechanical stresses during filling, leading to deformation and height variations, which affect distribution and labeling efficiency.
Innovation Solution
The container design incorporates continuous channels in the sidewall and optimized base structures with increased PCR content, allowing for interactive movement under pressure changes to regulate internal forces and maintain shape during hot filling and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If containers are made with increased recycled content (PCR), then environmental sustainability is improved, but structural integrity and shape stability deteriorate due to variable thermal and mechanical stresses during filling
Solution Approach 1:
The container incorporates a moveable base that can dynamically adjust its position and shape in response to thermal and mechanical stresses during filling. The base includes alternating angled inner and outer walls that can move independently to accommodate pressure changes, allowing the container to adapt its structure rather than resist forces rigidly, thus maintaining integrity with high PCR content
Solution Approach 2:
The container design allows parameter changes in the base structure during the filling process. The alternating angled walls enable the base to change its geometric configuration in response to temperature and pressure variations, allowing the material to flow and redistribute to maintain structural integrity while accommodating thermal expansion and contraction
2Temperature
If containers are designed to withstand hot-fill temperatures, then thermal stability is improved, but deformation under thermal and hydraulic stress increases
Solution Approach 1:
The container sidewalls incorporate continuous channels that allow dynamic deformation during hot-filling. These channels enable the sidewalls to expand and contract in a controlled manner under thermal and hydraulic stress, preventing rigid deformation while maintaining shape. The moveable base works in conjunction to absorb and distribute stresses throughout the container structure
Solution Approach 2:
The container base is segmented into multiple regions with alternating angled inner and outer walls, creating multiple movable segments that can deform independently. This segmentation allows stress distribution across multiple points rather than concentrating deformation in one location, reducing overall shape distortion while maintaining thermal stability
3Ease of manufacture
If containers are designed with fixed base structures, then manufacturing simplicity is improved, but adaptability to pressure changes and vacuum conditions deteriorates
Solution Approach 1:
The base structure transitions from a fixed design to a dynamic, moveable structure with alternating angled walls that can respond to pressure changes. During filling, the base moves to accommodate hydraulic pressure, and during cooling, it responds to vacuum conditions. This dynamic adaptability is achieved through the geometric design of the base rather than complex mechanical components, maintaining ease of manufacture
Solution Approach 2:
The base structure is designed to change its geometric parameters in response to pressure and vacuum conditions. The alternating angled walls allow the base to expand under pressure and contract under vacuum, adapting its volume and shape without requiring complex active control mechanisms. This passive parameter change maintains manufacturing simplicity while achieving pressure adaptation
4Productivity
If containers are designed to maintain consistent height, then labeling efficiency is improved, but structural flexibility under thermal stress deteriorates
Solution Approach 1:
The container incorporates controlled dynamic elements in the base that allow temporary deformation during filling followed by automatic return to original shape. The alternating angled walls provide a mechanism for controlled flexibility that enables height consistency during distribution and labeling while accommodating necessary structural movement during thermal stress, achieving both productivity and functional flexibility
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design effectively reduces non-recoverable deformation, maintains structural integrity, and ensures consistent container height, facilitating high-speed labeling and stable palletization despite increased PCR content.
Implementation Method 1
continuous channels having a first as molded channel configuration formed in and extending around a circumference of the cylindrical sidewall, wherein the continuous channels are configured to resist vacuum compression in the radial or transverse direction of the beverage container
Implementation Method 2
the sidewall is configured to expand longitudinally from a first unpressurized configuration to a second pressurized configuration
Implementation Method 3
the base portion is configured to move to a different extent longitudinally from a first unpressurized configuration to a second pressurized configuration
Implementation Method 4
after cooling the sidewall is configured to contract longitudinally to a third pressurized configuration
Data Source
AI summary
The disclosure relates to a beverage container. Channels of the container can have a first as molded channel configuration formed in and extending around a circumference of a sidewall of the container and can be configured to resist vacuum compression in the radial or transverse direction of the container. After hot filling and capping and prior to cooling, the sidewall and base can be configured to move interactively and in differential amounts under changing pressure conditions. The sidewall can be configured to expand longitudinally from a first unpressurized configuration to a second pressurized configuration, and the base portion can be configured to move to a different extent longitudinally from a first unpressurized configuration to a second pressurized configuration. After cooling, the sidewall can be configured to contract longitudinally to a third pressurized configuration, and the base can be configured to move to a different extent to a third pressurized configuration.