1

CONTINUOUS STRETCH BLOW MOULDING SYSTEM APPLIED TO SPECIFIED INTEGRAL HANDLE PET PREFORM AND CONTAINER STRUCTURES

TECHNICAL FIELD

[0001] The present invention relates to the equipment and method for the production of stretch-blow-moulded PET containers from injection-moulded preforms.

[0002] More particularly the present invention relates to a continuous stretch blow moulding system for production of PET containers from PET preforms in a continuous stretch blow moulding process.

[0003] More particularly but not exclusively there are disclosed additional processes and improvement processes for the system including but not limited to controlled variation of the wall thickness of the preforms; controlled variation of the wall thickness of the blown container and more particularly but not exclusively controlled variation as a function of radial angle in a horizontal plane passing through selected sections of the preform; and more particularly but not exclusively controlled variation as a function of radial angle in a horizontal plane passing through selected sections of the blown container.

BACKGROUND

[0004] The process of stretch-blow-moulding polymer containers from a prior injection moulded preform is long established in the art. Generally, preforms, as injection moulded, comprise an elongate cylindrical body portion and a neck. In the stretch blow-moulding process, the preform enters a die, held by the neck which retains its injection moulded shape, and the body is firstly mechanically stretched in at least one direction followed by the injection of air to force the polymer material into the desired shape as defined by the die cavity and also stretching the polymer material in at least one other direction - termed biaxial orientation. Where time has elapsed between the injection moulding of the preforms and their entry into the blow moulding process so that the preforms have cooled to ambient temperature, a preheating process is applied before preforms enter the blow mould die. In the latter case, because the handle of the preform should not be affected by the stretch-blow moulding process, the handle must be inserted into a handle cavity of the mould.

[0005] The process is considerably more complicated if the preform is rotationally non- symmetric and, as in the present case, is injection moulded with an integrally attached handle, and more particularly if the handle is in the form of a loop, integrally attached at two points on the body of the preform. The complication arises primarily from the need to control the orientation of the handle and to correctly preheat the body of the preform while protecting the handle from excessive heat absorption, as well as the correct insertion of the preform into the stretch-blow-moulding die. In the latter case, because the handle of the preform is not affected by the stretch blow-moulding process, the handle must be inserted into the mould to nest into a handle cavity of the mould.

[0006] Such a preform and systems for its transformation into a container with integral handle are disclosed in W02007101309. The entire disclosure of W02007101309 is incorporated herein by cross reference. In that disclosure, preforms enter a production machine such as schematically shown in Figures 55 and 72 of that document after orientation of the handle, which orientation is then maintained, through the preheating stage and into the stretch-blow-moulding die.

[0007] In the systems disclosed in W02007101309 however, the process of production is discontinuous or ‘batch’; that is, the production machines progress preforms incrementally, 2 pausing at each index to allow for pick and place loading of preforms, their insertion into a supporting mandrel and the entry into and exit from the stretch blow-moulding cavities, while the preforms are stopped for each moulding cycle. A disadvantage of this incremental processing is that it is clearly less efficient than a continuous process.

[0008] The present invention relates to a machine and process for the stretch blow moulding of preforms with an integral handle in a continuous feed, thus non-incrementing system. Because of the several stages in the process, the requirements of establishing handle orientation, the preheating stage and the stretch-blow-moulding stage as well as the removal of finished containers, requires the transfer of preforms between rotating in-feed, preheating, moulding and transport elements of the system. A continuous process makes these processes and transfers for a preform with integral handle, considerably more complex.

[0009] A system for handling a non-rotationally symmetric preform requiring a known orientation for selective preheating and prior to loading into a stretch-blow-moulding die was disclosed in US8,632,333 B2. In the arrangement of this patent, orientation is established with reference to a small reference tab or notch, but this preform not having a handle there is no need for orientation relative a heat shield.

[0010] US 2012/0048683 also discloses a continuously rotating blow moulding system in which special precautions are taken against deformation of preforms due to centrifugal forces by specific orientation of the preforms passing through the system. Although it is noted that such orientation may be of benefit for non-symmetric preforms, for example those with a handle, there is no disclosure of orientation of a preform for entry into a handle heat shield.

[0011] US 6779651 specifically teaches the importance of orientation of preforms with handles prior to introduction of the preform into the stretch-blow-moulding die. There is however no suggestion that the handle requires shielding by means of a heat shield so that there is no arrangement in this patent of the control of orientation to marry the handle with a heat shield.

[0012] A suite of patents and applications to Thibodeau, US D746,142 S; US8,524,143 B2; US9,499,302 B2 and WO2015/112440 A1 are drawn to the production of containers with integral handle container stretch-blow-moulded from injection moulded preforms with integral handles. However, in contrast with the arrangement of the present application as set out below, the handle of a container according to Thibodeau is of radically different shape to the handle as injection moulded with the preform, being subjected to a sort of uncurling during the stretch- blow-moulding phase.

[0013] Another continuously rotating blow-moulding system is disclosed in US 5683729 in which mechanisms for the transfer of preforms between various stages of the system are described. There is however no disclosure of preforms with integral handles and thus no treatment of special orientation of the preforms.

[0014] International Patent Application PCT/AU2018/051285 to the present applicant discloses a continuous stretch blow moulding system for integral handle PET containers.

[0015] In order to render the process described in that application it would be advantageous if the process described therein could be improved to require more economical 3 use of plastic, to permit high throughput notwithstanding distortion that may occur during the reheating o the preforms and efficient accommodation of downstream processes.

[0016] It would be further advantageous if preform wall thickness could be controlled as a function of radial angle in a horizontal plane passing through selected sections of the preform; and if container wall thickness could be controlled as a function of radial angle in a horizontal plane passing through selected sections of the blown container.

[0017] It is an object of the present invention to address or at least ameliorate some of the above disadvantages.

NOTES

[0018] The term “comprising” (and grammatical variations thereof) is used in this specification in the inclusive sense of “having” or “including”, and not in the exclusive sense of “consisting only of’.

[0019] The above discussion of the prior art in the Background of the invention, is not an admission that any information discussed therein is citable prior art or part of the common general knowledge of persons skilled in the art in any country.

DEFINITIONS

[0020] Continuous preform feed: In this specification, continuous preform feed occurs where preforms are advanced at constant velocity from an entry location to an exit location along a path. This is to be distinguished from a batch mode operation where the preform feed advances and then stops whilst a blow mould operation takes place.

[0021] Non-symmetric preform: In this specification, a non-symmetric preform is a preform which is not symmetric about its longitudinal axis. The primary source of nonsymmetry occurs where the preform incorporates an integral handle. In certain embodiments the preform walls are also a source of non-symmetry.

[0022] Integral handle preform: In this specification, an integral handle preform is a non- symmetric preform which has a handle portion extending from a body of the preform and wherein the handle is integrally moulded with the body of the preform.

[0023] Stretch blow moulding die: In this specification, a stretch blow moulding die comprises an openable cavity adapted to receive a preheated preform for subsequent stretch blow moulding of the preheated preform within the cavity of the die.

SUMMARY OF INVENTION

[0024] Accordingly, in one broad form of the invention there is provided a PET container having a neck portion and a body portion to which is integrally connected a PET handle; the PET handle integrally connected at least a first connection point to the container; the PET container blown from a PET preform in a stretch blow moulding process; wherein a region in the form of a strip of PET material is located on the container under the PET handle. 4

[0025] Accordingly, in a further broad form of the invention there is provided a PET container having a neck portion and a body portion to which is integrally connected a PET handle; the PET handle comprising an elongate portion of PET material integrally connected at at least a first connection point to the container; the PET container blown from a PET preform in a stretch blow moulding process; wherein a region in the form of a strip of PET material is located on the preform and corresponding container opposite the elongate portion of PET material.

[0026] Accordingly, in a further broad form of the invention there is provided a PET container having a neck portion and a body portion to which is integrally connected a PET handle; the PET handle integrally connected at least a first connection point to the container; the PET container blown from a PET preform in a stretch blow moulding process; wherein a region in the form of a strip of PET material is located on the preform and corresponding container opposite the PET handle.

[0027] Preferably the handle and the narrow strip form a solid mass thereby to maintain the integral connection between the handle and the blown container.

[0028] Preferably the integrally connected handle and the narrow strip form a solid connected mass thereby to strengthen the integral connection between the handle and the blown container.

[0029] Accordingly, in a further broad form of the invention there is provided a PET container stretch blow-moulded from a preform; the preform and the container having a neck portion and a body portion to which is integrally connected a PET handle; the PET handle comprising an elongate portion of PET material integrally connected at least at a first connection point on a body portion of the preform and to on the container; the PET container blown from a PET preform in a stretch blow moulding process; wherein a region in the form of a strip of PET material is located on the preform and corresponding container opposite the elongate portion of PET material handle; the strip of material differentiated in thickness from thickness of a wall of the container on a side opposite from that of the connection point.

[0030] Preferably the handle and the narrow strip forms a solid mass thereby to maintain the integral connection between the handle and the blown container.

[0031] Preferably the elongate portion of PET material comprises a stem.

[0032] Preferably the PET handle is connected at a second connection point to the container.

[0033] Preferably the first connection point is an upper connection point.

[0034] Preferably the second connection point is a lower connection point.

[0035] Preferably the preform has a neck portion and an expandable portion located there below the neck portion.

[0036] Preferably the region of the preform body defined by the strip between the two attachment points remains substantially stable during the stretching and blowing of the container. 5

[0037] Preferably both the regions of the outer and inner surface layers laterally away from the narrow trip are subjected to biaxial stretching.

[0038] Preferably the outer surface of the narrow strip remains substantially stable but the wall of the container at the strip and the inner layers between the handle attachment points undergoes a degree of flow and thinning together with surrounding regions as the plasticised PET material comes under the influence of the stretching and blowing forces.

[0039] Preferably the PET handle is formed in the same mould as and at the same time as the preform is moulded.

[0040] Preferably the loading of plastics material in the region of the wall subtended between the first location and the second location is differentially controlled as a function of location on the circumference of the wall in this region.

[0041] Preferably the region is designated the differential loading region.

[0042] Preferably there is an increased loading of material in the region of immediately between the first location and the second location points whilst, an opposite region located diametrically opposite the differential loading region has is reduced in material thickness removed from it as indicated in dotted outline.

[0043] Preferably the differential material loading is a function of circumferential position on walls of the preform aids in providing control over the wall thickness of the blown container.

[0044] Preferably the stretch blow moulding process is a two stage stretch blow moulding process.

[0045] Preferably the differential loading region subtended between the first location and the second location remains substantially unchanged during the blowing process.

[0046] Preferably the differential loading region is an extension of and part of the neck portion of the preform.

[0047] Preferably the preform includes a symmetrical thickening of the wall of the preform in the lower region of the body portion which extends from immediately below the point of connection of the lower end of handle.

[0048] Preferably at a second, intermediate region located between the first connection point and the second connection point of handle, the wall thickening of the preform tapers gradually from a first thickness T1 to a second thinner thickness T2.

[0049] Preferably the thickening is symmetrical about the longitudinal axis of the preform.

[0050] Preferably the thickening results in a controllable increase in the thickness of material in the blown container in the corresponding intermediate region, and also in a sub- region immediately below the first connection point of the lower end of handle. 6

[0051] Preferably the thickening results in a controllable increase in the thickness of material in the blown container in the corresponding intermediate region, and also in a sub- region immediately below the second connection point of the lower end of handle.

[0052] Accordingly in a further broad form of the invention there is provided an integral handle of a stretch blow-moulded container and injection moulded preform; the integral handle respectively comiected at a single comiection region on a body portion of the preform and at a single connection region of a body of the container, wherein the wall thickness of the body portion of the preform and of the container in a region extending below the handle connection region on the body of the container is substantially equal to thickness of adjoining wall regions.

[0053] Preferably the handle extends from the single region on the preform and on the container proximate a neck portion common to both the preform and the container.

[0054] Preferably the handle includes an upper arcuate portion extending from the single connection region; the arcuate upper portion transitioning into a substantially straight, downwardly projecting portion.

[0055] Preferably the handle includes a central web lying in a central plane passing through a centre line of the body portion of the preform and a plane bisecting the body portion of the container.

[0056] Preferably the central web is bounded by an edge; the edge extending continuously around a periphery of the web from an upper junction point to a lower junction point on both the preform body portion and on the body of the container.

[0057] Preferably a rib normal to the web extends along the edge; the rib projecting outwardly and symmetrically from both sides of the plane; the rib and central web forming an I-beam like cross section.

[0058] Preferably the upper and lower comiection cross sections of the rib meld with surfaces of both the preform body portion and the body of the container.

[0059] Preferably inward facing sections of both the web and the rib is provided with one or more scalloped configurations; the scalloped configurations aiding in gripping the handle in use.

[0060] Preferably a thumb support is provided projecting from an upper portion of the rib.

[0061] Accordingly in a further broad form of the invention there is provided a method of reducing volume of PET polymer in a container stretch blow-moulded from an injection moulded preform with an integral handle; the handle formed as a loop extending between first and second connection points on the body of the preform; the method including the steps of: a. changing the integral handle of the preform from the integral handle formed as a loop to a single connect handle extending from a single connection region on the body portion of the preform, 7 b. reducing wall thickness of the body portion of the preform in a region below the connection region of the single connect handle from a reinforced thickened wall to a thickness equal to wall thickness of adjoining regions of the preform.

[0062] Preferably the handle extends from the single connection region on the preform and on the container proximate a neck portion common to both the preform and the container.

[0063] Preferably the handle includes an upper arcuate portion extending from the single region; the arcuate upper portion transitioning into a substantially straight, downwardly projecting portion.

[0064] Preferably the handle includes a central web lying in a plane passing through a centre line of the body portion of the preform and a plane bisecting the body portion of the container.

[0065] Preferably the central web is bounded by an edge; the edge extending continuously around a periphery of the web from an upper junction point to a lower junction point on both the preform body portion and on the body of the container.

[0066] Preferably a rib normal to the edge extends along the edge; the rib projecting outwardly and symmetrically from both sides of the web; the rib and central web forming an I-beam like cross section.

[0067] Accordingly in a further broad form of the invention there is provided a single connect handle of a stretch blow-moulded container; the container stretch blow-moulded from an injection moulded preform; the preform including an integral handle connected at a single connection region of the preform; the handle extending outward from, and generally parallel, for a section of a body portion of the preform and, wherein wall thickness of the preform in the section of the body portion is equal to wall thickness of adjacent regions of the preform.

[0068] Accordingly in a further broad form of the invention there is provided an injection moulded preform with integral handle for stretch blow-moulding a container with an integral handle; the preform having a cylindrical body portion extending from below a neck of the preform and a curved closure at a base of the body portion; walls of the cylindrical body portion of the preform being of constant thickness.

[0069] Preferably the integral handle is connected to the preform at a single connection region; the handle extending outwardly and generally parallel for a section of the body portion of the preform.

[0070] Accordingly in a further broad form of the invention there is provided a PET container stretch blow-moulded from a preform; the preform and the container having a neck portion and a body portion to which is integrally connected a PET handle; the PET handle comprising an elongate portion of PET material integrally connected at least at a first connection point on a body portion of the preform and on the container and wherein perform wall thickness is controlled so that the wall thickness of corresponding locations on the blown container 1428 is such that the wall thickness 1421B in the region of the container 1420B located beneath the handle 1426 and on the side of the container closest to the handle 1426 may be differentiated from the wall thickness 1441B in a region 1440B located on an opposite side of the container 1428 from the region 1420B.

[0071] Preferably the handle and the narrow strip form a substantially planar region thereby to maintain the integral connection between the handle and the blown container. [0072] Preferably the elongate portion of PET material comprises a stem.

[0073] Preferably the PET handle is connected at a second connection point to the container.

[0074] Preferably the first connection point is an upper comiection point.

[0075] Preferably the second connection point is a lower comiection point.

[0076] Preferably the preform has an expandable portion located below the neck portion.

[0077] Preferably the region of the preform body defined by the strip between the two attachment points remains substantially stable during the stretching and blowing of the container.

[0078] Preferably both the regions of the outer and inner surface layers laterally away from the narrow trip are subjected to biaxial stretching.

[0079] Preferably the outer surface of the narrow strip remains substantially stable but the wall of the container at the strip and the inner layers between the handle attachment points undergoes a degree of flow and thinning together with surrounding regions as the PET material comes under the influence of the stretching and blowing forces.

[0080] Preferably the PET handle is formed in the same mould as and at the same time as the preform is moulded.

[0081] Preferably loading of plastics material in the region of the wall subtended between the first location and the second location is differentially controlled as a function of location on the circumference of the wall in this region; the region designated the differential loading region.

[0082] Preferably there is an increased loading of material in the region immediately between the first location and the second location points whilst, he an opposite region located diametrically opposite the differential loading region is reduced in material thickness.

[0083] Preferably differential material loading as a function of circumferential position on walls of the preform aids in providing control over the wall thickness of the blown container.

[0084] Preferably the stretch blow molding process is a two stage stretch blow molding process.

[0085] Preferably the differential loading region subtended between the first location and the second location remains substantially unchanged during the blowing process.

[0086] Preferably the differential loading region is an extension of and part of the neck portion of the preform.

[0087] Preferably the preform includes a symmetrical thickening of the wall of the preform in the lower region of the body portion which extends from immediately below the point of connection of the lower end of handle.

[0088] Preferably at a second, intermediate region located between the first connection point and the second connection point of handle, the wall thickening of the preform tapers gradually from a first thickness to a second thinner thickness.

[0089] Preferably the thickening is symmetrical about the longitudinal axis of the preform.

[0090] Preferably the thickening results in a controllable increase in the thickness of material in the blown container in the intermediate region, and in a sub-region immediately below the second connection point of the lower end of handle. 9

[0091] Accordingly in a further broad form of the invention there is provided a method of controlling a preform for stretch blow-moulding a container with an integrally formed handle; the preform comprising a body portion and the integrally formed handle; the preform transferred from a perform supply source to a blow moulding die for blowing the container; the method including the steps of

- passing the preform through a preform handle orientating apparatus, transferring the preform to a preform transportation system, maintaining orientation of the preform handle imposed by the perform handle orientating apparatus during transfer to the perform transportation system and transfer to the blow moulding die, rotating the preforms during transport along the transportation system past an array of preform heating elements while shielding the integrally formed handle from excessive exposure to the heating elements, transferring the preform from the transportation system to the blow moulding die, and wherein the handle comprises orientable plastic material extending from at least an upper connection region on the body portion of the preform; characterised in that the handle includes a curved strengthening element at a lower end of the handle; the orientable plastic material bifurcating to form an enclosed generally triangular element.

[0092] Preferably the handle extends from the upper connection region to a lower connection region on the body portion of the preform.

[0093] Preferably the curved strengthening element abuts the body portion of the preform and the body of the blow moulded container.

[0094] Preferably the curved strengthening element conforms generally in width and cross section to width and cross section of the handle.

[0095] Preferably the handle has a gradually widening cross section approaching the upper connection region; the cross section reaching and maintaining a maximum width proximate the upper connection region cross section of the handle.

[0096] Preferably the cross section extends from opposing outer edges towards a central line; the cross section increasing in thickness progressively from the outer edges to a maximum thickness at the central line.

[0097] Preferably the handle includes a straight section angling downwardly from a lower connection region and an arcuate section extending from an end of the straight section to the upper connection region.

[0098] Preferably integrally moulded first, second and third strengthening elements are provided respectively at each of the upper connection region and the lower connection region and at the junction between the straight section and the arcuate section.

[0099] Preferably the first strengthening element at the upper connection region comprises a first curved element conforming in width and in cross section to the width and cross section of the handle proximate the upper connection region; the first curved element extending from a first separate connection region below the upper connection region to merge with the handle proximate to a first end of the maximum width of the handle. 10

[00100] Preferably the second strengthening element at the lower connection region comprises a straight element conforming in width and cross section with the width and cross section of the straight section of the handle; the straight element extending from a second separate connection region above the lower connection region to a merge with the straight section of the handle proximate the lower connection region.

[00101] Preferably the third strengthening element at the junction of the straight and arcuate sections of the handle comprises a further curved element conforming in width and cross section with the width and cross section of the handle adjacent the junction of the straight and arcuate sections of the handle; respective outer ends of the curved element merging with the straight and arcuate sections of the handle.

[00102] Preferably each strengthening element includes a web of orientable plastic material within boundaries formed respectively between the body of the preform and the first and second strengthening elements, and between the third strengthening element and the straight and arcuate sections; each web of orientable plastic material aligned with and extending equally in both directions from the central line.

[00103] Accordingly in a further broad form of the invention there is provided a method of reducing strain on a supporting finger of a hand lifting a blow-moulded container; the container provided with an integral handle; the method including: stretch blow-moulding the container from a preform which includes an orientable plastic material forming the handle; the orientable plastic material extending from at least an upper connection region, and wherein the handle includes a curved strengthening element at a lower end of the handle; the orientable plastic material bifurcating to form an enclosed generally triangular element.

[00104] Preferably the handle extends from the upper connection region to a lower connection region on the body portion of the preform.

[00105] Preferably the curved strengthening element abuts the body portion of the preform and the body of the blow moulded container.

[00106] Preferably the curved strengthening element conforms generally in width and cross section to width and cross section of the handle.

[00107] Preferably a strengthening element proximate the upper connection region; the strengthening element comprises a first curved element conforming generally in width and in cross section to a width and cross section of the handle proximate the upper connection region; the first curved element extending from a first separate connection region below the upper connection region to merge with the handle proximate to a first end of a maximum width of the handle.

[00108] Accordingly in a further broad form of the invention there is provided a handle of a stretch blow moulded container; the container blown from a preform including the handle extending from at least an upper connection region; the handle including a curved strengthening element at a lower end of the handle; the curved strengthening element 11 conforming generally in width and cross section to width and cross section of the handle; the orientable plastic material bifurcating to form an enclosed generally triangular element.

[00109] Preferably the handle extends from the upper connection region to a lower connection region on the body portion of the preform.

[00110] Preferably the curved strengthening element abuts the body portion of the preform and the body of the blow moulded container.

[00111] Preferably the curved strengthening element conforms generally in width and cross section to width and cross section of the handle.

[00112] Preferably the handle further includes a straight lower section and an arcuate section extending from an end of the straight lower section to the upper connection region; the handle having a gradually widening cross section approaching the upper connection region; the cross section reaching and maintaining a maximum width proximate the upper connection region.

[00113] Accordingly in a further broad form of the invention there is provided a blown container formed according to any of the above methods.

[00114] Accordingly in a further broad form of the invention there is provided a blown container incorporating the handle as described above.

[00115] Accordingly in a further broad form of the invention there is provided a preform having a handle: the preform being formed in a first production step of a stretch blow moulded container; the container blown from the preform including the handle extending from at least an upper connection region; the handle including a straight lower section and includes a curved strengthening element at a lower end of the handle; the orientable plastic material bifurcating to form an enclosed generally triangular element.

[00116] Preferably the handle extends from the upper connection region to a lower connection region on the body portion of the preform.

[00117] Preferably the curved strengthening element abuts the body portion of the preform and the body of the blow moulded container.

[00118] Preferably the curved strengthening element conforms generally in width and cross section to width and cross section of the handle.

[00119] In preferred forms, all of the above cavities, systems, preforms, processes, containers, handles, features and methods are effected in a continuously rotating, non- symmetric preform feed, stretch-blow-moulding machine dedicated to the stretch-blow moulding of containers from non-symmetric injection moulded preforms; the non-symmetric preforms including an integral handle extending from a junction point on a body of the preform; the body of the preform and the integral handle constituted from the same material.

[00120] Additional features of the machine in preferred forms are outlined immediately below: 12

[00121] Accordingly, in one broad form of the continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine there is provided a continuously rotating, non- symmetric preform feed, stretch-blow-moulding machine dedicated to the stretch-blow- moulding of containers from non-symmetric injection moulded preforms; the non-symmetric preforms including an integral handle extending from a junction point on a body of the preform; the body of the preform and the integral handle constituted from the same material.

[00122] In a further broad form of the continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine there is provided a method of controlling paths of grippers of pick and place apparatuses of rotating transfer systems; the rotating transfer systems operating in a continuous non-symmetric preform feed stretch-blow-moulding machine; the paths of the grippers following respective loci of non-symmetrical preforms as preforms are transferred by the rotating transfer systems from a preform pick off position, inserted into and extracted from a preform support mandrel of a preheating stage and inserted into and extracted as a stretch-blow-moulded containers from rotating stretch-blow-moulding dies; the non-symmetrical preforms comprising a body portion and an integral handle extending from the body portion; the method including the step of rotationally mounting each of the pick and place apparatuses on a rotating arm of a respective rotating transfer system.

[00123] In a farther broad form of the continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine there is provided a method of transferring a non-symmetric preform between stages of a continuous non-symmetric preform feed rotating stretch-blowmoulding machine; the non-symmetric preform being transformed into a stretch-blow- moulded container by a step of stretching and blowing the non-symmetric preform in a cavity of the stretch-blow-moulding die; the method including the step of orienting the non- symmetrical preform so that an integral handle of the preform has a known orientation at arrival at a pick off position in the machine.

[00124] In a further broad form of the continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine there is provided a method of manipulating a non- symmetrical injection moulded preform into a stretch-blow-moulding die of a continuous preform feed stretch-blow-moulding machine; the method including the step of extracting a preform from a preform preheating stage with a pick and place apparatus of a continuously rotating transfer system such that an integral handle of the preform has a predetermined orientation.

[00125] In a further broad form of the continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine there is provided a method of controllably heating a pre-form to a die introduction temperature; the pre-form having a neck portion extending from a body portion; said pre-form further having a handle portion extending radially; said method comprising controllably transferring an integral handle PET pre-form onto a continuously moving conveyor; securing the preform by its neck portion to the conveyor whereby the preform is transported by the conveyor at substantially constant velocity along a reheating path from a pre-form entry location to a pre-form exit location.

[00126] Preferably at least portions of the pre-form controllably heated to the die introduction temperature by the time it reaches the pre-form exit location.

[00127] Preferably a controllable heater array distributed along the path arranged to direct heat to selected portions of the pre-form. 13

[00128] Preferably the pre-form controllably transferred from the preform exit location into a die for stretch blow moulding of the pre-form thereby to form a blown container.

[00129] In a further broad form of the continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine there is provided a method of orienting a non-symmetrical preform for entry to stages of a stretch blow-moulding machine; the none symmetrical preform including an integral handle extending from a first junction point below a neck of the preform to a second junction point on the body of the preform; the method including the step of providing preforms to slide down inclined rails towards an orientation mechanism while supported by the necks of the preforms along upper rails of the inclined rails.

[00130] In a further broad form of the continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine there is provided a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine in which injection-moulded preforms with integral handles are transferred from a first transfer system to a preheating stage; the transfer of a preform from a gripper of the first transfer system to a preform supporting mandrel achieved in one fluid motion as a vertical axis of the preform is brought into alignment with a vertical axis of the preform supporting mandrel and the handle of the preform is slid into a heat shield provided on the mandrel.

[00131] Accordingly in further broad form of the continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine there is provided a continuous non-symmetric preform feed stretch-blow-moulding machine dedicated to the stretch-blow-moulding of containers from non-symmetric injection moulded preforms; the non-symmetrical preforms including an integral handle extending from a first junction point to a second junction point on a body of the preform; the body of the preform and the integral handle constituted from the same material; the machine including a preform orientation system to orient the handle of the preform into a known orientation at arrival at a pick off position.

[00132] Preferably the preforms are in continuous motion from an initial preform pick off point through stretch-blow-moulding into the containers and ejection from the machine as stretch-blow-moulded containers .

[00133] Preferably the integral handle retains a shape of the handle as injection moulded through all stages of the stretch-blow-moulding machine to forming a handle on the stretch- blow-moulded container.

[00134] Preferably the stages of the stretch-blow-moulding machine include a handle orientation stage; all preforms arriving at the pick off point having the integral handle oriented in a predetermined direction relative to motion of the preform approaching the pick off position.

[00135] Preferably the stages of the stretch-blow-moulding machine include a continuously rotating first transfer system transferring preforms from a continuously rotating preform feeder wheel at the preform pick off position to a transfer to preheating position at a continuously rotating preheating stage.

[00136] Preferably a first pick and place apparatus of the first transfer system includes a preform grasping gripper; reciprocating rotation and linear displacement of the grasping 14 gripper induced by a combination of a rotating carrier of the pick and place apparatus and two cam loci.

[00137] Accordingly in a further broad form of the invention there is provided a method of controllably heating a pre-form to a die introduction temperature; the pre-form having a neck portion extending from a body portion; said pre-form further having an integrally injection- moulded handle portion extending radially; said method comprising

- controllably transferring an integral handle PET pre-form onto a continuously moving conveyor while maintaining a known orientation of the handle portion; securing the preform by its neck portion to the conveyor whereby the preform is transported by the conveyor continuously from a pre-form entry location to a pre-form exit location; at least portions of the pre-form controllably heated to the die introduction temperature by the time it reaches the pre-form exit location; a controllable heater array distributed along the path conveyor arranged to direct heat to selected portions of the pre-form;

- the pre-form controllably transferred from the preform exit location into a die for stretch blow moulding of the pre-form thereby to form a blown container, and wherein the preform comprises an open neck portion and a hollow body extending from the neck portion; at least a portion of the walls of the hollow body varying in thickness, and wherein cross sections of at least a portion of inner surface of the hollow body are ovoid in section.

[00138] Preferably the handle portion is solid and has a first end and a second end; the first end integrally connected at a first, upper location to the pre-form; the second end integrally connected at a second, lower location to the pre-form.

[00139] Preferably the first, upper location is located on the body portion.

[00140] Preferably the first, upper location is located on the neck portion.

[00141] Preferably the second, lower location is located on the body portion.

[00142] Preferably the elements are arranged in modules; the modules arrayed around the continuously rotating preform conveyer; the elements controlled as a group based on height wherein the top most elements of the modules are controlled to a predetermined temperature together whilst the next down in height elements are also controlled together to a predetermined temperature - and so on down to elements at the lowest level.

[00143] Preferably a processor controls the speed of rotation of a motor in order to control the continuous speed of advancement of the preforms.

[00144] Preferably a temperature sensor provides environment temperature sensing which is utilised by processor to modulate the degree of heating of all elements by a difference factor delta (D).

[00145] Preferably the step of controllably transferring the integral handle PET pre-form onto the continuously moving conveyor includes orienting the handle of the preform into a known orientation at arrival at a pick off position. 15

[00146] Preferably the preform comprising an open neck portion and a hollow body extending from the neck portion; the preform further including an integrally injection- moulded handle; at least a portion of walls of the hollow body varying in thicknesses.

[00147] Preferably at least a portion of an inner surface of the hollow body is non- concentric with outer surfaces of the hollow body.

[00148] Preferably the outer surfaces of the hollow body are defined by diameters centred on a central longitudinal axis of the preform to form a substantially cylindrical body.

[00149] Preferably the cross sections of at least a portion of the inner surface of the hollow body are ovoid in section.

[00150] In a further broad form of the invention there is provided a method of optimizing wall thickness in a stretch-blow-moulded container; the method including the steps of: injection moulding hollow preforms in which at least a lower portion of each preform has internal cross sections non-concentric with external surfaces of the lower portion,

- bringing the preforms to a temperature suitable for stretch-blow-moulding, inserting the preforms into cavities of a stretch-blow-moulding machine, mechanically stretching the preforms and injecting air to form the container.

[00151] In yet a further broad form of the invention there is provided a mandrel forming internal surfaces of an injection-moulded hollow preform; the mandrel including at least one portion with cross sections which are non-concentric with diameters defining outer surfaces of the preform.

[00152] In yet a further broad form of the invention there is provided a method of biasing distribution of polymer material from walls of at least one portion of a preform to selected side walls of a container stretch-blow-moulded from the preform as defined above; the method including the steps of: arranging a mandrel defining inside surfaces of the preform with cross sections of the at least one portion which are non-concentric with corresponding outer surfaces of the preform as defined by a cavity of a preform injection moulding die, arranging the mandrel in the injection moulding die such that major axes of the cross sections of the mandrel of the at least one portion are aligned with a central vertical plane of the cavity, injection moulding the preform, introducing the preform into a cavity of a stretch-blow-moulding machine such that the central vertical plane of the preform is aligned with a central vertical plane of a blown container of generally rectangular cross section, and wherein the central vertical plane of the container is parallel to opposing longer sides of the container.

[00153] Preferably the centres of the cross sections of ovoid shape are centred on a longitudinal axis of the preform.

[00154] Preferably the centres of the cross sections of ovoid shape are offset from a longitudinal axis of the preform.

[00155] Preferably the centres of circular cross sections of a portion of the hollow body are offset from a longitudinal axis of the hollow body. 16

BRIEF DESCRIPTION OF DRAWINGS

[00156] Embodiments of the present invention will now be described with reference to the accompanying drawings wherein:

[00157] Figure 1 is a side view of a perform with integral handle for stretch blowmoulding a container by means of a continuous blow moulding machine;

[00158] Figure 2 is a side view of a container with integral handle stretch blow-moulded from the preform of Figure 1 ;

[00159] Figure 3 is a plan view of the stretch blow-moulding machine producing the container of Figure 2;

[00160] Figure 4 is a side view of a preform orientation and loading section of the machine of Figure 3;

[00161] Figure 4A is a plan view of the preform orientation and loading section of the machine of Figure 3;

[00162] Figure 4B is a plan view of a further preferred embodiment of a preform orientation arrangement for the machine of Figure 3;

[00163] Figure 4C is a side elevation view of the orientation arrangement of Figure 4B;

[00164] Figure 4D is a perspective view from below of the orientation arrangement of

Figures 4B and 4C;

[00165] Figure 5 is a plan view of a loading end of the preform orientation and loading section of Figure 4 and a first preform transfer system;

[00166] Figure 6 is a side view of the first preform transfer system of Figure 5;

[00167] Figure 7 is a plan view of a portion of the preform transfer system of Figures 5 and 6 and a preform loading and unloading area of a preform preheating stage of the machine;

[00168] Figure 8 is a perspective view of a perform of Figure 1 inserted into a mandrel with heat shield for transport through the preform preheating stage of the machine;

[00169] Figure 9 is an enlarged plan view of section of the machine showing a portion of the preform loading and unloading area of Figure 7, a second transfer system and a portion of the stretch-blow-moulding dies assembly of the machine;

[00170] Figure 10 is a front view of one half of a stretch-blow- moulding die for the production of the container shown in Figure 2; 17

[00171] Figure 11 is a plan view of a portion of the machine of Figure 3 showing the region of transfer of blown containers from a stretch-blow-moulding die to a container receiving bin;

[00172] Figure 12 is a schematic block diagram of control components associated with control of the heating and transport of the preforms usable with any of the above described embodiments;

[00173] Figure 13 is a side view of a typical injection-moulded preform for stretch-blowmoulding of a polymer container according to prior art.

[00174] Figure 13A is a sectioned side view of a preform according to a preferred embodiment of the invention in which a central vertical plane passing through a central vertical axis of the preform lies in the plane of the paper,

[00175] Figure 14 is a side view of a mandrel for injection-moulding the preform of Figure

13 A in which a central vertical plane passing through a central vertical axis of the mandrel lies in the plane of the paper;

[00176] Figure 15 is cross section along the vertical central axis of the mandrel of Figure

14 taken at the level of A-A;

[00177] Figure 16 is a cross section along the vertical central axis of the mandrel of Figure 3 taken at the level B-B;

[00178] Figure 17 is a side view of a container stretch-blow-moulded from the preform of Figure 2;

[00179] Figure 18 is an end view of the container of Figure 17;

[00180] Figure 19 is a sectioned side view of a further preferred embodiment of a preform according to the invention;

[00181] Figures 19A and 19B are selected cross sections of the preform of Figure 19;

[00182] Figure 20 is a sectioned side view of a further preferred embodiment of a preform according to the invention;

[00183] Figures 20A and 20B are selected cross sections of the preform of Figure 20;

[00184] Figure 21 is a sectioned side view of a further preferred embodiment of a preform according to the invention;

[00185] Figures 21A and 21B are selected cross sections of the preform of Figure 21;

[00186] Figure 22 is a sectioned side view of a further preferred embodiment of a preform according to the invention;

[00187] Figures 22A and 22B are selected cross sections of the preform of Figure 22; 18

[00188] Figure 23 is a sectioned side view of a further preferred embodiment of a preform according to the invention;

[00189] Figures 23 A and 23B are selected cross sections of the preform of Figure 23;

[00190] Figure 24 is a schematic view of an injection moulding process for producing the preforms of Figures 13 A and 19, 20 to 23;

[00191] Figure 25 is a container with integral handle as blow-moulded from the preform of Figure 13,

[00192] Figure 26 is a preform of reduced PET volume according to a preferred embodiment of the invention,

[00193] Figure 27 is a cross section view of the body of the preform of Figure 26 showing variations in wall thickness,

[00194] Figure 28 is a side view of a container stretch-blow-moulded from the preform of Figures 26 and 27,

[00195] Figure 29 is a further side view of a preform with integrally formed handle according for stretch-blow-moulding in the machine of the invention,

[00196] Figure 30 is a sectioned, schematic side view of an injection moulding press and injection moulding die for moulding the preforms for use in the continuous rotating stretch- blow-moulding machine of the invention, with the die opened prior to an injection moulding cycle,

[00197] Figure 31 is a front view of the face of the moving die section of the injection moulding die of Figure 30 at the end of an injection moulding cycle (with the heated fixed die section removed)

[00198] Figure 32 is a further view of a part of the injection moulding press showing extraction of moulded preforms by vacuum elements inserted into the opened die by a robot.

[00199] Figure 33 is a side view of a preferred embodiment of a preform and integrally attached handle according to the invention.

[00200] Figure 34 is an end view of the preform of figure 33.

[00201] Figure 35 is a view from above of the preform and handle of Figures 33 and 34.

[00202] Figure 36 is a sectioned side view of a further preferred embodiment of a preform according to the invention;

[00203] Figures 36A and 36B are selected cross sections of the preform of Figure 36;

[00204] Figure 37 is a sectioned side view of a further preferred embodiment of a preform according to the invention; 19

[00205] Figures 37A and 37B are selected cross sections of the preform of Figure 37;

[00206] Figure 38 is a perspective view of a container according to an embodiment of the invention having variable wall thickness as a function of radial angle in selected horizontal planes,

[00207] Figure 39 is a side view of the container of figure 38 defining the selected horizontal planes,

[00208] Figure 40 is a view from above of the container of Figure 38 defining angle references and graphing wall thickness through the selected planes XX, YY, ZZ.

[00209] Figure 41 is a schematic plan view of a container reorientation device located intermediate the stretch blow-moulding machine and a filling and capping machine.

[00210] Figure 42 is a side view of a preform with an integral handle attached at two locations arranged and manufactured according to further preferred embodiments.

[00211] Figure 43 is a side view of a container stretch blow-moulded from the preform of figure 42.

[00212] Figure 44 is a side view of a preform with an integral handle attached at a single point according to the invention.

[00213] Figure 45 is a side view of a container with a single connect integral handle for stretch blow-moulded from the preform of figure 44.

[00214] Figure 46 is a side section view of a further example of a preform with a handle attached at a single point with an alternative variable wall profile.

[00215] Figure 47 is a side section view of a further example of a preform with a handle attached at a single point with an alternative variable wall profile.

[00216] Figure 48 is a side view of a preform for stretch blow-moulding a container with an integral, double-connected handle.

[00217] Figure 49 is a side view of the preform of figure 1, distorted after passage through a preconditioning stage in a stretch blow-moulding machine.

[00218] Figure 50 is a front view of one half of a stretch blow-moulding die adapted to correct distortion of the preform of figure 49.

[00219] Figure 51 is a side view of a container with integral double-connected handle stretch blow-moulded from the preform of figure 49 in the die of figure 50.

[00220] Figure 52 is a side view of a preform for stretch blow-moulding a container with an integral, single-connected handle distorted after preheating;

[00221] Figure 53 is a side view of a container with integral single-connected handle stretch blow-moulded from the preform of figure 6 in the die of figure 52; 20

[00222] Figure 54 is a further side view of the container of figure 53

DESCRIPTION OF EMBODIMENTS

[00223] The following is a detailed description of a continuous stretch blow moulding system applied to specified integral handle PET preform and PET blown container structures stretch blown from the preforms.

[00224] The continuous stretch blow moulding system will be described first and then the specified applications will follow. In its simplest form the stretch blown moulding system may be a single stage moulding system. In an alternative form, it may be a one and a half stage system. In yet a further form, it may be a two-stage system.

[00225] The system stretch blows integral handle PET containers from integral handle PET preforms using a continuous process as will be described.

[00226] The system stretch blows integral handle PET containers from non-symmetric injection moulded preforms; the non-symmetric preforms including an integral handle extending from at least one junction point on a body of the preform; the body of the preform and the integral handle constituted from the same PET material.

[00227] In a first preferred form, a feature of the present continuous machine 10, a preferred configuration of which is shown in Figure 3, is that motion through the machine of a non-symmetric injection moulded preform 12 as shown in Figure 1, from its initial intake to its emergence as a stretch blow-moulded container 14 (as shown in Figure 2), is continuous. As shown in Figure 1, the previously injection moulded polymer preform comprises a cylindrical elongate body 16 and neck 18. An integral handle 20 extends from a first junction point 22 just below the neck 18 to a second junction point 24 on the body 16 of the preform.

[00228] Referring again to Figure 3, the continuous, non-incrementing process of the machine 10 includes the transfer of preforms from a loading or pick off position 26 to a preheating stage 28, through the preheating stage and transfer to a stretch-blow moulding die 30 with subsequent removal of the blown container 14 from the die and removal from the machine. These stages will now be described in detail.

Entry of Preforms and Handle Orientation - First Preferred Embodiment

[00229] As shown in the preferred layout of the machine 10 in Figure 3 and referring also to Figures 4 and 5, the previously injection moulded preforms 12 (as shown in Figure 1) are fed, for example from a hopper (not shown but as well understood in the industry) to slide under gravity down inclined rails 32 while supported by their necks 18. The inclined rails 32 comprise a pair of upper rails 32a between which the preforms are suspended by their necks 18, and a pair of lower rails 32b which constrain the handles 20 of the preforms approximately in line with the long axis of the rails. For reasons that will become clear, it is essential however, that during the passage of preforms through the stages of the machine, the orientation of the integral handle 20 of the preform is controlled precisely.

[00230] Preforms 12 with a handle roughly oriented pass one by one through an escapement 34 to be captured by a continuously rotating feeder wheel 36 which carries the preform between the feeder wheel and a short rail 40, in such a way that friction between the body 16 of the preform and the rail 40 induces rotation of the preform and its handle. The rotating handle collides with a stop 40a under the rail 40 forcing each handle into a rearward orientation with respect to the direction of travel, to arrive at a pick off position 26. 21

[00231] At the instance that a preform arrives at the pick of position 26, a pair of opposing actuators (not shown) located under the pick off position 26, simultaneously briefly close on, and then release, the preform handle 20 to fix its orientation relative the gripper 58 which, also at that instant engages with the neck 18 of the preform.

Entry of Preforms and Handle Orientation - Second Preferred Embodiment

[00232] In this second preferred embodiment, with reference now to Figure 4A, the injection moulded preforms 12 are again fed onto inclined rails 32a, down which they slide under gravity supported by the flanges at the necks 18. Again, as described for the first preferred embodiment above, the handles are loosely constrained between lower rails 32b, with the handles either in a “leading”, that is pointing in the direction of movement of the preforms as they progress down the incline, or “trailing”, pointing rearwardly.

[00233] In this second preferred embodiment, an orientation mechanism 34A is located at a point along the rails 32 approaching the lower end of the rails. As can be seen in Figure 4 A, the mechanism includes two contra-rotating drive wheels 33 and 35, arranged at opposite sides of the rails 32, at a level coincident with the lowermost portion of the bodies of the preforms and below the lower rails 32b and the lowermost point of the handles. The axes of the wheels are normal to the slope of the inclined rails. Note only the lower rails 32b are shown in Figure 4 A.

[00234] The drive wheels 33 and 35 are separated by a gap 37 which is somewhat narrower than the diameter of the body 16 of the preforms. Each of the wheels 33 and 35 is provided with one or two tyres 39 of a sufficiently soft polymer material to allow a preform body 16 to pass through the gap but providing a degree of grip on the body.

[00235] As shown in Figure 4A, drive wheel 33 rotates in an anticlockwise direction while drive wheel 35 rotates in a clockwise direction. The combination of these two rotations has the effect of drawing a preform through the gap 37. The two drive wheels do not however rotate at the same rate, with, in the preferred arrangement shown in Figure 4 A, drive wheel 35 rotating at a significantly lower rpm than that of guide wheel 33. A preferred ratio of rotation of drive wheel 33 to drive wheel 35 is of the order of 2: 1.

[00236] The effect of this differential in rate of rotation of the two drive wheels is that drive wheel 35 exerts a considerably greater grip on the body 16 of the preform so that it acts to rotate the preform in an anticlockwise direction as the preform passes through the gap 37 between the two drive wheels. By this means a handle 20 of a preform which is in a leading position as the preform enters the gap 37, is rotated until it contacts the right hand lower rail 32b (as seen from above in Figure 4A). To allow for this rotation of the handle a gap 40 is provide in the left hand lower rail.

[00237] It will be understood that the anticlockwise rotation induced by drive wheel 35 has no effect on those preforms entering the gap with their handles trailing, except to drive the trailing handle into contact with the right hand lower rail. Thus, all preforms downstream of the orientation mechanism 34A approach the escapement 34 in the preferred orientation with the handles in the trailing position. 22

[00238] The escapement 34 controls the feeding of the handle oriented preforms to the feeder wheel 36 as described above, retaining the trailing orientation of the handles as induced by the mechanism 34A. As for the first arrangement above, at the instance that a preform arrives at the pick of position 26, a pair of opposing actuators (not shown) located under the pick off position 26, simultaneously briefly close on, and then release, the preform handle 20 to fix its orientation relative the gripper 58 which, also at that instant engages with the neck 18 of the preform.

[00239] It will be understood that although the above description is specific to the rotation of the preform in an anticlockwise direction by the clockwise rotating drive wheel, orientation according to the principles of the mechanism may equally be achieved by reversing the differential rates of rotation of the two drive wheels and providing the gap in the lower guide rail on the opposite side to that illustrated in Figure 4A. In this alternative arrangement, it is then the anticlockwise rotating drive wheel which induces clockwise rotation to the body of a preform passing between the wheels, rotating a leading oriented handle until it contacts the left hand lower rail (as seen from above in Figure 4A), the gap allowing rotation of the handle then being provided in the right hand lower rail.

[00240] Precise orientation of the handle throughout the stages of the machine is critical to the process of preheating where the orientation must align with the alignment of heat shields, and for correctly placing the preform and the handle into the stretch-blow-moulding die.

Entry of Preforms and Handle Orientation - Third Preferred Embodiment

[00241] With reference now to Figures 4B to 4D, in this further preferred arrangement of a handle orientation mechanism 34b, injection moulded preforms 12 emerge one at a time from a bulk supply via, for example, a conveyor (not shown) to be deposited centrally onto a pair of contra-rotating, downward sloping rollers 11 and 13. The rollers 11 and 13 are so spaced as to allow the body 16 and handle 20 of each preform to drop through the gap between them but retain the wider diameter of the projecting collar below the neck 18 of the preform. The rollers 11 and 13 are mounted above a pair of spaced apart guide rails 15 and 17 (as best seen in Figure 4D) similarly spaced as the gap between the rollers. As the bodies and the handles of the preforms drop through the gap between the rollers and that between the guide rails 15 and 17, the handles 20 are constrained into approximate alignment between these rails, but at this stage handles may be “leading” or “trailing” relative to movement in the downward direction shown in Figures 4C and 4D. Since it is a requirement imposed by the design of the blow-moulding machine described below, that preform handles at entry of preforms into the feeder wheel 36 must be in the trailing position, those leading must be turned around.

[00242] At the downward ends of the rollers, the preforms drop to the level of main support rails 19 and 21, so that preforms are now retained between these main support rails by their collars. A combination of gravity and pressure from following preforms forces each preform against the upward outer ends of side by side, contra-rotating auger screws 23 and 25 located on either side of a median vertical plane between the support rails. The flutes 27 of the auger screws are sized so as to capture between them the necks 18 of the preforms. The pitch of the auger screws is such as to separate preforms while being driven in the downward direction by the screws’ rotation.

[00243] Generally coextensive with the length of one of the auger screws, (in the arrangement shown in the drawings, auger screw 25), the main support rail 21 is provided at its underside with a friction strip 29 (as best seen in the enlargement inset of Figure 4D). This 23 friction strip 29 projects slightly into the gap between the main support rails 19 and 21 so that its inner edge engages with the body of a preform as it progresses between the augers. This friction contact urges rotation of the preform in an anticlockwise direction as seen from above.

[00244] Also, approximately coextensive with the length of the auger screw 25 is a gap in the guide rail 17. Any rotation of an already trailing handle, will only force the handle into engagement with the opposite guide rail 15, and remain trailing. But, as can be seen from the enlarged inset of Figure 4D, handles of preforms with handles leading at entry between the auger screws will gradually be rotated from the position where the handle is leading to it being in the trailing position, (being free to do so by the gap in guide rail 17) until these handles also are arrested from further rotation by the opposite guide rail 15. From here as can be seen from Figures 4C and 4D, the preforms, ah with handles trailing, proceed down the main support rails 19 and 21 with the handles constrained between the now continuous guide rails 15 and 17 until they reach the final orientation operation at the feeder wheel 36.

[00245] As well as spacing and rotating preforms as they pass between the auger screws 23 and 25, the rotation rate of the auger screws is such as to deliver a preform to the feeder wheel 36 in synchronization with the rotation of that wheel. Furthermore, the rotation of the auger screws provides pressure to ensure preforms proceed down the main support rails.

Transfer to Preheating

[00246] Referring now to Figure 5 and Figure 6, a first rotating transfer system 42 is positioned adjacent the feeder wheel 36 with a continuously rotating carrier 44 of the first rotating transfer system 42 and the feeder wheel 36 contra-rotating one to the other.

[00247] The rotating carrier 44 of the first rotating transfer system 42 includes, in this embodiment, four opposing support arms 46 extending radially from a fixed centre of rotation 48 to rotate about a vertical axis 50. Each end of the arms carries a first pick and place apparatus 52. Each first pick and place apparatus 52 includes a linear guide 54, a housing 56 which is rotatably mounted to the outer end of the support arm 46, enabling rotation of the housing 56 about a vertical axis 51. A two-fmgered gripper 58 is mounted to a rotary actuator 60 supported by vertical plate 62 at an outer end of a free sliding element 64 of the linear guide 54. The gripper fingers 66 are centred on a gripper effective vertical axis 68, with the gripper able to be rotated about the horizontal axis 61 of the rotary actuator 60.

[00248] A fixed horizontal cam plate 70 is mounted at a level below the rotating carrier 44 so that its centre is coincident with the vertical axis 50 of the rotating earner. The perimeter edge 72 of the cam plate 70 forms an outer cam surface 74 and its upper surface 76 is provided with a cam channel 78 which is inboard of the perimeter edge 72 and the outer cam surface 74.

[00249] The housing 56 of the linear guide 54 is provided with an outrigger arm 80 extending radially from the centre of rotation 82 of the linear guide 54. The outer end of the outrigger arm 80 supports a first cam follower 84 locating in the cam channel 78. The free sliding element 64, adapted to reciprocating linear motion in a horizontal plane, is provided with a second cam follower 86 with the free sliding element 64 biased by springs 88 to maintain contact between the second cam follower 86 and the outer cam surface 74. 24

[00250] The cam channel 78 and outer cam surface 74 are arranged so that as a first pick and place apparatus 52 rotates past the preform pick off position 26, the rotation of the rotating carrier 44, combined with the loci of the first and second cam followers 84,86 causes the gripper 58 to be both reciprocatingly extended and retracted, and rotated relative the arm 46. The gripper motion is such that at the approach to the preform pick off position 26, the free sliding element 64 and thus the gripper 58 is extended followed by rotation of the linear guide 54 and gripper 58 in retrograde or negative direction relative to the direction of rotation of the rotating carrier 44.

[00251] At the instant a preform 12 arrives at the pick off position 26 after its approximate orientation, so that the handle 20 of the preform is trailing but not yet fixed, the extending movement of the gripper 58 through the first cam follower 84 against the outer cam surface 74, brings the gripper effective axis 68 into coincidence with the central axis of the preform. At this instance also, a pair of opposing actuators located under the pick off position 26 simultaneously briefly close on, and then release, the preform handle 20 to fix its orientation relative the gripper 58 which, also at that instant engages with the neck 18 of the preform.

The gripper 58 is then rotated positively to carry the preform 12 clear of the supporting short rail 40 and away from the pick off position 26.

[00252] This combination of reciprocating rotation and extension and retraction of the gripper 58 compensates for the divergence of the loci of the supporting tooth formation 38 of the feeder wheel 36 and the rotating earner 44 as they contra rotate one relative the other. It is by the means of the reciprocating rotation and retraction movements of the gripper through a combination of a rotating linear guide and the two cam loci that a smooth continuous transfer of preforms is possible between two rotating elements; that of the feeder wheel 36 and the rotating carrier 44.

Loading Into Mandrel Stage

[00253] With reference now to Figure 7, rotation of the rotating earner 44 brings a preform 12 retained in a gripper 58 to the preheating stage 28 as was shown in Figure 3 of the machine 10. Because the preheating of the preforms is conducted with the preforms inverted from their initial position at the pick off position 26, that is, with the neck 18 upward, the rotary actuator 60 at the end of the free sliding element 64 rotates the grippers 58 and the preforms through 180degree during their transit between pick off position 26 and the transfer to a preheating transport system 90. The effect of this rotation is that the handle 20 of the preform is now “leading” with respect to the direction of rotation of the rotating carrier 44, instead of trailing as it was at the pick off position 26 as could be seen in Figure 5.

[00254] The preheating transport system 90 is also in continuous movement and comprises a loop rail system 92 with proximate and distal rotating guide wheels 94 and 96 respectively at either end of the loop. A plurality of preform supporting mandrels 98 are adapted to move around the loop rail system 92, driven into motion around the straight sections of the loop by a drive chain (not shown) to which they are fixed and around the guide wheels 94,96 by nesting in niches 103 of the guide wheels. As well as travelling around the loop rail system 92, the mandrels 98 are continuously rotated about their vertical axes.

[00255] Preheating of the preform 12 is required for the body 16 of the preform, that is for that portion of the preform which will be subjected to stretching and blow-moulding, to sufficiently soften the polymer. But the handle 20 and the neck 18 which retain their as injection moulded form in the blown container shown in Figure 3, must be protected from 25 excessive heat as the preform moves through the preheating stage. For this reason, as shown in Figure 8, a preform supporting mandrel 98 is provided with a heat shield 100 comprising a channel 102 rising from a cylindrical collar 104 in which the handle 20 is protected while the neck 18 is protected by its insertion into the cylindrical collar 104 of the mandrel.

[00256] It may be noted that the patterns of the outer cam surface 74 and that of the cam channel 78 of the first rotating transfer system 42 as shown in Figure 5, near the pick off position 26 differ from those at the approach to, and following the preform transfer to preheating position 106. This reflects the difference in movements required of a gripper 58 as it steers the preform into the position in which the vertical axis of the preform becomes aligned with that of the cylindrical collar 104 of the mandrel 98 and the handle 20 is aligned with the heat shield channel 102. At the instant these axes are aligned and the handle 20 of the preform is aligned between the side elements of the channel 102, a cylindrical plunger 108 within the collar 104 rises into the neck 18, then lowers to bring the neck to an inserted position within the collar. These movements of course take place while the first rotating transfer system 42 and the proximate guide wheel 94 are in continuous contrarotation. This complex movement is again made possible by the combination of the rotation of the arm 46 and the rotation and linear movements of the free sliding element 64, and thus of the gripper fingers 66 of the first pick and place apparatus 52.

[00257] Thus the transfer of a preform from the gripper of the first transfer system 42 to a preform supporting mandrel 98 is achieved in one fluid motion as the vertical axis of the preform is brought into alignment with that of the mandrel and the oriented handle of the preform slides into the heat shield, while accommodating each of the rotations of the loop rail, the mandrel and the transfer system as well as the movements of the gripper.

Preheating of Preforms

[00258] As best seen in Figures 3 and 8, banks 110 of heating elements 109 are positioned along each of the straight sections of the loop rail system 92. Graded hot air 111 is drawn across the path of the preforms 12 by extractor fans 113. To prevent excessive heat build-up of the cylindrical collar 104 and the neck 18 of the preform in the collar, a cooling air stream 115 is directed at the collars.

[00259] As a mandrel 98 and preform 12 are rotated away from the transfer-to-preheating position 106 by the proximate rotating guide wheel 94, the mandrels supported in the chain of the preheating transport system 90 travel along the first straight section 112, around the distal rotating guide wheel 96 and back along the second straight section 114 to arrive at a transfer- from-mandrel position 116. While traversing these straight sections, the mandrels are rotated about their vertical axes by a gear 105 of the mandrel engaging with chain 107 to evenly expose the bodies of the preforms to heat from the banks 110 of heating elements 109. The heating elements 109 are each arranged as a series of infra-red heating elements which are individually adjustable as to their proximity to the passing preforms.

[00260] It will be understood that the orientation of each mandrel 98 at both the transfer to preheating position 106 and at the transfer from mandrel position 116 is critical to allow the respective first and second transfer systems to insert and extract a preform handle from the channel of the mandrel’s heat shield. These heat shield orientations with respect to the periphery of the proximate guide wheel 94 are not the same at these two positions so that the orientation of the mandrel and its heat shield need to be changed from that demanded at the 26 handle extraction position to that required at the handle insertion position.

[00261] To this end, each mandrel is provided with a guide carriage 98a fixed to the mandrel. As a mandrel approaches the transfer-from-mandrel position 116, cam followers 98b and 98c engage with guide channels to rotate the mandrel into the required orientation. During transit about the periphery of proximate guide wheel 94, the cam followers 98b and 98c follow cam channels of a cam plate above the proximate guide wheel to bring the orientation of the heat shield to that required at the transfer-to -preheating position 106.

Transfer to Mould

[00262] With reference now to Figure 9, a second rotating transfer system 118 operates to transfer preforms 12 from the preheating transport system 90 to a stretch blow moulding die assembly 120. The stretch blow moulding die assembly 120 comprises of four stretch blow moulding dies 30, two of which can be seen in the truncated view of the machine in Figure 9. In the present embodiment, four radially disposed stretch blow moulding dies 30 rotate continuously about a common centre 122.

[00263] The second rotating transfer system 118 is of similar configuration to that of the first rotating transfer system 42 described above. That is, it includes a cam plate 124, also provided with an inboard cam channel 126 and an outer cam surface 128 around its periphery.

[00264] In this instance, second rotating transfer system 118 includes two, rather than four, continuously rotating opposing radial arms 130, each of which carries a second pick and place apparatus 132. Again, similar to the first pick and place apparatuses 52 of the first rotating transfer system 42 above, each includes a linear guide rotatably mounted to the respective outer end of the radial arm 130, with the free sliding element of the linear guide supporting a rotary actuator which, in turn supports a gripper. In this arrangement also, a first cam follower of an outrigger arm attached to the housing of the linear guide, locates in the inboard cam channel 126, while a second cam follower of the free sliding element of the linear guide remains in contact with the outer cam surface 128 by means of a spring.

[00265] Preforms still retained in preform supporting mandrels 98 arrive back at the rotating proximate guide wheel 94 of the preheating system and approach the transfer-from- mandrel position 116, and are rotated into the required orientation of the heat shield as explained above. The cylindrical plunger 108 of a mandrel 98 approaching the transfer-from- mandrel position 116, lifts the preform so that the neck is clear of the cylindrical collar 104 to allow the gripper of the second rotating transfer system 118 to engage the preform by the exposed neck 18. Again, it is the motion of the gripper induced by the combination of rotation of the radial arm 130, the rotation of the linear guide and linear movements of the free sliding element supporting the gripper as controlled by the cam channel 126 and outer cam surface 128, which allows the preform and its handle to be smoothly removed from the preheating transport system 90.

[00266] As one rotating radial arm 130 of the second rotating transfer system 118 approaches and removes a preform from the preheating transport system 90, the opposite radial arm approaches the die loading position 134. During its rotation from the transfer- from-mandrel position 116 to the die loading position 134, the rotary actuator of the second pick and place apparatus 132 rotates about its horizontal axis to change the preform from its inverted position held during the preheating stage, back into an upright position. (It should be 27 noted that Figure 9 shows both a rotating arm 130 and a stretch blow moulding die 30 approaching the die loading position 134)

[00267] Stretch blow moulding dies of the die assembly 120, are in the form of two die halves 136, one of which is shown in Figure 10. Die halves 136 are hinged together about a vertical axis 142 in the maimer of a bivalve, and with the hinge supported from a central structure 146 of the die assembly 130 in a typical arrangement for radial stretch-blow moulding machines. The face surface 138 of the die half shown in Figure 10 has been shaded to highlight the die cavity 148 for the body 16 and integral handle 20 of the preform. As is common in the stretch-blow-moulding of containers, the neck 18, which remains unaltered in the stretch-blow-moulding process, projects out of the die when closed.

[00268] Referring again now to Figure 9, as stretch-blow-moulding dies 30 approach the loading position 134 the die halves open symmetrically about a bisecting radial line 152 passing through the centre of rotation 122 and the vertical axis 142 of the die hinge 144, in preparation for receiving a preform. It may noted from Figures 3 and 9, that the rotation centres of the second rotating transfer system 118, the proximate rotating guide wheel 94 of the preheating stage and that of the stretch-blow-moulding die assembly 120, lie along a straight line 154.

[00269] As an opened die 30 approaches the die loading position 134 lying on the straight line 154, a radial arm 130 with a preform retained in the gripper of the second pick and place apparatus 132 also approaches the loading position. As the bisecting radial line 152 of the die halves 136 becomes coincident with the straight line 154, the movements of the second pick and place apparatus 132 has brought the gripper effective vertical axis and thus the vertical axis of the preform into coincidence with the axis 156 of the die (as defined by the centre of the preform body when held in the die) and with the handle oriented to lie in the vertical plane defined by the straight line 154. While the die halves close and the paths of the die 30 and the end of the rotating arm 130 begin to diverge, the rotation and extension of the gripper, still holding the neck 18 of the preform, ensures the orientation of the handle is maintained in that vertical plane defined by the bisecting line of the die halves until closure is complete. The gripper then disengages from the preform neck.

[00270] It can be seen from Figure 10, that the curved section of the handle 20 of the preform is nested in a constricting cavity 150 of the die which ensures that the handle is not distorted, nor the region between the junction points 22,24 stretched. The underside of the straight section of the handle forms a surface which, in effect, determines the shape of the container under the handle.

[00271] With the die halves 136 closed, stretch-blow-moulding of the container proceeds and the die 30 loaded at the die loading position 134 rotates towards the die unloading position 158 as shown in Figure 11.

Container Unloading

[00272] A third rotating transfer system 160 is located adjacent the stretch-blow-moulding die assembly 120, and is configured in similar manner to that of the first and second rotating transfer systems 42,132 described above. As for the second rotating transfer system 132, the third rotating transfer system 160 includes opposing radial arm 162 at the ends of each of which is a third pick and place assembly 164. It does not however include a rotary actuator 28 since the container which emerges from the die remains in an upright position through the discharge process.

[00273] As for the first and second rotating transfer systems, movements of a gripper 166 is controlled by a combination of the rotation of the opposing radial arms 160, the linear movement of the free element of the linear guide and the two cam loci.

[00274] As the stretch-blow-moulding die 30, now containing a finished container 14, nears the die unloading position 158 lying on the line 168 joining the centres of rotation of the stretch-blow-moulding die assembly 120 and of the opposing radial arms 160 of the third transfer system, the gripper of the pick and place is maneuvered into position to grasp the neck of the container. As the die reaches the die unloading position, the die halves open and the gripper extracts the blown container 14 from the die 30.

[00275] The third rotating transfer system 160 continuous to rotate, taking the container 14 held by the gripper 166 into a discharge channel 172, with the base of the container passing over a guide rail 170. Guide rail 170 transitions from concentricity with the third rotating transfer system to concentricity with a rotating two-tiered outfeed wheel 172. As the container 14, now in the discharge channel 172, reaches a release position 174 lying on the line 176 joining the centres of rotation of the third rotating transfer system 160 and that of the outfeed wheel 172, the gripper 166 releases the neck and retracts. At the same time a scalloped indentation 172a of the rotating outfeed wheel captures the body of the container feeding it into a discharge channel 178. As containers follow the path of the gripper 166 and then a path determined by the outfeed wheel 172, the base of the container receives cooling air from orifices 182 in guide rail 170, backpressure from accumulating containers in the discharge channel 172 force containers to drop into a container receiving bin 180, or in the case of containers being transferred to a filling and capping machine onto a conveyor 178 as shown in figure 38.

Control of the Machine

[00276] The operation of the machine 10 is under the control a programmable logic controller. As well as ensuring that all rotation drive servo motors operate synchronously, the controller provides for fully adjustability of the parameters of the preheating elements and of the parameters of the stretch-blow-moulding dies. This includes setting differential temperature gradients allowing for a gradually increasing exposure to heat as preforms progress around the preheating transport system, and automatic adjustment of heating element temperatures for changing ambient temperatures.

[00277] Control of the preheating is particularly critical in the present system because of the unique characteristics of the preform dictated by the integral handle of the preform. The preheating is thus designed to allow for lateral flow of material in the area between the two junction points of the handle while limiting longitudinal flow and extension during the stretching phase of the stretch-blow-moulding process. Instead, the manner in which heat is applied to the preform ensures that the bulk of polymer which forms the outer shell of the container of Figure 2, is produced from that region of the preform below the lower junction point of the handle.

[00278] Figure 12 is a schematic block diagram of control components associated with control of the heating and transport of the preforms usable with any of the above described 29 embodiments.

[00279] As best seen in the inset of figure 12, banks 110 of heating elements 109 are positioned along each of the straight sections of the loop rail system 92. Graded hot air 111 is drawn across the path of the preforms 12 by extractor fans 113. To prevent excessive heat build up of the cylindrical collar 104 and the neck 18 of the preform in the collar, a cooling air stream 115 is directed at the collars.

[00280] In a preferred form each bank 110 comprises a module 201. The modules 201 are arranged sequentially around the conveyer 202 as illustrated in figure 12.

[00281] In a preferred form a processor 203 in conjunction with memory 204 executes a program for control of the heating elements 109 of the modules 201.

[00282] In a particular preferred form each element 109 of each module 201 is controlled individually by the processor 203.

[00283] In an alternative preferred form the elements 109 are controlled as a group based on height - so the top most elements 109 of the modules 201 are controlled to a predetermined temperature together whilst the next down in height elements 109B are also controlled together to a predetermined temperature - and so on down to elements 109G at the lowest level.

[00284] In addition the processor 203 controls the speed of rotation of motor 205 in order to control the continuous speed of the preforms 16.

[00285] A temperature sensor 206, in one form an infrared temperature sensor provides environment temperature sensing which is utilised by processor 203 to modulate the degree of heating of all elements 109 by a difference factor delta (D).

[00286] This allows for a global control of the system temperature in response to variations in ambient temperature.

[00287] As noted above, the stretch-blow-moulding machine is especially developed for, and adapted to, the feeding and transportation of a non-symmetrical preform with integral handle and, ultimately the stretch-blow-moulding of that preform into a container with an integral handle. The preform according to the invention may take a number of different forms described below, although common to all are the neck portion 18 and the integral handle 20 as shown in Figure 1.

[00288] The preforms now to be described differ primarily in respect of the configuration of their internal surfaces, offering benefits of improved distribution of polymer material to the walls of the blown container as well as significant improvement in economy of manufacture due to reductions in the volume of polymer required.

First Preferred Non-Symmetrical Preform Embodiment

[00289] In a first preferred embodiment a preform 310 according to the invention as shown in Figure 13 A includes a finished neck portion 312 and a tubular hollow body portion 314 extending from below the neck portion. Similar to preforms of the prior art, the outer surfaces of the body portion 314 are defined by diameters centred on a central vertical axis 316, so that the body portion 314 approximates a cylinder but with a decrease in diameters 30 from the neck portion 312 to the closed end 318 of the preform.

[00290] The internal surfaces of the preform 310 include surfaces of the hollow body portion 314 which are not concentric with the outer surfaces. Preferably, as shown in Figures 15 and 16, cross sections of the internal surfaces of the preform 310 are circular and concentric in the neck portion 312 of the preform as indicated by the cross-section A-A, but below the neck portion are of ovoid form as indicated by section B-B. All sections are however centred on the central longitudinal axis 316 of the body of the preform.

[00291] Referring now to Figure 14, in a preferred arrangement, the mandrel 322 around which the preform 310 is injection moulded, comprises an upper region 324 of circular cross sections adapted to position and retain the mandrel in its correct position in an injection moulding cavity. A first prefoim-defming portion 326 of the mandrel extends from this upper region 324 to a depth equal to that of the neck portion 312 and is of circular cross section A- A as shown in Figure 4 to form the concentric walls of the neck portion. The ovoid portion 328 of the mandrel depends from the first portion 326, extending to the tip 330 of the mandrel.

[00292] Given the ovoid shape of the cross sections of the ovoid portion 328, there is a short transition portion of the mandrel immediately below portion 326 forming the internal form of the neck portion, which transitions from the circular cross section A-A of portion 326 to the ovoid sections B-B. This transition thus takes the form an asymmetrical frustum of a cone; an upper end of which has a diameter equal to that of a lower end of the first portion 326 with the lower end of the transition portion conforming in cross section to the upper end of the ovoid cross section B-B of the remaining length of the preform.

[00293] It can be seen from Figure 13 A, that both the outer surfaces of the body portion 314 of the preform and the ovoid portion of the inside surfaces as defined by the mandrel 322, are tapering; that is, the diameters defining the external surface of the preform are decreasing from below the neck portion 312 to the bottom 318, while similarly, the major axis 344 and the minor axis 342 of the cross sections of the ovoid portion 328 also decrease accordingly.

[00294] Referring still to Figure 13 A, the preform 310 of the invention further includes, as noted above, an integral handle 334 which forms a loop of material extending vertically from an upper junction 336 below the neck portion 312 to a lower junction 338 with the outer surface of the preform. The handle 334 is centred on and defines a central vertical plane 340 (lying in the plane of the paper) which contains the central longitudinal axis 316 of the preform.

[00295] The mandrel 322, and thus the internal surfaces of the ovoid portion 328, are so oriented relative the handle 334, that major axis 344 of the ovoid cross section B-B lies in the central vertical plane 340.

[00296] It can thus be seen from Figure 16 and cross section B-B that the wall thicknesses of the preform 310 in that portion 328 of the preform in which the inner surfaces are defined by the ovoid cross section, varies from a maximum at opposite ends of the minor axes 342 of the ovoid cross section to minimum thicknesses at outer ends of the major axis 340. Preferably, the ratio of maximum wall thickness to minimum wall thickness of the ovoid 31 portion lies in the range of 2: 1 and 2.2:1.

[00297] The distribution of polymer in the preform according to the invention, afforded by the non-symmetry of the ovoid portion, allows polymer walls of the preform in the region of maximum thickness to be biased predominantly towards the longer side walls 346 of a rectangular cross section blown container 348, while the polymer walls of the preform from the region of minimum thickness is predominantly distributed towards the shorter side walls 350 of the blown container such as shown in Figures 17 and 18. It can be seen from Figures 17 and 18 that the longer side walls 346 lie on either side of the central vertical plane 340 and thus the handle 334 so that the alignment of the major axis 344 with the vertical plane 340 ensures that the polymer from regions of maximum wall thickness are directed to those longer side walls. In preferred forms the preform of the first embodiment is produced by an injection moulding process as described earlier in this specification. In preferred forms the preform thus produced is reheated and blown on a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine as described earlier in this specification.

Second Preferred Non-Symmetrical Preform Embodiment

[00298] With reference now to Figure 19, in this preferred embodiment, the exterior surface 410 of the preform 400 of this embodiment, is of substantially cylindrical form. As for the first embodiment above, it too includes an integrally injection moulded handle 434. In this embodiment, the internal surfaces 414 of the preform are consistently circular in section as shown in the two sample cross sections Figure 17A and Figure 17B. However, again as is clear from the two cross sections and the sectioned side view of Figure 17, there is a tapering of the internal surface 414 so that the wall sections, though concentric to the external surface, increase from a minimum thickness at the neck portion 412 of the preform to a maximum proximate its lower end 418. In preferred forms the preform of the second embodiment is produced by an injection moulding process as described earlier in this specification. In preferred forms the preform thus produced is reheated and blown on a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine as described earlier in this specification.

Third Preferred Non-Symmetrical Preform Embodiment

[00299] In this further preferred embodiment of the invention, a preform 500 as shown in Figure 20, is formed to significantly reduce the volume of material required to produce the containers shown in Figures 17 and 18. As in the embodiments above, the preform 500 includes an injection moulded integral handle 534. Although in this embodiment, the neck portion 512 is identical in its exterior and internal forms to that of the earlier embodiments, there is a substantial reduction in the diameter of the substantially cylindrical portion of the body of the preform below the neck portion.

[00300] In this embodiment also, as in the second preferred embodiment above, the internal surfaces of the preform are consistently circular in section as shown in the two sample cross sections A and B of Figures 20A and 20B, but taper with the wall sections increasing from the minimum thickness obtaining in the neck portion and through the transition in diameters below the neck portion, to a maximum wall thickness proximate the lower end 518 of the preform. 32

[00301] As a further means of reducing the volume of material in the preform of this embodiment, the outer surface 510 below the neck portion 512, also tapers towards the lower end 518. In preferred forms the preform of the third embodiment is produced by an injection moulding process as described earlier in this specification. In preferred forms the preform thus produced is reheated and blown on a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine as described earlier in this specification.

Fourth Preferred Non-Symmetrical Preform Embodiment

[00302] With reference now to Figure 21, this preferred embodiment of a preform 600 according to the invention, shares a number of characteristics with that of the first and second preferred embodiments above. It has, (as have all the preform embodiments of the present invention), an integral handle 634 as previously described, and, as in the first preferred embodiment above, the internal surfaces 614 of the preform are not consistently of circular section throughout the length of the preform. However, the external surfaces 610 of the perform are substantially cylindrical in form as in the second preferred embodiment.

[00303] Thus, although the external surfaces 610 are defined by circular cross sections, the internal surface 614 varies from circular in cross section from the neck portion 612 down to section A-A in Figure 21 A, to then transition to an ovoid section B-B as shown in Figure 21B, approaching the lower end 618.

[00304] A feature of this particular embodiment is that the wall thickness of the ovoid portion of the internal surface 614 of the perform at the ends of the major axes remains constant with the wall thicknesses of the concentric cross sections from section A-A and upwards, while there is a thickening of the walls increasing to maximum at the minor axis of the ovoid cross section. In preferred forms the preform of the fourth embodiment is produced by an injection moulding process as described earlier in this specification. In preferred forms the preform thus produced is reheated and blown on a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine as described earlier in this specification.

Fifth Preferred Non-Symmetrical Preform Embodiment

[00305] The preform of this embodiment of a preform 700 shown in Figure 22 is similar to that of the fourth preferred embodiment above, but here, as shown in the cross section views A-A and B-B of Figures 22 A and 22b, the wall thickness at the outer ends of the major axes of the ovoid cross section portion of the preform is not maintained equal with the wall thickness of at and below the neck portion 712. Rather the wall thickness gradually increases from below the neck portion towards the lower end 718 of the preform.

[00306] It may be noted at this point, that in those forms of the perform as in this embodiment and that of the first preferred embodiment above, shaping the internal surface in these non- concentric forms of outer and inner surfaces, introduces considerable issues for the injection -moulding of the preforms.

[00307] As shown in Figure 24, preforms, including those of the present invention, are typically injection moulded in multi-cavity dies 800 in which the cavities 820 in the die conform to the outer shape of the preform, including in the present cases, the shape of the integral handle. In preforms with concentric wall thicknesses, that is, with circular cross sections, the mandrels 840 for forming the internal surfaces will also be of circular cross sections. Thus, the only requirement for positioning such a mandrel relative the injection- 33 moulding cavity is its concentricity with the neck portion of the cavity.

[00308] A mandrel for producing an internal surface of a preform which is wholly or partially non-circular in section may firstly require, a considerably more complex machining operation and, secondly it must be specifically oriented in the injection-moulding cavity.

[00309] Mandrels for preforms with non-circular cross sections must be positioned within the cavities of an injection-moulding die 820, one half of which is shown in Figure 24 so that the major axes of the ovoid portion are aligned relative to a vertical central plane of the cavities. For preforms according to the present invention with integral handles, that vertical plane is the plane on which the handle of the preform is centred as set out above (in effect the face 842 of the die half).

[00310] To be effective in biasing polymer material flow from different wall thickness areas of the preform towards designated regions of the blown container, the orientation of the preform must be maintained in the cavity of the stretch-blow-moulding machine. That is, the vertical plane of the preform must coincide with a defined vertical plane of the container. In the present invention the vertical plane of the preform is defined by the integral handle and is made coincident in the stretch-blow-moulding cavity with the central vertical plane of the blown container which again is central to the integral handle of the container.

[00311] In a moulding cycle, the die halves are brought together to close the die and the array of mandrels 840 driven into the cavities 820. The injection nozzle 848 is then advanced into the injection pocket 844 and molten polymer forced through the runner system 846 to fill the spaces between the external surfaces of the cavities 820 and the mandrels 840 to produce the preforms.

[00312] Although the above description has focused in some embodiments on use of ovoid or offset cross sections to vary the wall thicknesses of at least a portion of a preform at any given cross section of that portion, it will be understood that such variation can be achieved with other non- concentric shaping of the mandrel. Again, although the ovoid cross sections described for the preferred embodiment are centred on the vertical axis of the preform, other material distribution effects may be achieved by an asymmetric positioning of these cross section. In preferred forms the preform of the fifth embodiment is produced by an injection moulding process as described earlier in this specification. In preferred forms the preform thus produced is reheated and blown on a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine as described earlier in this specification.

Sixth Preferred Non-Symmetrical Preform Embodiment

[00313] This further preferred embodiment of a preform according to the invention and shown in Figure 23, the preform 900 is provided with a wall thickness 911 in the region between the junction points 936 and 938 of the integrally injection-moulded handle 934 specifically to optimise control of the material in this region in the stretch-blow-moulding stage of producing a container from the preform.

[00314] In this embodiment, the external surface 910 of the preform is again substantially cylindrical. The internal surface 914 of the preform is likewise formed of circular cross sections, but as can be seen in both the side sectioned view of Figure 23 A and cross section AA of Figure 23 A, the centres of a portion of the cross sections (typified by section A- A) do not lie on the central axis 930 of the body of the preform, but are offset towards the handle 34

934.

[00315] The effect is to “thin” the wall thickness in the region between the junction points 936 and 938 of the handle. This is possible and desirable, because firstly there is a lesser volume of material required to form the container since there is no longitudinal stretching of this region and, secondly the thinning provides a significant cost saving in material.

[00316] It will be understood that all the above embodiments of the preform seek to optimise both the distribution of the polymer material of the preform into the blown container and do so by reducing the weight and thus the volume of material for reasons of economy of production. In preferred forms the preform of the sixth embodiment is produced by an injection moulding process as described earlier in this specification. In preferred forms the preform thus produced is reheated and blown on a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine as described earlier in this specification.

Seventh Preferred Non-Symmetrical Preform Embodiment

[00317] With reference to Figure 26 and 27, a preform 1000 for stretch-blow-moulding the container 1040 shown in Figure 28, is comprised of a neck portion 1012, a collar 1014 and a body 1016 extending from below the collar. As in the preform according to prior art shown in Figure 1, the preform 1000 includes an integral handle 1018 joined to the body 1016 at first junction position 1020 just below the collar 1014 and a second junction position 1022 along the length of the body.

[00318] The first cylindrical portion 1024 of the body extending below the collar 1014, is substantially of constant diameter, and in the region immediately below the collar, the diameter is substantially that of the finished container as can be seen in Figure 28.

[00319] But it can be seen firstly from a comparison between the preform 1000 according to the present invention, and the preform of the prior art, that there is a significant reduction in diameter of the body 1016 below the first cylindrical portion 1024.

[00320] Furthermore, it is clear that this second portion 1026 of the body, between the reduction in diameter and the tangent line 1028 with the bottom portion 1030, is not cylindrical but forms a portion of a narrow cone, with the base diameter 1030 of the cone, that is its largest diameter, significantly smaller than the diameter of the first cylindrical portion 1024. Thus, this large reduction in diameter and the tapering provide a first significant reduction in the volume of PET contained in the preform of the invention.

[00321] Turning now to the cross-section view of Figure 27, the walls of the body 1016 of the preform 1000, vary considerably in thickness. While the wall thickness of the neck portion 1012 and the first portion 1024 below the collar 1014 are substantially of a constant thickness, that of the second portion 1026 varies from a relatively thin wall section at the base diameter 1030, to a maximum thickness proximate the tangent line 1028.

[00322] The wall thickness of the bottom portion 1032 is further varied, being reduced from the maximum thickness at the tangent line 1028 to a minimum at the base of the bottom portion.

[00323] This thinning of the wall thickness in the region below the maximum diameter 1030 of the second portion 1026, augments the reduction in material volume provided by the diameter reduction and the form of the second portion 1026. 35

[00324] As well as providing savings in material volume, these variation in wall thicknesses are designed to evenly distribute the volume of PET material to various areas of the walls of the stretch-blow-moulded container 1040 shown in Figure 28, to an average thickness of approximately 0.5mm. In preferred forms the preform of the seventh embodiment is produced by an injection moulding process as described earlier in this specification. In preferred forms the preform thus produced is reheated and blown on a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine as described earlier in this specification.

Eighth Preferred Non-Symmetrical Preform Embodiment

[00325] With reference to figures 33, 34 and 35 there is illustrated a preform having an integral handle with a flared portion thereby to impart an ergonomic aspect to the lifting of containers blown from the preform.

[00326] Turning now to Figure 33, in a preferred form of the preform, a preform 2100 includes a neck 2102, a body portion 2103 and a handle 2113. The neck 2102 has a threaded portion 2104 and a locating ring 2105. The preform is injection moulded from PET material in accordance with the teaching elsewhere in this specification. The handle in its configuration as injection moulded in its preform state, remains unaltered by the stretch blow moulding process forming the resulting container from the continuous blow moulding process described elsewhere in this specification.

[00327] In order to produce the container, the preform 2100 shown in Figures 33 to 35, is fed into a blow moulding machine such for example as the machine 10 shown schematically in Figure 3, and blow moulded according to bi-axial orientation blow moulding techniques. During this process the neck 2102 is held in a mandrel 322, as shown in Figures 14 of a transport system of the machine 10 in such a way as to prevent its expansion in the stretch blow-moulding die 30.

[00328] The loop of orientable material forming the handle 2113 has a generally uniform cross section from proximate the lower connection region 2116 to a gradually widening cross section 2124 approaching the upper comiection region 2115 with the cross section reaching and maintaining a maximum width proximate the upper connection region 2115 as can be seen in Figures 34 and 35.

[00329] With reference again to Figure 33, integrally moulded first, second and third strengthening elements 2135, 2136 and 2137 are provided respectively at each of the upper connection region 2115, the lower connection region 2116 and at the junction between the straight section 2118 and the arcuate section 2120 of the handle 2113.

[00330] The first strengthening element 2135 at the upper connection region 2115 comprises a curved strengthening element conforming generally in width and in cross section to the width and cross section of the widened portion 2124 of the handle proximate the upper connection region. The curved strengthening element extends from a first separate connection region 2140 on the body portion 2103 of the preform (and on the blown container) below the upper connection region 2115 and merges with the loop of orientable material proximate a first end 2141 of the maximum width of the handle.

[00331] The second strengthening element 2136 at the lower connection region 2116 of the handle, comprises a straight strengthening element conforming generally in width and 36 cross section with the width and cross section of the straight section 2118. The straight strengthening element extends ifom a second separate connection region 2142 above the lower connection region 2116 of the straight section of the handle, to merge with the straight section of the handle proximate the lower connection region.

[00332] The third strengthening element 2137 at the junction of the straight section 2118 and the arcuate section 2120 of the handle, comprises a further curved strengthening element conforming generally in width and cross section with the width and cross section of the handle of both the straight section 2118 and the arcuate section 2120 adjacent the junction. Respective outer ends of this further curved element merge with each of the straight 2118 and arcuate 2120 sections.

[00333] It should be noted that, in this instance, the width of the first strengthening element 2135 is the same as that of the maximum width of the widened part 2124 of the handle proximate the upper connection region 2115. It is this increased width of the first strengthening element 2135 which provides for a larger area for distributing the load of a container over the index finger of a hand (not shown) lifting the container, while the curvature of the first strengthening element is selected to fit comfortably on the average index finger of a human hand.

[00334] Preferably, each strengthening element 2135, 2136 and 2137 includes a web of orientable material within boundaries formed respectively between the body portion 2112 of the preform and the first and second strengthening elements 2135 and 2136, and between the third strengthening element 2137 and the straight and arcuate sections 2118 and 2120. Each web of orientable material is aligned with and extends equally in both directions from the central line 2132 of handle. In preferred forms the preform of the eighth embodiment is produced by an injection moulding process as described earlier in this specification. In preferred forms the preform thus produced is reheated and blown on a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine as described earlier in this specification.

Ninth Preferred Non-Symmetrical Preform Embodiment

[00335] With reference to figure 36 there is illustrated a ninth embodiment of the preform showing alternative cross section arrangements for the purpose of reducing volume of the preform. In this instance like components are numbered as for the fourth embodiment with reference to figure 21. In this instance the cross section wall profile as shown in section AA and section BB is rotated 90 degrees as compared with the wall profile of figure 21. In preferred forms the preform of the ninth embodiment is produced by an injection moulding process as described earlier in this specification. In preferred forms the preform thus produced is reheated and blown on a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine as described earlier in this specification.

Tenth Preferred Non-Symmetrical Preform Embodiment

[00336] With reference to figure 37 there is illustrated a tenth embodiment of the preform showing alternative cross section arrangements for the purpose of reducing volume of the preform. In this instance like components are numbered as for the fifth embodiment with reference to figure 22. In this instance the cross section wall profile as shown in section AA and section BB is rotated 90 degrees as compared with the wall profile of figure 22. In preferred forms the preform of the tenth embodiment is produced by an injection moulding process as described earlier in this specification. In preferred forms the preform thus 37 produced is reheated and blown on a continuously rotating, non-symmetric preform feed, stretch-blow-moulding machine as described earlier in this specification.

Differential Wall Thickness System

[00337] With reference to figures 38, 39 and 40, there is illustrated a blown container having a variable wall thickness as a function of radial angle in a horizontal plane and also as a function of the location of the horizontal plane through the blown container 950.

[00338] The variation may be achieved by a selection of preform wall thickness from amongst the various preform profiles described earlier in the specification.

[00339] The variation in the wall thickness of the blown container may also be achieved independently of the preform wall thickness profile by construction of the interior of the blow mould to assist and encourage differential stretch blowing of different regions of the preform as the walls of the preform located in the blow mould are stretched in both the horizontal and vertical directions to the extent that such is permitted by the internal walls of the preform cavity and the cavity in which the handle 950 is nested.

[00340] In further aspects, control over the wall thickness of the blown container is achieved by a combination of selection of preform wall thickness and blow mould cavity design.

[00341] In further aspects, control over the wall thickness of the blown container is also achieved by control over the temperature profile of the preform walls immediately prior to the introduction to the blow mould cavity.

[00342] This control can be achieved by the shape of the shields covering the handle of the preform during the reheating phase.

[00343] This control can be achieved by timing of the progression of the preforms through the reheating phase.

[00344] With reference to figure 38 there is illustrated a PET container 950 having a neck portion 951 and a body portion 952 to which is integrally connected a PET handle 953; the PET handle 953 integrally connected at least a first connection point 954 to the container; the PET container blown from a PET preform in a stretch blow moulding process; wherein a region in the form of a strip 955 of PET material is located on the container 950 under the PET handle 953.

[00345] Figure 38 further illustrates a PET container having a neck portion and a body portion to which is integrally connected to a PET handle; the PET handle comprising an elongate portion of PET material integrally connected at least a first connection point to the container; the PET container blown from a PET preform in a stretch blow moulding process; wherein a region in the form of a strip of PET material is located on the preform and corresponding container opposite the elongate portion of PET material.

[00346] Figure 38 further illustrates a PET container having a neck portion and a body portion to which is integrally connected to a PET handle; the PET handle integrally connected at least a first connection point to the container; the PET container blown from a PET preform in a stretch blow moulding process; wherein a region in the form of a strip of PET material is located on the preform and corresponding container opposite the PET handle. [00347] Preferably the handle 953 and the narrow strip 955 form a solid mass 956 thereby to maintain the integral connection between the handle 953 and the blown container 950. [00348] Preferably the integrally connected handle and the narrow strip form a solid connected mass thereby to strengthen the integral connection between the handle and the blown container.

[00349] Accordingly, in a further broad form of the invention there is provided a PET container stretch blow-moulded from a preform; the preform and the container having a neck portion and a body portion to which is integrally connected a PET handle; the PET handle 38 comprising an elongate portion of PET material integrally connected at least at a first connection point on a body portion of the preform and to on the container; the PET container blown from a PET preform in a stretch blow moulding process; wherein a region in the form of a strip of PET material is located on the preform and corresponding container opposite the elongate portion of PET material handle; the strip of material differentiated in thickness from thickness of a wall of the container on a side opposite from that of the connection point. [00350] Preferably the handle and the narrow strip forms a solid mass thereby to maintain the integral connection between the handle and the blown container.

[00351] Preferably the elongate portion of PET material comprises a stem.

[00352] Preferably the PET handle is connected at a second connection point to the container.

[00353] Preferably the first connection point is an upper connection point.

[00354] Preferably the second connection point is a lower connection point.

[00355] Preferably the preform has a neck portion and an expandable portion located there below the neck portion.

[00356] Preferably the region of the preform body defined by the strip between the two attachment points remains substantially stable during the stretching and blowing of the container,

[00357] Preferably both the regions of the outer and inner surface layers laterally away from the narrow trip are subjected to biaxial stretching.

[00358] Preferably the outer surface of the narrow strip remains substantially stable but the wall of the container at the strip and the inner layers between the handle attachment points undergoes a degree of flow and thinning together with surrounding regions as the plasticised PET material comes under the influence of the stretching and blowing forces.

[00359] Preferably the PET handle is formed in the same mould as and at the same time as the preform is moulded.

[00360] Preferably the loading of plastics material in the region of the wall subtended between the first location and the second location is differentially controlled as a function of location on the circumference of the wall in this regiom [00361] Preferably the region is designated the differential loading region.

[00362] Preferably there is an increased loading of material in the region of immediately between the first location and the second location points whilst, an opposite region located diametrically opposite the differential loading region has is reduced in material thickness removed from it as indicated in dotted outline.

[00363] Preferably the differential material loading is a function of circumferential position on walls of the preform aids in providing control over the wall thickness of the blown container.

[00364] Preferably the stretch blow moulding process is a two stage stretch blow moulding process.

[00365] Preferably the differential loading region subtended between the first location and the second location remains substantially unchanged during the blowing process.

[00366] Preferably the differential loading region is an extension of and part of the neck portion of the preform.

[00367] Preferably the preform includes a symmetrical thickening of the wall of the preform in the lower region of the body portion which extends from immediately below the point of connection of the lower end of handle.

[00368] Preferably at a second, intermediate region located between the first connection point and the second connection point of handle, the wall thickening of the preform tapers gradually from a first thickness T1 to a second thinner thickness T2. 39

[00369] Preferably the thickening is symmetrical about the longitudinal axis of the preform.

[00370] Preferably the thickening results in a controllable increase in the thickness of material in the blown container in the corresponding intermediate region, and also in a sub- region immediately below the first connection point of the lower end of handle.

[00371] Preferably the thickening results in a controllable increase in the thickness of material in the blown container in the corresponding intermediate region, and also in a sub- region immediately below the second comiection point of the lower end of handle.

[00372] With reference to Figure 42, there is illustrated a preform 1010 injection moulded entirely from PET plastics. In this instance, the preform includes an integral PET handle 1426 in this instance connected at least at an upper connection point 1422. In this particular instance, the handle 1426 is also connected at a lower connection point 1424.

[00373] As for previous embodiments, the wall thickness of the preform may be differentiated throughout the preform in order to achieve particular end wall thicknesses of the container 1428 blown there from - see Figure 43.

[00374] In particular, the wall thickness 1421A in the region of the preform 1420A located beneath the handle 1426 and on the side of the preform closest to the handle 1426 may be differentiated from the wall thickness 1441A in a region 1440A located on an opposite side of the perform from the region 1420 A. The intention is to control preform wall thickness so that the wall thickness of corresponding locations on the blown container 1428 is such that the wall thickness 1421B in the region of the container 1420B located beneath the handle 1426 and on the side of the container closest to the handle 1426 may be differentiated from the wall thickness 1441B in a region 1440B located on an opposite side of the container 1428 from the region 1420B.

[00375] The resultant differentiated wall thicknesses in the blown container may be achieved by selection of wall thicknesses in the preform 1410. In an alternative form, the resultant differentiated wall thicknesses in the blown container may be achieved by selective movement of the PET in the walls during the stretch blow moulding process. In particular forms, both methodologies may be used together.

[00376] In a particular form, the region 1420B is blown against a substantially planar inside wall 1460 of the blow mould 1461 (see inset of Figure 43) such that the region 1420B itself constitutes a substantially planar region.

[00377] In a particular preferred form, the upper connection point 1422 is located on a non-expanding region 1470A of the preform corresponding to a substantially non-expanding region 1470B of the resultant blow container 1428.

[00378] In a particular preferred form where the lower end of the integral handle 1426 is integrally connected to the preform at lower connection point 1424, the lower connection point is connected to the substantially planar region of the blown container 1410.

[00379] In this embodiment of the preform and container blown there from with reference to figures 42 and 43 a region of the wall of the blown container is differentiated in thickness by an increased loading of material in the region from the reduced wall thickness diametrically opposite the handle. The region 1420B may be substantially planar. 40

[00380] In a particular form, the rigid handle 1426 and the substantially planar region form an interconnected rigid structure whereby flex of the handle 1426 in use relative to the container 1428 is resisted. This feature may be particularly advantageous for larger volume containers 1428 - for example four litre containers where the weight of the liquid in the container may be substantial.

[00381] In one form during the stretch blow moulding operation the region 1420A/ 1420B remains substantially stable, with regions laterally on either side of the region subjected to bilateral stretching.

[00382] A PET container stretch blow-moulded from a preform; the preform and the container having a neck portion and a body portion to which is integrally connected a PET handle; the PET handle comprising an elongate portion of PET material integrally connected at least at a first comiection point on a body portion of the preform and on the container; wherein a region in the form of a planar region is located on the container opposite the handle; the planar region differentiated in thickness from thickness of a wall of the container on a side opposite from that of the handle.

[00383] Preferably the handle and the planar region form a solid mass thereby to maintain the integral comiection between the handle and the blown container.

[00384] Preferably the integral handle comprises a stem.

[00385] Preferably the PET handle is connected at a second connection point to the container.

[00386] Preferably the first connection point is an upper connection point.

[00387] Preferably the second connection point is a lower connection point.

[00388] Preferably the preform has an expandable portion located below the neck portion.

[00389] Preferably the region of the preform body defined by the substantially planar region between the two attachment points remains substantially stable during the stretching and blowing of the container.

[00390] Preferably the PET handle is formed in the same mould as and at the same time as the preform is moulded.

[00391] Preferably loading of plastics material in the region of the wall 1420A/1420B subtended between the upper connect point and lower connection point is differentially controlled as a function of location on the circumference of the wall in this region; the region designated the differential loading region. 41

[00392] Preferably there is an increased loading of material in the region immediately between the first location and the second location points whilst, an opposite region located diametrically opposite the differential loading region is reduced in material thickness.

[00393] Preferably differential material loading as a function of circumferential position on walls of the preform aids in providing control over the wall thickness of the blown container.

[00394] Preferably the stretch blow molding process is a two stage stretch blow molding process.

[00395] Preferably the differential loading region subtended between the first location and the second location remains substantially unchanged during the blowing process.

[00396] Preferably the differential loading region is an extension of and part of the neck portion of the preform.

Bifurcated Strengthening System

[00397] With reference to Figures 42 and 43 and the differential wall thickness system embodiment described above a further feature may be added to the integral handle of that embodiment to further strengthen its connection to the body of the container 1428.

[00398] In this embodiment as shown in Figures 42 and 43, the handle 1426 includes a curved strengthening element 1481 at a lower end of the handle. In one instance, the strengthening element 1481 is located at the junction between the arcuate section 1482 and the straight sections of the handle 1483. In this region the orientable plastic material is bifurcated to form an enclosing, generally triangular element 1484 which may include a central web of conforming generally triangular shape.

[00399] Similar bifurcated and preferably webbed strengthening elements 1485 and 1486 may be provided at each of the upper and lower comiection regions.

[00400] The combination of the connection to the substantially planar region 1420A,

1420B with the strengthening elements 1485 and 1486 provides a closed rigid structure imparting confidence to the user, particularly when the container is of relatively large volume.

Notes on the Handle

[00401] In preferred forms the integral handle of the preform is not substantially deformed or substantially changed in shape during the stretch-blow-moulding process but substantially retains its as-injection-moulded shape. The blow-moulding cavity shown in Figure 10 includes a recess specifically shaped to the form of the handle as injection moulded. This it will be understood is also a primary function of the heat shield to protect the handle from heat which could cause distortion of the handle while the preform is transported around the preheating stage of the machine.

Injection Moulding of Preforms 42

[00402] A preferred system of injection moulding any one of the above described preforms will now be described with reference to Figures 29 to 31. As noted elsewhere, the integral, double connect handles of the containers which are stretch-blow-moulded from the preforms, introduce considerable complexity in the design and operation of the injection moulding tooling.

[00403] Typically, in the injection moulding of preforms for symmetrical or non-handled containers, the bodies of the preforms below the neck are formed in cavities in the “hot”, fixed section of the injection moulding die, with the threaded neck portions formed in opposing half cavities carried on the face of the moving die section. After a mould cycle, when the die opens, the bodies of the preforms are drawn out of their cavities by the necks which, at this first opening stage, are retained in the still closed opposing half cavities and move with the opening die section. The opposing half cavities now part to release the necks and a stripper plate is activated to force the preforms off the cores (which are fixed to the moving die section).

[00404] With reference now to Figure 29 to 31 , for preforms 1100 with handles 1112, only that section 1114 below the handle can be formed in cavities 1116 in the heated, fixed section 1118 of the die 1120, with the neck 1122 and handle 1112 formed in much longer and more complex opposing half cavities 1124 carried on the moving die section 1126. Again, the cores 1128 to form the internal shape of the preforms 1100 are fixed to the moving die section 1126 and are located on the common axis of the cavities 1116 in the heated fixed side of the die and the opposing half cavities.

[00405] In contrast to the demoulding of symmetrical preforms, the bodies of which are exposed to air immediately the die opens, a much larger section of the preforms of the present invention is retained in the opposing half cavities 1124 and therefore require a longer delay before preforms have cooled and are sufficiently stable for stripping off the cores 1128. This adds considerably to the mould cycle time for preforms with handles.

[00406] In order to reduce cycle time and thus increase production, in the system of the present invention referring now to Figure 32, a robot 1130 (only a portion of the arm of which is shown in Figure 32) is employed in the demoulding of the preforms 1100. The robot arm end effector 1132 is fitted with an array 1134 of vacuum cups 1136, equal in number and spaced according to the number and spacing of the cavities in the injection moulding die as shown in Figure 31. Towards the end of a mould cycle this array 1134 of vacuum cups is poised above (or to the side of) the injection moulding die 1120 and as soon as the die opens sufficiently to allow insertion of the array, the robot brings the array into registered position between the parted sections 1118 and 1126 of the die, and advances the vacuum cups 1136 to fit over the lower ends of the preforms.

[00407] It is important for correct extraction of the preforms that the handles remain aligned in their as-moulded orientation to prevent rotation of the handles into positions at which they may be caught on edges of the opposing cavity halves. For this reason the vacuum cups are provided with a slot or channel 138 at their outer ends which slides around the lower end of the handle. By this means also a larger portion of the preform is covered by the vacuum cup. Vacuum is now applied to the cups 1136 and the robot retracts the array 1134, and the preforms 1100 now secured by vacuum pressure in the cups, to draw the preforms off the cores. Once free of the cores the array of vacuum cups and retained preforms are withdrawn from between the heated fixed section 1118 and the moving side 1126 of the die, 43 and rotated so that the axes of the preforms are in a substantially vertical orientation. Vacuum pressure is then cut allowing the preforms to fall from the vacuum cups into a receiving bin.

[00408] The advantage of the use of vacuum in the demoulding process rather than a conventional stripper plate, is that the application of vacuum aids significantly to the cooling of the preforms, thus allowing their extraction at an earlier point in the mould cycle and shortening that cycle. This is particularly beneficial for the preforms of the present invention in which the end below the handle, being the last part of the preform to be formed (injection proceeding from the tip of the closed end of the preform), is at the highest temperature when the die opens. Additionally the slot or channel which accommodates the lower part of the handle, provides for a greater portion of the preform to be subjected to the cooling provided by air flow into the suction cups when vacuum is applied just before suction cups fully envelop the lower and mid portions of the preforms.

[00409] The cooling proceeds further as the robot draws the array of vacuum cups and preforms away from the die and over a receiving bin. The array is then rotated from the initial as-removed from the die position, that is with the axes of the preforms horizontal, to the vertical allowing the preforms to fall out of the cups when vacuum pressure is cut, and into the receiving bin.

Single Connect Integral Handle of PET Container and Method of Production

[00410] PET polymer is an expensive material from which to produce what are in the main, single use bottles. There are of course well-known advantages of PET; firstly in the clarity of the material allowing clear viewing of a container’s contents and, secondly, that the material lends itself to recycling. However, it is not possible, or at least very complicated to provide an integral handle in a PET stretch blow-moulded container such as the handle provided by forming around a hole in the side of the bottle as commonly provided in HDPE containers.

[00411] As well as its aesthetic appeal, PET containers provided with an integral handle would add a desirable feature in ease of manipulating the container. Some solutions are known in which a separately injection moulded handle is positioned in the stretch blowmoulding cavity and the container blown so that the ends of the handle are captured by material flowing around them, such as disclosed in JP2010-274967. But these arrangements are complicated and difficult in practice.

[00412] As best seen in figure 1, to provide the strength needed for a secure connection of the loop of the handle 26 to the container 28 of figure 43, a considerable volume of polymer is expended in the bracing structures at the upper and lower connection areas 22, 24 and at the intersection 30 of the arcuate portion 32 of the handle with the straight lower part 34.

[00413] Turning now to figures 44 and 45, the integral handle 40 of the preform 42 and of the container 44 of the present invention, is connected to the cylindrical body portion 46 of the preform. It will be noted that, in this form of the handle 40, it has been found there is no need for an increased thickness of the wall in the connection region 48 or in the region 50 extending below the connection region, so that in effect the wall thickness of the cylindrical body portion 46 of the preform, is uniform. Again, that uniform wall thickness is carried over into the container 44 of figure 4, blown from the preform of figure 44. 44

[00414] In this instance, the handle 40 includes and upper arcuate portion 52 extending from the single connection region 48 which transitions into a substantially straight, downwardly projecting portion 54. The handle 40 comprises of a central web 56 lying in a plane passing through the centreline 58 of the body portion of the preform. The web 56 is bounded by a continuous edge 60 around the periphery of the web from an upper junction point 62 to a lower junction point 64 on the body portion 46 of the preform.

[00415] The handle 40 is further comprised of a rib 66, normal to the web 56 which extends along the edge 60. The rib 66 projects outwardly and symmetrically from both sides of the plane so that in effect the web 56 and the rib 66 form an I-beam like cross section. The upper and lower cross sections of the rib 66 extend to meld with the surfaces of both the preform and of the container. These areas of the rib and of the central web combine to provide the strength of connection of the handle with the container required for manipulating a filled container.

[00416] In some preferred embodiments, the inward facing sections 68 of both the web 56 and the rib 66 are provided with one or more scallops configured to aid the gripping of the handle by a user. Also preferably in some embodiments, the handle may additionally be provided with a thumb support 70 as that shown on the container of figure 45, projecting from an upper portion of the rib.

[00417] By means of the handle 40 connected at a single connection region on both the body portion of the preform and on the body of the container stretch blow-moulded from the preform, significant savings in PET polymer are achieved over the double connect handle of the prior art. This has allowed the reduction in wall thickness in the region of connection of the handle so that in both the preform and the container, the wall thickness in the region of the handle connection is substantially equal to the wall thicknesses of adjacent regions.

[00418] Figure 46 is a side section view of a further example of a preform with a handle attached at a single point with an alternative variable wall profile.

[00419] In this instance the preform A10 has side walls having a first relatively thin thickness All near the neck end of the preform and having a second relatively thick thickness A12 near a lower end of the preform furthest from the neck A13.

[00420] In this instance the first relatively thin thickness wall transitions to the relatively thick thickness wall by way of a transition zone A14 as illustrated in Figure 46.

[00421] In this instance the inside wall diameter A15 reduces as a function of the length of the preform, reducing progressively away from the neck A13 thereby to create the wall thickness of the transition zone A14 and the relatively thick thickness wall A12.

[00422] In this instance the outside wall diameter A16 either remains relatively constant as a function of the length of the preform or, in alternative version, increases slightly as a function of length away the neck A13.

[00423] The end result is a preform having a relatively thick wall thickness furthest away from the neck. In a preferred form, this provides increased material for stretch blowing to form a relatively enlarged volume of a blown container blown from the preform A10. The rationale for the location of wall thickening in a preform intended for stretch blowing as part 45 of a two stage stretch blowing process or system is described in the technical literature - see for example Plastic Blow Moulding Handbook by N.C. Lee published Springer Netherlands 31 May 1990 - in particular pages 101 to 107 thereof.

[00424] Figure 47 is a side section view of a further example of a preform with a handle attached at a single point with an alternative variable wall profile.

[00425] In this instance the preform A20 has side walls having a first relatively thin thickness A21 near the neck end of the preform and having a second relatively thick thickness A22 near a lower end of the preform furthest from the neck A23.

[00426] In this instance the first relatively thin thickness wall transitions to the relatively thick thickness wall by way of a transition zone A24 as illustrated in Figure 47.

[00427] In this instance the inside wall diameter A25 either remains relatively constant as a function of the length of the preform or, in alternative version, increases slightly as a function of length away the neck A23.

[00428] In this instance the outside wall diameter A26 increases as a function of the length of the preform, increasing progressively away from the neck A23 thereby to create the wall thickness of the transition zone A24 and the relatively thick thickness wall A22.

[00429] The end result is a preform having a relatively thick wall thickness furthest away from the neck. In a preferred form, this provides increased material for stretch blowing to form a relatively enlarged volume of a blown container blown from the preform A10. The rationale for the location of wall thickening in a preform intended for stretch blowing as part of a two stage stretch blowing process or system is described in the technical literature - see for example Plastic Blow Moulding Handbook by N.C. Lee published Springer Netherlands 31 May 1990 - in particular pages 101 to 107 thereof.

[00430] In the instance of single comiect handle A17, A27 illustrated in Figures 46 and 47 the single connect located higher up on the preform near the neck A13, A23 allows for more flexibility in wall thickness design and optimum use of PET material as described earlier.

Preform Distortion Control and Method

[00431] Figures 48 and 49 show an injection moulded preform 10 with an integrally connected, in this instance a double- connected handle 12, as initially injection moulded and distorted subsequent to passage through a preheating conditioning stage of a stretch blow moulding machine. As can be seen in figure 49, substantial distortion of the preform may occur due to the asymmetry of the preform introduced by the integrally connected handle.

The bending of the body portion 14 of the preform pulls the handle out of its as injection moulded position.

[00432] Within limits, the distortion of the cylindrical body 12 of the preform is not of major concern, as long as the stretch rod’s movement is not impaired. However, in the stretch blow-moulding of preforms with integral handles, the handles must not be distorted to an extent where they cannot be properly inserted into the pockets in the stretch blow-moulding die intended to maintain their configuration during the stretch blow-moulding cycle. 46

[00433] To produce a stretch blow-moulded container such as shown in figure 51, in which the handle has a desired configuration, it is necessary to firstly reduce the distortion to within a manageable minimum range, and secondly, to adapt the stretch blow-moulding die to accommodate distortions within this minimum range.

[00434] In a preferred embodiment of the invention, a minimum range of distortions is established by repeated test runs of passing injection moulded preforms 10 through the conditioning stage of the machine with carefully controlled and adjusted parameters. These parameters may include the settings and disposition of heating elements, the temperature gradients at various locations, time of passage and rotation of preforms etc. These test runs will establish a repeatable minimum range of distortions for a given set of parameters around which strategies for controlling the distortion of the handle can be devised.

[00435] Heat shields which protect the handle from excessive heat as a preform passes through the preheating stage must be designed to accommodate a maximum distortion within the minimum distortion range.

[00436] In one arrangement, the design of the integrally connected handle of the injection moulded preform and the cavity of the preform injection moulding die may be adjusted so that, at least to some extent, the distortion induced by the conditioning stage will tend to bring the handle back towards the desired configuration for entry into the handle pockets in opposing cavities of a stretch blow-moulding die.

[00437] The distortion may further be accommodated by a particular shaping of the periphery of the handle accommodating pocket. As shown in figure 50 the handle nesting pocket 16 in each die half 18 are provided with angled lead-in surfaces 20 to guide and force a distorted handle into a proper seated position within the pocket 16. In this arrangement, the outer edges 22 of the lead-in surfaces 20 is such as to define at least a maximum distortion of the range of distortions. By these means, a container as shown in figure 51 can be produced with the integral handle in its correct designed disposition on the blown container.

[00438] The same strategies for correcting a single-connected integral handle can be adopted as shown in figures 52 and 53. As for the double-connected handle, the single- connected handle 114 of the preform 100 is distorted from its as injection moulded position by the distortion of the body 112 of the preform.

[00439] As described above, strategies for establishing a minimum range of distortions, possibly adjusting the design of the preform as well as providing special lead-in surfaces 120 for the handle nesting pocket 116 in the die halves 118 may be deployed to produce the final stretch blow-moulded container of figure 53.

Industrial Applicability

[00440] The continuous movement of previously injection moulded, non-symmetrical preforms from their initial feeding into the machine 10 through the various continuously rotating stages described above, provides a marked improvement in output and quality of containers stretch-blow-moulded from such preforms. This continuous flow from preform infeed to the outfeed of container is made possible by the unique features of the transfer systems of the machine and the control of orientation of the preform handles at each transfer, 47 and that of the preform supporting mandrels at transfers into and away from the preheating stage.

[00441] The preforms of the above described embodiments, provide for the stretch-blow- moulding of a container in the stretch-blow-moulding machine, which is equal in capacity to that of the container in Figure 25, but with a significant reduction in the volume of PET and conferring an optimum distribution of material from the preform to form the containers shown in Figures 17 and 18. Thus, the preforms of the invention provide for a considerable reduction in raw material costs in the production of PET containers with integral handle.