PRODUCTION METHOD FOR DISPOSABLE LARGE WATER BOTTLE WITH A

CASE

Technical Field

The invention relates to the returnable plastic containers with approximately 19-20 kg weight, which is used in the sector of packed drinking water sales and which is colloquially known as demijohn.

State of the Art

The routine method implemented until now is established on collecting the empty containers by vendors and re-selling of these after cleaning and refilling. Serious health problems occur in case necessary attention is not shown during cleaning and repeatedly refilling of these packages. Moreover, as the water used in the cleaning process is at least the amount of the water filled in the water bottle, this causes waste of water. On the other hand, as chemicals mix into the cleaning water, said cleaning water is also polluted.

The water bottle encounters many hygiene problems until it reaches to the user from the manufacturer. Moreover, as a great variety of bacteria and viruses have evolved today, cleaning of these containers is insufficient in elimination of some viruses. This is because the easiest and fastest way people can get infected is via the substances taken orally.

On the other hand, arranging and stacking problems in carrying and storing large water bottles have been experienced until now. The protrusion on the neck section of the water bottle makes it impossible to stack the containers on one another and occupies a large place in both shipment and storage. Moreover, due to the unhealthy conditions experienced in large water bottle packages, consumers tend to use small disposable PET packages. Consequently, the consumer has to pay for the package every time s/he purchases water. Another disadvantage is that as PET water bottles are thrown away after use, they cause environmental pollution.

Moreover, the conventional water bottle use in the prior art causes waste of national resources. Conventional water bottles are made of polycarbonate raw materials and such raw material includes BisPhenol A. This material makes the water container rigid and durable. As the material, named BisPhenol A, has carcinogenic effect, its continuous use can cause severe health problems in the long run.

In conventional large water bottles, when the bottle is closed with the cap, the outer section is covered with shrink stretch by heat treatment.

In the research regarding the prior art, no application regarding the production of large bottle plants with case was found; however, related applications numbered US2005/0067434, WO03/035540 were found.

As a result, due to the drawbacks mentioned above and the inadequacy of the existing solutions regarding the subject matter, it is required to make a development in the related technical field.

Object of the Invention The invention, configured by being inspired by the current conditions, aims to solve the above mentioned drawbacks.

Invention can be easily integrated with current production and recycling processes and it reduces production costs and provides many advantages in obtaining healthy products in contrast with previous techniques. The invention is considered as an alternative to the package type which is colloquially named demijohn, used in selling drinking water, marketed with deposit practice, used repeatedly by cleaning and is mold plastic based (made of polycarbonate material).

The method according to the invention shall eliminate two of the most important problems experienced in returnable drinking water sector. First of these is the rewashing problem of the water bottles and the other is the stacking problems. Conventional large water bottles are refilled every time. However, as the water bottles will be produced as disposable thanks to the method according to the invention, rewashing problem will be eliminated.

Regarding the second problem, in order to make it possible to stack the neck sections on one another, a cove is created at the bottom of the water bottle. Thus, when the water bottles are stacked on one another, the protrusions on the neck sections of the water bottles below fit into the cove formed at the bottom of the water bottle above. Thus, it is aimed to use the space efficiently in arranging process.

On the other hand, as the sections of the protective plastic case that spread over the bottom and top surfaces of inner PET (Poly-Ethylene Teraphthalate) package are pressed on one another, inner package is not subjected to any pressure. Thus, shipment and stacking are made easier by placing the water bottles on one another without any gaps, and shipment and storage costs are made significantly advantageous. Moreover, forming a circle shaped handle and stacking collar that wraps the water bottle all around on the upper section of the protective case will make handling easier.

The large water bottles produced by using the method according to the invention are as thin as the small water bottles (for example 0.5 I, 1 .5 I and 5 I packages). When the thickness of current large water bottles is considered, the water bottles which will be produced in the novel system will be 5-6 times thinner than the current large water bottles. Thus, the amount of raw material will be reduced and an economic value will be achieved.

Besides, as the plastic protective case around the water bottle does not contact the product, it can be used repeatedly. Aluminum foil will be adhered with heat treatment to the cap of the large water bottle produced from PET material with the water bottle production method according to the invention and it will be sold by this way. This aluminum foil will be pierced or torn by the consumer and the water bottles with previously pierced or torn foil will not be purchased by the next consumer. Moreover, in the case of empty water bottles, as the aluminum foil on the cap is pierced and the section on the cap which is adhered with heat treatment cannot be removed, it will be obvious that the foils are adhered on one another. Thus, refilling the used water bottles is made impossible. In a preferred embodiment of the invention, the method according to the invention includes the following: while placing lower core inside the lower core print of right mold, cove forming section, which is used to form a lower stacking cove at the lower section of the large water bottle, is placed together with the lower core inside the lower core print, left mold is connected with the right mold in a way to have the case between them, in order for the preform to inflate and take the form of the surfaces it contacts, high-pressure air or gas is injected inside the preform via an air nozzle until a part of the exterior surface of preform contacts the case and another part thereof contacts the interior sections of right and left mold, after the inflated preform expands until the interior surface of the case, a section of the exterior surface of formed PET water bottle contacts the cove forming section of the lower core.

In a preferred embodiment of the invention, in order to cover the cap section of the formed water bottle, capping foil made of aluminum material is adhered over the neck section thereof with heat treatment. In a preferred embodiment of the invention, after use, the air inside the water bottle made of PET material is vacuumed by connecting the vacuum nozzle of a vacuum machine to the cap of the water bottle for the purpose of shrinking and contracting the water bottle and thus the water bottle can be removed out of the case from the opening at the top section of the case. In a preferred embodiment of the invention, said case is manufactured with injection molding method in a manner to comprise handling and stacking collar that allows handling the water bottle from the top and stacking the water bottles on one another.

The structural and characteristic features and all the advantages of the present invention will be more clearly understood thanks to the figures below and the detailed description written with reference to those figures, therefore, the evaluation needs to be done by taking said figures and the detailed description into consideration. Figures for a Better Understanding of the Invention

Figure 1 is the perspective view of the water bottle from bottom.

Figure 2, is the cross sectional view of the water bottle.

Figure 3, is the cross sectional perspective view of the water bottle.

Figure 4, is the cross sectional perspective view of the protective case.

Figure 5, is the detail view of the cross section of the bottom of the protective case. Figure 6, is the cross sectional view of the protective case.

Figure 7, is the perspective view of the protective case.

Figure 8 is the perspective view of the water bottle from top.

Figure 9, is the cross sectional perspective view of the water bottle and the protective case.

Figure 10, is the detail cross sectional view of the state in which the water bottle is inside the protective case.

Figure 1 1 , is the detail view of the inside of the right mold in the state comprising the water bottle and the protective case.

Figure 12, is the side cross sectional view of the water bottle and the protective case . Figure 13, is the perspective view of lower core from the top.

Figure 14a, is the view of the interior surface of the left mold.

Figure 14b is the view of the right mold in the state comprising neck core and lower core.

Figure 15 is the perspective view of half of the mold, inside which the preform and mold lower core is shown.

Figure 16, is the perspective view of the water bottle and the protective case from top in the state that the mold is opened.

Figure 17, is the perspective view from the top after the mold is opened and the water bottle and the protective case are removed.

Figure 18, is the separate perspective views of the water bottle and the case from the top. This figure is provided only for the purpose of showing also the water bottle. This state does not occur during use.

Figure 19, is the view that shows the state in which the water bottles are stacked on one another.

Figure 20, is the side cross sectional perspective view of Figure 19.

Figure 21 , is the side cross sectional view of Figure 19. Figure 22 shows the configuration in which the protective case comprises the handling and stacking collar in accordance with an alternative embodiment of the invention. Figure 23, is the drawing that shows how the protective cases, which comprise the configuration shown in Figure 22, with the water bottles inside are stacked on one another.

Figure 24, is the side cross sectional view of Figure 23.

Figure 25, is the cross sectional perspective view of Figure 23.

Figure 26, is the drawing that shows how the first user lock cap foil is connected with the cap of the water bottle.

Part References

1 . Case

1 1 . Upper surface

12. Lower surface

13. Handling and stacking collar

2. Large water bottle

21 . Neck section

22. Lower stacking cove

31 . Right mold

32. Left mold

33. Neck core print

34. Lower core print

4. Neck core

5. Air nozzle

6. Lower core

61 . Cove forming section

7. Cap foil

8. Cap foil tape

9. Preform

The drawings do not need to be scaled and the details that are not necessary for understanding the present invention may have been ignored. In addition, the members that are at least identical to a great extent or at least have identical functions to a great extent are referred with the same number. Detailed Description of the Invention

In this detailed description, the preferred embodiments of the production method for disposable large water bottle with case outside according to the present invention are described only for the subject to be understood better.

The elements used in the production method for disposable large water bottle with case according to the invention and the characteristics thereof are given below:

- Mold: Mold consists of two separate parts as right mold (31 ) and left mold (32) with identical interior surface forms. Right mold (31 ) and left mold (32) are made of metal and interior surfaces thereof have the same form of the exterior surface of the case (1 ). Besides, on both of the right mold (31 ) and left mold (32), neck core print (33) and lower core print (34) are formed.

Neck core (4): Neck core (4) is located inside the neck core prints (33). The function of the neck core (4) is to prevent air leaks from the upper section of the preform (9) during its inflation. In other words, neck core (4) serves as a tap.

- Air nozzle (5): Air nozzle (5) is the pipe shaped structure that provides inflation of the preform (9) by injecting pressured air or gas. Lower core (6): Lower core (6) made of metal is located inside the lower core prints (34). The function of the lower core (6) is to form lower stacking cove (22) on the bottom of the water bottle (2) during the inflation of the preform (9) via the cove forming section (61 ) it comprises.

Cap foil (7): Cap foil (7) serves as the first user lock. Untorn cap foil (7) shows that the water bottle (2) will be used for the first time. Capping foil (7) made of aluminum material is adhered over the neck section (21 ) with heat treatment in order to cover the cap section of the formed water bottle (2).

Cap foil tape (8): Cap foil tape (8) is the tape which comprises the cap foils (7) thereon.

Case (1 ): Case (1 ) is used to form the preform (9) into a water bottle (2). Besides, the case (1 ), which is preferably made of hard plastic, provides strength to the preform (9) externally and as the preform (9) is thin due to being made of PET material, it prevents possible damages. Moreover, it prevents the distortion of the thin structure when the water bottles (2) are shipped or stacked on one another. As it can be reused after the use of the water bottle (2) is over, case (1 ) eliminates cost losses. The upper surface (1 1 ) of the case (1 ) is the surface that comes into contact with the lower surface (12) of the case (1 ) on the water bottle (2) when the water bottles (2) with case (1 ) are stacked on one another. The upper surface (1 1 ) of the case (1 ) prevents the water bottle (2) made of weakened PET material inside the case (1 ) from being damaged and pierced. The lower surface (12) of the case (1 ) is the section that provides contact with the ground when the water bottle (2) is put on the ground. Besides, when the water bottles (2) with case (1 ) are stacked on one another, it is located on the upper surface (1 1 ) of the case (1 ) below. Moreover, it prevents the water bottle (2) made of PET material from being damaged and pierced.

Preform (9): Preform (9) is made of PET material. It is the structure that has the form of the water bottle (2) before inflation.

Water bottle (2): Water bottle (2) is the structure that is created after the preform (9) takes the form of the surfaces of case (2), right mold (31 ), left mold (32), neck core (4) and lower mold (6) it contacts. The neck section (21 ) on the upper section of the water bottle (2) is the section that provides water flow. The lower stacking cove (22) located at the bottom of the water bottle (2) is formed by inflation of the preform (9) by means of locating the lower core (6) cove section at the lower core prints

(34) before inflation. When water bottles (2) with case are stacked on one another, the neck section (21 ) goes into the lower stacking cove (22) of the water bottle (2) above and thus, they require less shipment and storage area. If the lower core (6) is placed inside the lower core print (34) without having the cove forming section (61 ) on it, the lower section of the water bottle (2) is shaped in the form of the upper section of the lower core (6).

The invention relates to the new large water bottles (2) developed for use in drinking water sector and by utilizing protective plastic case (1 ) around the water bottle (2), said water bottle (2) is strengthened. By previously placing the exterior protective plastic case (1 ) into the right mold (31 ) (or left mold (32)) during the production of the water bottle (2) and then inflating the interior PET water bottle (2), it is ensured that the water bottle (2) fits rigidly into the interior section of the case and cooled, and the sections which get into contact with case (1 ) get the same form as the case (1 ). This way, the water bottle (2) becomes integrated with the case (1 ) and after filling, the water bottles (2) with case (1 ) will be marketed by easily stacking on one another. After their use, the empty water bottles (2) with case (1 ) are recollected and the water bottle (2) made of PET material is vacuumed by means of a vacuum machine. The surface of the water bottle (2) is thin. Thus, during the vacuum process, a vacuum nozzle is connected to the cap of the water bottle (2), the air inside the water bottle (2) is vacuumed and thus, the water bottle is shrank and contracted. The contracted water bottle (2) is removed from the opening at the top section of the protective plastic case (1 ). The case (1 ) is used again in right mold (31 ) and left mold (32) to be used in production of another water bottle (2). The waste water bottle (2) with thin walls removed from the case (1 ) will be melted and involved in the reproduction process. This way, a new water bottle (2) will be filled with water each time. The cleaning process of the water bottles (2) will be eliminated and the hygiene problem arising from washing will be solved.

The method according to the invention relates to the production process of large water bottles (2). However, the case (1 ) also needs to be produced beforehand. Instead of the right mold (31 ) and left mold (32) in which the water bottle (2) is produces, the production of the case (1 ) will be conducted with a separate mold. Protective plastic case (1 ) is produced with plastic injection molding method. The produced case (1 ) is then placed inside the right mold (31 ). Next, the preform (9) is heated and placed inside the right mold (31 ) to obtain the water bottle (2). The inflation process is conducted through the cap section of the preform (9) by using an air nozzle (5). Some surfaces of the inflated PET preform (9) fits into the interior surface of the case (1 ), some fit into the interior surfaces of the right mold (31 ) and the left mold (32) and thus, it takes the shape of the case (1 ) and the mold. Later, the water bottle (2) is left for cooling. Thus, the exterior surface of the water bottle (2) gains strength. The water bottle (2) with case (1 ) produced by this way is transferred to the filling line.

The production of the case (1 ) is conducted as follows: The package referred to as case (1 ) is produced by using plastic injection molding method. First, a steel mold consisting of two parts that has the form which is intended on the surface of the case (1 ), in other words, which has the form that matches the form of the water bottle (2) to be manufactured, is prepared. On one surface of each of these molds, half of the package figure is imprinted. When the mold consisting of two separate parts is joined, the imprinted half figures inside the two molds are made in a way to have figures on the case (1 ). In case this mold is plastic injection mold, a steel mold, on which the figures inside the case (1 ) are imprinted, is placed into the section inside the interior section of the case (1 ). If the mold is not a plastic injection mold but a plastic inflation mold, it will not be necessary to place a separate mold inside the interior section. Plastic based material is poured into the mold as molten and by applying high pressure air or gas inside the package, the molten material is rigidly adhered to the interior surfaces of the mold. The package obtained by this way is cooled and formed. When the mold is opened, the product will be ready. The molds mentioned here are not the molds used for production of thin PET water bottles, in other words, the mold (4) used for production of the water bottle (2) is not used for the production of the case (2). The water bottle (2) made of PET material is produced as follows: preform (9), which is the material in the shape of a small tube and which forms the water bottle, is prepared in the plastic injection mold as it is in the case of the water bottles (2) produced in the prior art. After this phase, the process steps given below are executed: placing the case (1 ) inside the right mold (31 ), connecting the left mold (32) with the right mold (31 ) in a way to have the case between them, placing the lower core (6) inside the lower core print (34) of the right mold, placing the preform (9) made of PET material on the neck core print (33) of the protective case (1 ), located on the right mold (31 ) and left mold (32), with the neck core (4) after heating and softening, injecting high-pressure air or gas inside the preform (9) via an air nozzle (5) until a part of the exterior surface of preform (9) contacts the case (1 ) and another part of it contacts the interior sections of right mold (31 ) and left mold (32) in order for the preform (9) to inflate and take the form of the surfaces it contacts, cooling the formed water bottle (2), separating the left mold (32) and the right mold (31 ) from each other.

After the inflation process, in the contact of the water bottle (2) with the case (1 ), the water bottle (2) and the case (1 ) are rigidly fastened to each other, however, this connection is not in the form of adherence. This is because, as the protective plastic case (1 ) is produced before and has a cold surface, the thin PET material heated and inflated inside does not adhere to the material on the exterior.