HK1110567B - Container - Google Patents

Description

Container with a lid

Technical Field

The present invention relates generally to plastic containers and, more particularly, to hot-fillable containers having crimped or vacuum panels.

Background

The application of hot fill imposes significant and complex mechanical stresses on the container structure due to thermal stresses, hydraulic pressure during filling and immediately after capping, and vacuum pressure during fluid cooling.

When a hot fluid is introduced, thermal stresses are applied to the vessel walls. The hot fluid softens the container walls and then shrinks unevenly, further deforming the container. Therefore, the plastic walls of containers typically made of polyester may require heat treatment in order to alter the molecules, resulting in containers exhibiting better thermal stability.

During the filling process, pressure and stress act on the side walls of the heat-resistant container, a very important period thereafter. When the container is filled with a hot liquid and sealed, an initial hydraulic pressure is applied to the container with an increased internal pressure. The liquid under the lid and the air in the headspace then cool, and the thermal contraction causes the container to be partially evacuated. The vacuum created by this cooling tends to mechanically deform the container walls.

In general, a container comprising multiple longitudinal planes is easier to adjust the vacuum force. For example, U.S. patent No. 4,497,855 (Agrawal et al) discloses a container having a plurality of recessed shrink panels separated by shoulder regions (landarea) which are said to deform uniformly inwardly under vacuum forces. The vacuum effect is said to be controlled without adversely affecting the shape of the container. The panels are said to be drawn inwardly to vent the internal vacuum so that excessive pressure is prevented from being applied to the container structure which would otherwise deform the inflexible pillar or shoulder region structures. However, the amount of "bending" available in each panel is limited, and there is an increase in the force transferred to the side walls as the limits are approached.

To minimize the effect of forces transmitted to the sidewalls, most prior art has been directed to providing a container with a reinforced area, including a panel, to prevent the structure from yielding to vacuum forces.

The arrangement of horizontal or vertical ring-shaped portions, or "ribs" (rib), throughout the container has become a convention in the construction of containers and is not limited to hot-fill containers only. Such an annular portion will also reinforce the portion disposed thereon. For example, U.S. patent No. 4,372,455 (Cochran) discloses a longitudinally reinforced annular rib placed in the area between the planes of hydrostatic forces subject to inward deformation under vacuum forces. U.S. patent No. 4,805,788 (Ota et al) discloses ribs extending longitudinally alongside the panels to increase the strength of the container. The patent also discloses the reinforcing effect of providing a larger step in the side of the shoulder region, which provides greater size and strength to the rib region between the panels. U.S. patent No. 5,178,290 (Ota et al) discloses a recess for reinforcing the panel area itself. Finally, U.S. patent No. 5,238,129 (Ota et al) discloses another reinforced annular rib that is directed horizontally in strip-like fashion over and under and outside the hot-filled panel portion of the bottle.

In addition to the need to strengthen the container against thermal and vacuum stresses, there is also a need to allow an initial hydraulic pressure and increased internal pressure to be exerted on the container when hot liquid is introduced with the closure. This will also cause stresses to be placed on the side walls of the container. It may also cause the hot panel to be forced outwardly in the barrel of the container.

Thus, U.S. patent No. 4,877,141 (Hayashi et al) discloses a panel structure that accommodates initial and natural outward bending caused by internal hydraulic pressure and temperature, and subsequent inward bending caused by vacuum formation during cooling. It is important that the panel remains relatively flat in profile, but has a central portion that is slightly displaced to increase the strength of the panel but does not prevent radial in and out movement thereof. However, the amount of movement is limited in both directions by the substantially flat panel. The panel ribs must not include additional resilience as the resilience will prevent the panel from moving back generally inwardly and outwardly.

As mentioned above, the use of blow-molded plastic containers for packaging "hot-filled" beverages is well known. However, containers for hot-fill applications are subjected to additional mechanical stresses, which will result in the containers being more likely to be damaged during storage and handling. For example, it has been found that when the container is filled with a hot fluid, the thin walls of the container deform or crumple. Furthermore, when a hot fill liquid is introduced into the container, the rigidity of the container immediately decreases. As the liquid cools, the volume of the liquid contracts, thereby creating a negative pressure or vacuum in the container. The container must be able to withstand this pressure variation without damage.

Hot-fill containers typically include a generally rectangular vacuum panel that is designed to collapse inwardly when the container has been filled with a hot liquid. However, the inward bending of the panel due to the hot-fill vacuum creates high stress points at the top and bottom edges of the vacuum panel (especially at the upper and lower corners of the panel). These stress points weaken the sidewall portions near the edges of the panels, allowing the sidewalls to collapse inwardly during handling of the containers or when the containers are stacked together. See, for example, U.S. patent No. 5,337,909.

In us patent No. 5,337,909 there is shown an annular reinforcing rib extending continuously around the circumference of the container side wall. These ribs are shown supporting the vacuum panels at their upper and lower edges. This maintains the edges stationary while allowing the central portion of the vacuum panel to flex inwardly as the bottle is filled. These ribs also resist deformation of the vacuum panel. The reinforcing ribs may be integral with the edges of the vacuum panels at the label edges of the upper and lower mounting panels.

Another hot-fill container with reinforcing ribs is disclosed in WO 97/34808. The container includes a peripheral series of spaced apart, short horizontal ribs having upper and lower portions longitudinally separated by a label mounting area. It is noted that each of the upper and lower ribs is located within the label mounting portion and is centered above or below a respective one of the shoulders. The container also includes several rectangular vacuum panels that also experience high stress points at the corners of the collapsed panels. These ribs stiffen the container at the lower corners adjacent the shrink panels.

Stretch blow molded containers, such as containers of hot-filled PET juice or sports drinks, must be able to retain their functionality, shape and labeling (labelability) when cooled to room temperature or refrigerated. In the case of non-circular containers, the crystallinity is naturally lower on the narrower sides in the front and back, since the level of orientation factor will be more challenging. Since the front and rear portions are typically the locations where the vacuum panels are located, these areas must be made thicker to compensate for their relatively low strength.

The reference to any prior art in this specification is not, and should not be taken as, any acknowledgment or any form of suggestion that prior art forms part of the common general knowledge in any country or region.

Disclosure of Invention

The present invention provides an improved blow molded plastic container in which a controlled deflection flex panel is provided on one sidewall of the container and a second controlled deflection flex panel having a different response to vacuum pressure is provided on the other sidewall. By way of example, a container having four controlled deflection flex panels may be disposed in two pairs on symmetrically opposing sidewalls, thereby causing one pair of controlled deflection flex panels to respond to vacuum forces at a different rate than the other pair of positions. The pair of controlled deflection flex panels may be positioned equidistant from the central longitudinal axis of the container or may be positioned non-equidistant from the centerline of the container. Furthermore, the design allows for better control of the response to vacuum pressure, and improves dent resistance and resists torsional displacement of the column or shoulder regions between the panels. Further, improved container weight reduction is achieved with the potential for development of squeezable container designs.

In one preferred form of the invention, a container is provided having four controlled deflection flex panels, wherein each of the controlled deflection flex panels has a generally variable outward flex relative to a centerline of the container. The first pair of panels is positioned such that one panel of the first pair is disposed opposite the other panel, and the first pair of panels has a different geometry and surface area than the alternately positioned second pair of panels. The second pair of panels is also positioned such that the panels of the second pair of panels are disposed opposite each other. The container is suitable for use in a variety of applications including hot-fill applications.

In hot fill applications, plastic containers are filled with a liquid above room temperature and then sealed such that cooling of the liquid creates a reduced volume in the container. In this preferred embodiment, the first pair of opposed controlled deflection flex panels have a generally rectangular shape with a wider width at the base than at the top with a minimum of total surface area between the controlled deflection flex panels. The panels may be symmetrical to each other in size and shape. These controlled deflection flex panels have a generally outwardly curved cross-section, and an initial portion that is curved outwardly toward a central region that is less curved than the upper and lower regions. Alternatively, the amount of outward bow may vary evenly from top to bottom, bottom to top, or any other suitable arrangement. Alternatively, the entire panel may have a relatively uniform outward bow, but vary over a range of lateral circumferential amounts such that one portion of the panel begins to deflect inward before another portion of the panel. The first pair of controlled deflection flex panels may additionally include one or more ribs located above or below the panels. These optional ribs may also be symmetrical in size, shape and number to the ribs on the opposing side walls comprising the second set of controlled deflection flex panels. The ribs on the second set of controlled deflection flex panels have rounded edges that may be directed inwardly or outwardly relative to the interior of the container. In a first preferred form of the invention, the first pair of controlled deflection flex panels is thereby preferably initially acted upon by the vacuum force to a greater extent than the second pair of controlled deflection flex panels, preferably without ribbing incorporated into the first pair of panels in order to make the panels more easily movable.

The vacuum panel may be chosen such that it is highly effective. See, for example, PCT application No. PCT/NZ00/00019(Melrose), which shows panels with vacuum panel geometry. The "prior art" vacuum panels are generally flat or concave. Melrose's PCT/NZ00/00019 and the controlled deflection flex panel of the present invention are outwardly bowed and can extract a greater amount of pressure. Each curved panel has at least two distinct regions that curve outwardly. The less outwardly curved regions (i.e., the initial regions) react at a lower threshold to change the pressure than the more outwardly curved regions. By providing an initial portion, the control portion (i.e., the region of greater outward flexure) reacts more readily to pressure than would normally occur. Thus, the vacuum pressure is reduced to a greater extent than in the prior art, resulting in less stress being applied to the container sidewall. This increased vacuum pressure relief allows for the choice of design: different panel shapes, especially outwardly curved; a lighter weight container; less damage under load; a smaller panel area is required; container bodies of different shapes.

The controlled deflection flex panels can be shaped in different ways and can be used on inventive structures that are not standard and can yield improved structures in containers.

All of the sidewalls comprising the controlled deflection flex panels may have one or more ribs located therein. The ribs may have an outer edge or an inner edge relative to the container interior. These ribs may appear as a series of parallel ribs. The ribs are parallel to each other and to the base. The number of ribs in the series may be either odd or even. The number, size and shape of the ribs are symmetrical to the ribs in the opposite side walls. This symmetry enhances the stability of the container.

Preferably, the ribs on the side containing the second pair of controlled deflection panels and having the largest surface area of the panels are substantially identical to each other in size and shape. The individual ribs may extend across the length and width of the container. The actual length, width and height of the ribs may vary depending on the use of the container, the plastic material used and the requirements of the manufacturing process. Each rib is spaced apart from the others to optimize overall stability as either the inward or outward ribs. The ribs are parallel to each other and preferably also to the container base.

The fact that the advanced, efficient design of the controllable skew panel of the first pair of panels compensates more is that the controllable skew panel provides less surface area than the larger front and rear panels. By providing a first pair of panels for responding to a lower pressure threshold, these panels can begin the vacuum compensation function before a second larger panel set, albeit located further from the centerline. The second larger panel set may be configured to move only minimally and relatively uniformly in response to vacuum pressure, and because of the increased surface area, even small movements of these panels may provide adequate vacuum compensation. The first set of controlled deflection flex panels may be configured to reverse and provide a large amount of vacuum compensation required for packaging in order to prevent a larger set of panels from entering the reverse position. The use of thin-walled ultra-light preforms can ensure that a high level of orientation and crystallinity is transferred to the entire package. This increased level of strength, along with the rib structure and efficient vacuum panels, provides the container with the ability to maintain function and shape while cooling, while using a minimum grammage.

The provision of ribs and vacuum panels on adjacent sides within the area defined by the upper and lower container cushions may result in a lighter package without loss of structural strength. The ribs are provided on a larger, non-inverted panel, while the smaller inverted panel may generally be free of rib indentations, making it more suitable for embossing or debossing to form a brand logo or name. This configuration optimizes the geometric orientation of the squeeze bottle arrangement whereby the sides of the container are drawn inward as the major larger panels are collapsed toward each other. Generally, in the prior art, the sides are forced outward as the front and rear panels are drawn inward under vacuum. In the present invention, the side panels are reversed toward the center and remain in this position without being forced outward beyond the columnar structure between the panels. Further, this structure of ribs and vacuum panels appears to be contrary to the traditional.

These and various other advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and form a part hereof. However, for a better understanding of the invention, its advantages and objects obtained by its use, reference should be made to the drawings which form a further part hereof, and to accompanying descriptive matter, in which there are illustrated and described preferred embodiments of the invention.

Drawings

Fig. 1A and 1B show a side view and a front view, respectively, of a container according to a first embodiment of the invention;

fig. 1C, 1D, 1E and 1F show side, front, orthogonal and cross-sectional views, respectively, of a container according to a second embodiment of the invention, wherein the container has a vertically flat (i.e., generally planar) primary panel and secondary panels with horizontal ribs separated by intermediate regions;

fig. 2A, 2B, 2C and 2D show a side view, a front view, an orthogonal view and a cross-sectional view, respectively, of a container according to a third embodiment of the invention, wherein the container has a primary panel in the shape of a vertical recess (i.e. arc), and a secondary panel with horizontal ribs separated by intermediate regions, wherein the primary panel is relatively flat/slightly recessed in the horizontal direction;

3A, 3B and 3C show side, front and orthogonal views, respectively, of a container according to a fourth embodiment of the invention having a primary panel of concave shape (i.e., arcuate) extending through upper (i.e., top) and lower (i.e., bottom) cushioning walls (i.e., waist), and a secondary panel having horizontal ribs separated by intermediate regions;

4A, 4B and 4C show side, front and orthogonal views, respectively, of a container according to a fifth embodiment of the invention having a primary panel in the shape of a concave (i.e., arc) joined to upper (i.e., top) and lower (i.e., bottom) cushioning walls (i.e., large diameter), and a secondary panel having horizontal ribs separated by intermediate regions;

fig. 5A, 5B and 5C show side, front and orthogonal views, respectively, of a container according to a sixth embodiment of the invention having a primary panel bonded to upper (i.e., top) and lower (i.e., bottom) baffle walls, recessed groove ribs or channels, and a secondary panel having horizontal ribs separated by intermediate regions;

fig. 6A, 6B and 6C show side, front and orthogonal views, respectively, of a container according to a seventh embodiment of the invention, wherein the container has a primary panel with a concave shape (i.e., an arc), and a secondary panel with adjoining (i.e., not separated by intermediate regions) horizontal ribs;

fig. 7A, 7B and 7C show side, front and orthogonal views, respectively, of a container having a primary panel in the shape of a concave (arc) joined to upper (i.e., top) and lower (i.e., bottom) horizontal transition walls (major diameter), and a secondary panel having adjoining (i.e., not separated by intermediate regions) horizontal ribs, according to one embodiment of the invention;

fig. 8A, 8B and 8C show side, front and orthogonal views, respectively, of a container having a primary panel with a concave shape (arc shape) and shape, and a secondary panel with adjoining (i.e., not separated by intermediate regions) horizontal ribs, according to one embodiment of the present invention;

FIGS. 9A, 9B, 9C and 9D show side, front, orthogonal and cross-sectional views, respectively, of a container having a primary panel and a non-ribbed, similarly sized but geometrically different secondary panel, according to one embodiment of the present invention;

10A, 10B, and 10C show side, front, and orthogonal views, respectively, of a container having a vertically flat (generally planar) primary panel, and secondary panels of inwardly directed ribs separated by intermediate regions, according to one embodiment of the present invention;

11A, 11B, and 11C show side, front, and orthogonal views, respectively, of a container having a vertically flat (generally planar) primary panel, and a secondary panel with inward horizontal ribs separated by a middle region, according to one embodiment of the present invention;

12A, 12B, and 12C show side, front, and orthogonal views, respectively, of a container having an alternatively shaped vertically flat (generally planar) primary panel, and secondary panels of horizontal ribs separated by intermediate regions, according to one embodiment of the present invention;

13A, 13B, and 13C show side, front, and orthogonal views, respectively, of a container having an alternatively shaped vertically flat (generally planar) primary panel, and a secondary panel having adjoining (i.e., not separated by an intermediate region) horizontal ribs, according to one embodiment of the present invention;

FIG. 14A is a diagram showing Finite Element Analysis (FEA) of the container shown in FIG. 1A under a vacuum pressure of about 0.875 PSI;

FIG. 14B is a FEA view showing the container shown in FIG. 1B under a vacuum pressure of about 0.875 PSI;

FIG. 15A is a FEA view showing the container shown in FIG. 1A under a vacuum pressure of about 1.000 PSI;

FIG. 15B is a FEA view showing the container shown in FIG. 1B under a vacuum pressure of about 1.000 PSI; and

figures 16A-16E are FEA cross-sectional views through line B-B showing the container shown in figure 1A under vacuum pressure of about 0.250PSI (figure 16A), about 0.500PSI (figure 16B), about 0.750PSI (figure 16C), about 1.000PSI (figure 16D), about 1.250PSI (figure 16E).

Detailed Description

The thin-walled container according to the invention is intended to be filled with a liquid at a temperature above room temperature. According to the present invention, the container may be formed of a plastic material, such as polyethylene terephthalate (PET) or polyester. Preferably, the container is blow molded. The containers may be filled by automated, high-speed hot-fill equipment known in the art.

Referring now to the drawings, a first embodiment of the container of the present invention generally features a number of known hot-fill bottles generally shown in fig. 1A and 1B. The generally circular or oval shaped container 101 has a longitudinal axis L when the container is erected on its base 126. The container 101 includes a threaded neck 103 for filling and dispensing fluid through the opening 104. The neck 103 may be sealed with a cap (not shown). Preferably, the container further includes a generally circular base 126 and a bell 105 located below the neck 103 and above the base 126. The container of the invention also has a body 102 defined by a generally circular side comprising a pair of narrower controlled deflection flex panels 107 connecting the bell 105 and the base 126, and a pair of wider controlled deflection flex panels 108. Labels can be readily applied to the bell area 105 using methods well known to those of ordinary skill in the art, including shrink wrap labeling (shrink wrap label) and adhesive application methods. When applied, the label may extend around the entire bell 105 of the container 101 or over a portion of the label mounting area.

Generally, the generally rectangular curved panel 108 containing one or more ribs 118 is a panel having a width in the body region 102 greater than the adjacent pair of curved panels 107. The controlled deflection flex panels 108 and ribs 118 are arranged such that the opposing sides are generally symmetrical. These curved panels 108 have rounded edges at their upper and lower portions 112, 113. The vacuum panel 108 allows the bottle to flex inward as it fills with hot fluid, seals, and then cools. The ribs 118 may have a rounded outer or inner edge relative to the space defined by the sides of the container. The ribs 118 typically extend the majority of the width of the sides and are parallel to each other and to the base. The width of these ribs 118 is selected in keeping with the rib function. The number of ribs 118 on either adjacent side may vary depending on the size of the container, the number of ribs, the plastic composition, the bottle filling conditions, and the desired capacity. The arrangement of the riblets 118 on the sides may also be varied as long as the desired purpose associated with the interaction of the ribbed curved panels and the non-ribbed curved panels is not lost. The ribs 118 are also spaced from the upper and lower edges of the vacuum panel, respectively, and are arranged to maximise their function. Each series of ribs 118 is non-continuous, i.e., they do not touch each other. The ribs also do not contact the panel edges.

The number of vacuum panels 108 may vary. However, two symmetrical panels 108, one on each opposite side of the container 101, are preferred. The controlled deflection flex panel 108 is generally rectangular and has a rounded upper edge 112 and a rounded lower edge 113.

As shown in fig. 1A and 1B, the narrower sides contain controlled deflection flex panels 107 without reinforced ribs. Of course, the face sheet 107 may also include a plurality of ribs (not shown) of varying lengths and configurations. However, it is preferred that any ribs on this side correspond in location and size to ribs on the opposite side of the container.

The cross-section of each controlled deflection flex panel 107 is generally curved outwardly. Further, the amount of outward bending varies along the longitudinal length of the curved panel such that the response to vacuum pressure is different in different regions of the curved panel 107. FIG. 16A shows an outward bow in a cross-section taken through line B-B of FIG. 1A. A higher cross-section through the curved panel region (i.e., near the bell) will exhibit an outward bow that is lower than the cross-section through line B-B, while a cross-section through the curved panel that is relatively lower in the body 102 and near the connection with the base 126 of the container 101 will exhibit a greater outward bow than the cross-section through line B-B.

The cross-section of each controlled deflection flex panel 108 is also generally curved outwardly. Also, the amount of outward bending varies along the longitudinal length of the curved panel 108 such that the response to vacuum pressure is different in different regions of the curved panel. FIG. 16A shows an outward bow in a cross-section taken through line B-B of FIG. 1A. A higher cross-section through the curved panel region (i.e., near the bell) will exhibit an outward bow that is lower than the cross-section through line B-B, while a cross-section through the curved panel 108 relatively lower in the body 102 and near the connection with the base 126 of the container 101 will exhibit a greater outward bow than the cross-section through line B-B.

In this embodiment, the amount of arcuate flex contained within the controlled deflection flex panel 107 is different than the amount of arcuate flex contained within the controlled deflection flex panel 108. This provides greater control over the movement of the larger curved panel 108 than if the panel 107 were not present or replaced by, for example, a reinforced area, or a shoulder area or column. By separating a pair of curved panels 108 disposed opposite each other by a pair of curved panels 107, the amount of vacuum force generated against curved panels 108 during product shrinkage can be manipulated. In this way excessive deformation of the main panel can be avoided.

In this embodiment, the curved panel 107 provides for an earlier response to vacuum pressure, thus eliminating the pressure response requirement from the curved panel 108. Fig. 16A to 16E show the gradual increase of the vacuum pressure in the container. While the larger size of the flex panel 108 generally provides most of the vacuum compensation within the container, the flex panel 107 responds earlier and more aggressively than the flex panel 108. As the vacuum pressure increases, the controlled deflection flex panel 107 reverses and remains reversed. This will result in full vacuum containment before all potential energy is realized by the larger curved panel 108. The controlled deflection flex panel 108 may continue to be drawn inward, should experience increased vacuum under aggressive conditions, such as greatly reduced temperatures (e.g., deep cold storage), or may also result in increased vacuum forces if product degradation results in increased movement of oxygen and other gases through the plastic sidewall.

The improved arrangement of the foregoing and other embodiments of the present invention provides a greater potential for responding to vacuum pressure than arrangements known in the art. When the larger panels 108 are pressed toward each other, or even if the smaller panels 107 are pressed toward each other, the container 101 may be pressed to expel the contained ingredients. Releasing the squeezing pressure causes the container to immediately return to its intended shape rather than remaining wrinkled or distorted. This is also a result of the opposing sets of panels having different responses to vacuum pressure levels. In this way, a set of panels will always set the overall structure of the container and will not allow any redistribution of the set of panels, which might otherwise normally occur.

The vacuum response extends circumferentially throughout the container and allows the sidewalls to collapse effectively so that each pair of panels can be drawn against each other without excessive force being applied to the column 109 separating each panel. This overall arrangement results in less distortion of the container at all vacuum pressure levels and less distortion of the side walls when larger panels are connected together than in the prior art. Further, a higher level of vacuum compensation can be achieved by using smaller vacuum panel groups between larger panel groups than can be achieved by larger panel groups alone. Without the smaller panels, excessive force would be applied to the column by the larger panel shrinkage, creating an unfavorable orientation at higher vacuum levels.

The above is provided as an example only, the size, shape and number of panels 107 and panels 108 and the size, shape and number of reinforcing ribs 118 are related to the functional requirements for the container size and the given values may be increased or decreased.

It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size and arrangement of parts within the principles of the present invention without departing from the broad general meaning of the terms in which the appended claims are expressed.

The embodiments shown in fig. 1A and 1B, and in fig. 1C, 1D, 1E and 1F relate to containers 101, 101' having four controlled deflection flex panels 107 and 108 that work in cooperation in first and second volumes to reduce the negative internal pressure effect during product cooling.

For example, the containers 101, 101' can withstand the rigors of a hot fill process. In the hot-filling process, the product is added to the container at an elevated temperature of about 82 ℃, wherein the temperature may be close to the glass transition temperature of the plastic material and the container is capped. As the container 101, 101' and its contents cool, the contents tend to contract and this volume change creates a partial vacuum within the container. Other factors may also cause the contents of the container to shrink, creating an internal vacuum that may cause the container to deform. For example, internal negative pressure may be generated when the packaged product is placed in a cooler environment (e.g., when the bottle is placed in a refrigerator or freezer), or from moisture loss within the container during storage.

In the absence of some means for adjusting these internal volume and pressure changes, the container tends to deform and/or collapse. For example, a circular container 101, 101' may experience an oval shape, or may tend to deform or become non-circular. Other shapes of containers may be equally deformable. In addition to these variations which adversely affect the appearance of the container, distortion or deformation can cause the container to tilt or become unstable. This phenomenon is particularly true when deformations occur in the base region. When the support structure is removed from the side panels of the container, base deformation can be a problem in the absence of a mechanism for regulating the vacuum. In addition, the construction of the panels provides the additional advantage of making the container lighter in weight (e.g., improved maximum load performance).

The novel design of the container 101, 101 'increases volume shrinkage and vacuum absorption, thereby reducing negative internal pressure and unnecessary deformation of the container 101, 101' to provide improved aesthetics, performance, and end user usability.

Referring now to fig. 1C, 1D, 1E, and 1F, a container 101' may include a plastic body 102 suitable for hot-fill applications having a neck 103 defining an opening 104 connected to a shoulder 105 extending downward and connected to a sidewall 106 extending downward and connected to a bottom 122 forming a base 126. The side wall 106 comprises four controlled deflection flex panels 107 and 108 and includes a pillar or vertical transition wall 109 disposed between and connecting the main and secondary panels 107 and 108. The body 102 of the container 101' is adapted to increase in volumetric shrinkage and decrease in pressure during the hot fill process, while the panels 107 and 108 are adapted to contract inwardly during the hot fill application by the vacuum force created when cooling from the hot liquid.

The container 101' may be used to enclose many different liquid, viscous or solid products, including, for example, juices, other beverages, yoghurts, sauces, puddings, detergents, soaps in liquid or gel form, and beaded objects (e.g., candy).

The present container may be made by conventional blow molding processes including, for example, extrusion blow molding, stretch blow molding and injection blow molding. In extrusion blow molding, a molten tube of thermoplastic material or a plastic parison is extruded between a pair of open blow mold halves. The blow mold halves surround the parison and collectively provide a cavity into which the parison is blown to form the container. When formed, the container may include additional material or flash (flash) at the area where the molds come together, or additional material or sludge intentionally present on the finished container. After opening the half-moulds, the container is detached and then sent to a trimmer or cutter which can remove any sludge (moil) flash. The finished container may have a visible ridge formed where the two mold halves used to form the container are brought together. This ridge is commonly referred to as a parting line.

In stretch blow molding, a preformed parison or preform is typically prepared from a thermoplastic material by an injection molding process. The preform typically includes a threaded end that becomes the thread of the container. The preform is positioned between two open blow mold halves. The blow mold halves surround the preform and collectively provide a cavity into which the preform is blown to form the container. After molding, the mold halves are opened to release the container. In injection blow molding, a thermoplastic material is extruded through a stem into an injection mold to form a parison. The parison is positioned between two open blow mold halves. The blow mold halves surround the parison and collectively provide a cavity into which the parison is blown to form the container. After molding, the mold halves are opened to release the container.

In one exemplary embodiment, the container may be in the form of a bottle. The size of the bottle may be from about 8 to 64 ounces, from about 16 to 24 ounces, or 16 or 20 ounce bottles. The weight of the container can be on a gram basis (e.g., 4.5 square inches per gram to 2.1 square inches per gram) as a function of surface area.

The shaped sidewall is generally tubular and may have various cross-sectional shapes. For example, the cross-sectional shape includes a generally circular cross-section as described above; a substantially square cross-section; other generally polygonal cross-sectional shapes, such as triangular, pentagonal, etc.; or a combination of curved and arcuate shapes having a straight shape. It will be understood that when the container has a generally polygonal cross-sectional shape, the corners of the polygon may typically be rounded or chamfered.

In an exemplary embodiment, the shape of the container (e.g., the sidewall, shoulder, and/or base of the container) may be generally circular or generally square. For example, the sidewalls may be generally circular (e.g., as shown in fig. 1A-1F) or generally square (e.g., as shown in fig. 9).

The container 101' has a one-piece construction and may be made from a single layer of a plastic material, such as a polyamide, e.g., nylon; polyolefins, such as polyethylene, for example, Low Density Polyethylene (LDPE) or High Density Polyethylene (HDPE) or polypropylene; polyesters, for example, polyethylene terephthalate (PET), polyethylene naphthalate (PEN); or other plastic materials that may also include additives for altering the physical or chemical properties of the material. For example, certain plastic resins may be modified to increase oxygen permeability. Alternatively, the container may be made from a multi-layer plastic material. The layer may be any plastic material, including virgin, recyclable and reground materials, and may include plastic or other materials with additives for improving the physical characteristics of the container. In addition to the materials described above, other materials commonly used in multilayer plastic containers include, for example, ethyl vinyl alcohol (EVOH) and tie layers or adhesives to hold the materials being delaminated together when used in adjacent layers. The coating may be applied to the entire single or multi-layer material, for example, to introduce oxygen barrier properties. In an exemplary embodiment, the present container may be made of a substantially biaxially oriented polyester material, such as polyethylene terephthalate (PET), polypropylene, or any other organic blow-molded material that may be suitable to achieve the desired results.

In another embodiment, the shoulder, bottom and/or side walls may be used separately for label applications. The container may include a closure 123, 223, 323, 423, 523, 623, 723, 823, 923, 1023, 1123, 1223, 1323 (e.g., fig. 1C and 2A-13A) that engages the neck and seals the fluid within the container.

As illustrated in fig. 1C-1F, the four panels 107 and 108 may include a pair of opposing main panels 107 and a pair of sub-panels 108, wherein the main panels and the sub-panels operate in cooperation at first and second capacities.

In general, the primary panel 107 may include a smaller surface area and/or have a geometry suitable for greater vacuum absorption than the secondary panel. In an exemplary embodiment, the dimensions of the secondary panel 108 relative to the primary panel 107 may be slightly larger than the primary panel, for example, at least about 1: 1 (e.g., fig. 9). In another aspect, the dimensions of the secondary panel 108 to the primary panel 107 may be approximately 3: 1 or 7: a ratio of 5, or the secondary panel 108, may be at least 70% greater than the primary panel 107, or 2: 1 or 50%.

Before relieving the negative internal pressure (e.g., during a hot-fill process), the primary panel 107 and the secondary panel 108 may be designed to be convex, flat or concave and/or combinations thereof, such that when the closed container is cooled, or when the container is filled with hot product, sealed and cooled, the convexity of the primary panel and/or the secondary panel will decrease, become vertically flat or increase in concavity. The convexity or concavity of the main and/or secondary panels 107, 108 may be in a vertical or horizontal direction (e.g., in an up-down direction or a circumferential direction or both). In alternative embodiments, the secondary panel 108 may be slightly convex, while the primary panel 107 is flat, concave, or less convex than its primary panel 108. Alternatively, the secondary panel 108 may be generally flat, while the primary panel 107 is concave.

The main and secondary panels 107, 108 together serve to relieve internal negative pressure caused by packaging or subsequent handling and storage. For relieved pressure, the main panel 107 may be responsible for greater than 50% vacuum relief or absorption. The sub-panel 108 may be responsible for at least a portion (e.g., 15% or more) of vacuum relief or absorption. For example, the main panel 107 may absorb more than 50%, 56%, or 85% of the vacuum generated within the container (e.g., when cooled after hot filling).

Generally, while some minimal ribs may be present as described above to generally increase structural support to the container, the primary panel 107 is substantially free of structural elements, e.g., ribs, and thus may be more flexible, have less resistance to deflection, and thus, have more deflection than the secondary panel. As the panel deflects inward, the panel 107 may gradually exhibit an increase in resistance to deflection.

In alternative embodiments, the primary panel 107, secondary panel 108, shoulder 105, bottom 122, and/or sidewall 106 may include embossed graphics or text (not shown).

As illustrated in fig. 1A-1E, the main panel 107 may include upper and lower portions 110 and 111, respectively, and the sub-panel 108 may include upper and lower panel walls 112 and 113, respectively.

The width of the main panel 107 or the sub-panel 108 from the top to the bottom thereof may be independently varied. For example, the panel may maintain a similar width from its top to its bottom (i.e., the panel may be substantially linear), may have an hourglass shape, or may have an oval shape with a middle portion wider than the top and/or bottom, or the top of the panel may be wider (i.e., narrower) than the bottom of the panel, or vice versa (i.e., wider).

As shown in the embodiment of fig. 1C-1F, the main panel 107 is vertically straight (e.g., generally or substantially flat) and has an hourglass shape from its top to its bottom. The secondary panels 108 are vertically concave (e.g., inwardly curved from top to bottom) and have a generally uniform width from top to bottom thereof, although the width varies somewhat due to the hourglass shape of the primary panels. In other exemplary embodiments, for example, as shown in fig. 2-7, the main panel (e.g., 207) may be vertically concave in shape (e.g., moderately curved from top to bottom) and have an hourglass shape from top to bottom thereof. In one aspect, the main panel 107 may be vertically concave in shape (i.e., arcuate) and horizontally relatively flat/slightly concave (e.g., fig. 2C and 2D). The sub-panels (e.g., 208) in the exemplary embodiment shown in fig. 1-8 are vertically concave (i.e., arc-shaped) and have a uniform width from top to bottom thereof. In another embodiment, the main panel and/or the sub-panel may have a vertically convex shape with a middle portion (not shown) wider than the top and bottom of the main panel. In yet another embodiment, for example, as shown in FIGS. 8A-8C, the main panel 807 may be vertically concave in shape (i.e., curved) and gradually widen from its bottom to its top. The subpanel 808 may be vertically concave in shape (i.e., arcuate) and have a uniform width from its bottom to its top.

In an alternative embodiment, all four panels are similar in size (e.g., d)₁And d₂Nearly identical), as illustrated in fig. 9D, where fig. 9D is a cross-section of line 9D-9D of fig. 9A. The main panel 907 is vertically concave (e.g., gradually curved inward from top to bottom) and has a substantially uniform width from top to bottom thereof, while the sub-panel 908 is vertically flat (e.g., substantially or substantially flat) and has a uniform width from top to bottom thereof. In such an embodiment, the primary panel is arranged to respond more to the internal vacuum than the secondary panel. For example, the main panel 907 is flatter (smaller arc shape) in the horizontal direction than the sub-panel 908. I.e. the radius of curvature (r) of the main panel₁) Greater than the radius of curvature (r) of the sub-panel₂) (see, e.g., FIG. 9D). These differences in curvature result in the main panel having increased bending capabilities, thus allowing the main panel to account for a large portion (e.g., greater than 50%) of the total vacuum relief achieved in the container.

In other embodiments, as illustrated in fig. 10A-10C, the main panel (e.g., 1007) may be vertically straight shaped (i.e., generally flat) and have a uniform width from top to bottom. The subpanel (e.g., 1008) may be vertically straight (i.e., generally flat) and have a uniform width from top to bottom thereof.

The invention may comprise a plurality of these combinations and features. For example, as shown in fig. 12A-12C and 13A-13C, the main panel 1207 is vertically straight (i.e., generally or substantially flat) and has a profile shape that gradually widens from top to bottom thereof. In other exemplary embodiments (not shown), the sub-panel becomes progressively wider from its top to its bottom such that the upper panel wall is larger than the lower panel wall, and as a result, the upper portion of the sub-panel is more recessed than the lower portion.

The container 101 may further include an upper buffer wall 114 between the shoulder 105 and the side wall 106, and a lower buffer wall 115 between the side wall 106 and the bottom 122. The upper and/or lower cushioning walls may define a maximum diameter of the container, or alternatively may define a second diameter that may be substantially equal to the maximum diameter.

In the embodiments illustrated in fig. 1, 2, and 4-13, the upper buffer wall (e.g., 114) and the lower buffer wall (e.g., 115) may extend continuously along the circumference of the vessel. As illustrated in fig. 1, 6, and 8-13, the container may further include horizontal transition walls 116 and 117 defining upper and lower portions 110 and 111 of the primary panel 107 and connecting the primary panel to the bumper wall.

As shown in fig. 9-11, the horizontal transition walls (e.g., 916 and 917) may extend continuously along the circumference of the container 901. Alternatively, as illustrated in fig. 4, 5, and 7, there may be no horizontal transition wall such that the upper portion (e.g., 410) and the lower portion (e.g., 411) of the main panel (e.g., 407) transition or join to the upper bumper wall (e.g., 414) and the lower bumper wall (e.g., 415), respectively.

In an exemplary embodiment having a main panel that transitions into a bumper wall (e.g., as in the embodiment of fig. 3), the main panel 307 may lack horizontal transition walls at the top 310 and/or bottom 311 of the main panel 307. As shown in fig. 3, the upper portion 310 and the lower portion 311 of the main panel 307 extend through the upper bumper wall 314 and the lower bumper wall 315, respectively, such that the upper bumper wall 314 and the lower bumper wall 315 are discontinuous.

In certain exemplary embodiments (e.g., fig. 1-8 and 10-13), the profile of the secondary panel may include a grip region having an inwardly or outwardly convex anti-slip feature while providing a secondary means of vacuum suction and the primary panel provides a primary means of vacuum suction. Thus, the final exemplary design reduces internal pressure and increases vacuum intake and reduces trademark distortion while still providing a grippable area for easy handling by the end user/consumer.

The secondary panel 108 may include at least one horizontal rib 118 (e.g., fig. 1-8 and 10-11). For example, as illustrated in fig. 1-5 and 12, the secondary panel 108 may include three outwardly projecting horizontal ribs separated by intermediate regions 119. As illustrated in fig. 6-8 and 13, the horizontal ribs (e.g., 618) may be contiguous (i.e., not separated by an intermediate region).

Fig. 10A-10C illustrate an embodiment with directly inwardly recessed ribs 1018 separated by intermediate regions 1019, while fig. 11A-11C show inwardly recessed ribs 1118 with more horizontal transitions from intermediate regions 1119.

As can be seen in fig. 1C-1E, the container 101' may include at least one recessed rib or groove 120 between the upper bumper wall 114 and the shoulder 105 and/or between the lower bumper wall 115 and the base 126. Alternatively, as illustrated in fig. 9, 10, and 11, the container (e.g., 1001) may include at least one recessed rib or groove 1024 between the upper 1014 and/or lower 1015 bumper wall and the primary 1007 and secondary 1008 panels. The recessed ribs or grooves 120 may be continuous along the circumference of the container 101 (fig. 1-4 and 6-11). In another embodiment, the container 101 may comprise at least a second recessed rib or groove 121 or two second recessed ribs or grooves 421 (fig. 4-11) above the recessed rib or groove 120 above the upper baffle wall (fig. 1-3). The second recessed ribs or grooves (e.g., 121 or 421) may be higher or lower than the height of the recessed ribs or grooves 120. In another embodiment, the recessed ribs or grooves 520 on the upper bumper wall 514 may include recessed portions 522 (fig. 5A-5C) such that the ribs or grooves are discontinuous.

In further embodiments, the container may be a squeeze container that delivers or dispenses product once per squeeze. In this embodiment, once the container has been opened, it can be easily grasped or grasped with little resistance and the product can be dispensed by squeezing the container along the major or minor panels. Once the squeezing pressure is reduced, the container will retain its original shape without excessive deformation.

Referring again to fig. 14A and 14B, it can be seen from Finite Element Analysis (FEA) that the primary panel 107 and the secondary panel 108 react to vacuum changes by differential amounts of response. Figure 14A shows that the container has about 0.875 pounds Per Square Inch (PSI) of vacuum. Near the center point of the region 1430, the main panel 107 is displaced inwardly toward the longitudinal axis of the container by about 4.67 mm. It can be seen near region 1405 that the main panel 107 has a lesser amount of such inward deflection, with virtually no inward deflection due to vacuum. Region 1410 exhibits an inward deflection of about 0.50 mm; zone 1415 exhibits an inward deflection of about 1.00 mm; region 1420 exhibits an inward deflection of about 2.00 mm; while region 1425 exhibits an inward deflection of about 3.75 mm.

At the same time, the secondary panel 108 exhibits a relatively small inward deflection in the range of about 2.00mm to about 3.00 mm. Fig. 14B illustrates in more detail the vacuum impact on such a sub-panel 108. Near the center point of the region 1425, the secondary panel 108 is displaced inward toward the longitudinal axis of the container by about 3.75 mm. It can be seen near region 1405 that the secondary panel 108 has a lesser amount of such inward deflection, with virtually no inward deflection due to vacuum. Region 1410 exhibits an inward deflection of about 0.50 mm; zone 1415 exhibits an inward deflection of about 1.00 mm; region 1420 exhibits an inward deflection of approximately 2.00 mm.

Referring now to fig. 15A and 15B, it can be seen from the FEA that the primary panel 107 and the secondary panel 108 continuously react to vacuum changes by differential amounts of response. Figure 15A shows that the container has about 1.000 pounds Per Square Inch (PSI) of vacuum. Near the center point of the region 1530, the main panel 107 is displaced inwardly toward the longitudinal axis of the container by about 5.69 mm. It can be seen in the vicinity of region 1505 that the main panel 107 has a lesser amount of such inward deflection, with virtually no inward deflection due to vacuum. Region 1510 exhibits an inward deflection of about 0.50 mm; region 1515 exhibits an inward deflection of about 1.00 mm; region 1520 exhibits an inward deflection of about 2.00 mm; while region 1525 exhibits an inward deflection of approximately 3.75 mm.

Also, the secondary panel 108 exhibits relatively less inward deflection, albeit more so than in FIG. 14A. Fig. 15B illustrates in more detail the vacuum impingement on such a sub-panel 108 (e.g., as shown in fig. 15A, there are regions 1525 and 1530 on the sub-panel 108). For example, near the center point of the region 1530, the secondary panel 108 is displaced inwardly toward the longitudinal axis of the container by about 4.75mm to about 5.00 mm. It can be seen in the vicinity of region 1505 that the secondary panel 108 has a lesser amount of such inward deflection, with virtually no inward deflection due to vacuum. Region 1510 exhibits an inward deflection of about 0.50 mm; region 1515 exhibits an inward deflection of about 1.00 mm; region 1520 exhibits an inward deflection of about 2.00 mm; region 1525 exhibited an inward deflection of about 3.75 mm; while region 1527 exhibits an inward deflection of approximately 4.25 mm. Referring now to fig. 16A-16E, further details of the controllable radial deformation of the primary panel 107 and the secondary panel 108 according to embodiments of the present invention will now be described by way of FEA cross-sectional views taken along line B-B of the container shown in fig. 1A under varying degrees of vacuum pressure.

FIG. 16A illustrates the primary panel 107 and the secondary panel 108 under a vacuum of approximately 0.250 PSI. Even when subjected to this vacuum, both panels 107, 108 exhibit outward bowing and little inward deflection (i.e., in the range of 0.5mm to about 1.00 mm). However, as shown in FIG. 16B, when the vacuum is increased to about 0.500PSI, the primary panel 107 begins to exhibit a region 1620 deflected inward by about 2.00mm to about 2.50mm, while the secondary panel 108 is deflected inward by only 1.25 mm.

FIG. 16C also illustrates the continued inward deflection of the primary panel 107 at about 0.75PSI vacuum. The areas 1620, 1625, and 1630 begin to appear on the main panel 107, showing inward deflections of about 2.00mm to about 2.50mm, 3.75mm, and 4.00mm to about 4.25mm, respectively. At the same time, the sub-panel 108 only continuously exhibits an inward deflection of about 1.00mm to about 2.00 mm.

FIGS. 16D and 16E continuously illustrate controlled radial deflection of the container at about 1.00PSI and about 1.25PSI vacuum levels, respectively. As can be seen in FIG. 16D, the main panel 107 has begun to reverse direction with areas 1620, 1625, and 1630 that illustrate about the same amount of inward deflection as shown in FIG. 16C. However, it can also be seen that the secondary panel 108 has begun to deflect inwardly at an increased rate. Regions 1625 and 1630 begin to appear on subpanel 108, exhibiting inward deflection of about 3.75mm, and about 4.00mm to about 4.50mm, respectively. More importantly, as can be seen in FIG. 16E, substantially all of the sub-panels 108 have been inwardly deflected by about 4.00mm to about 4.25 mm. It can also be seen that the pillar or vertical transition wall separating the primary panel 107 and the secondary panel 108 exhibits an inward deflection of about 3.75 mm. Thus, the main panel 107 and the secondary panel 108 provide a bend at the pillar or vertical transition wall for the panels 107, 108 and create a leverage point to deflect. The main panel 107 and the sub-panel 108 are bent in unison, but at different rates.

As can be appreciated from the exemplary FEA described above, the cage structure and ribs (if any) comprising primary vacuum panel 107 and secondary vacuum panel 108 collectively maintain the shape of the container as it fills and cools. The shape of the container may also be maintained in the event that the container has not been hot filled but is subject to vacuum induced changes (e.g., refrigeration or evaporation loss) during the shelf life of the filled container.

The present invention has been disclosed in conjunction with the presently contemplated embodiments thereof, and a number of modifications and alterations have been discussed. Other modifications and variations will readily suggest themselves to persons of ordinary skill in the art. In particular, various combinations of the structures of the main panel and the sub-panel have been discussed. Various other container features have also been combined with some combinations. In addition to the forms already described, the invention also comprises combinations of main panels and sub-panels arranged in different ways. The present invention also includes alternative constructions having different container characteristics. For example, the recessed portion 522 of the upper bumper wall 514 may be incorporated into other embodiments. It is intended to embrace all such modifications and variations as fall within the broad scope and spirit of the present invention as defined by the appended claims.

Throughout the specification and claims, the words "comprise", "comprising", and the like are to be construed in a relatively exclusive or inclusive sense, i.e., in a sense of "including but not limited to", unless the context clearly dictates otherwise.

Claims (54)

1. A plastic container having a body portion with generally curvilinear sidewalls, a base, and a longitudinal axis, the plastic container comprising:

a first sidewall portion having a first controlled deflection flex panel configured to flex inwardly in reaction to pressure changes within the container; and

a second sidewall portion having a second controlled deflection flex panel, the second controlled deflection flex panel also configured to flex inwardly in reaction to pressure changes within the container;

wherein the first and second controlled deflection flex panels flex inwardly in response to a reduced pressure within the container, and the first and second controlled deflection flex panels flex inwardly by different amounts.

2. The container of claim 1, wherein the first sidewall portion has a first amount of outward bow;

the second sidewall portion has a second amount of outward bow; and is

Wherein the first amount is different from the second amount.

3. The container of claim 1, wherein the sidewall comprises a generally circular shape in cross-section.

4. The container of claim 1, wherein the cross-section of the sidewall generally comprises an oval.

5. The container of claim 1, comprising:

a plurality of said first sidewall portions;

a plurality of said second sidewall portions; and

a plurality of transition walls, each said transition wall disposed between and connecting each said first and second controlled deflection flex panels.

6. The container of claim 5, wherein the plurality of first sidewall portions are disposed about a longitudinal axis of the container in an alternating manner with the plurality of second sidewall portions.

7. The container of claim 5, comprising:

a pair of first side wall portions; and

a pair of second sidewall portions.

8. The container of claim 7, wherein the pair of first sidewall portions are disposed about a longitudinal axis of the container in an alternating manner with the pair of second sidewall portions.

9. The container of claim 1, wherein the first controlled deflection flex panel has a width that is less than a width of the second controlled deflection flex panel.

10. The container of claim 1, wherein the second controlled deflection flex panel has one or more ribs incorporated therein.

11. The container of claim 1, including a pair of opposing first and second sidewall portions, wherein each of said sidewall portions is symmetrical with the opposing sidewall portion in terms of the arrangement, size and number of its curved panels.

12. The container of claim 9, including a pair of opposing first and second sidewall portions, wherein each of said sidewall portions is symmetrical with the opposing sidewall portion in terms of the arrangement, size and number of its curved panels.

13. The container of claim 10, including a pair of opposing first and second sidewall portions, wherein each of said sidewall portions is symmetrical to the opposing sidewall portions in terms of the arrangement, size and number of its ribs and curved panels.

14. The container of claim 13, wherein the ribs and the curved panels collectively form a cage-like structure for maintaining the shape of the container as the container is filled and cooled.

15. The container of claim 1, wherein the container is adapted for hot filling.

16. The container of claim 1, wherein the first controlled deflection flex panel includes at least two distinct regions of outward flex.

17. The container of claim 16, wherein a first of the at least two regions is less outwardly curved and serves as an initial region that reacts to the changing pressure within the container with a smaller threshold value than a second region that is more outwardly curved.

18. The container of claim 1, wherein there is a pair of opposing first controlled deflection flex panels and an adjacent pair of opposing second controlled deflection flex panels.

19. The container of claim 9, wherein there is a pair of opposing first controlled deflection flex panels and an adjacent pair of opposing second controlled deflection flex panels.

20. The container of claim 1, wherein the first controlled deflection flex panel has one or more ribs incorporated therein.

21. The container of claim 10, wherein the ribs incorporated therein have a rounded edge facing outwardly or inwardly relative to the interior of the container.

22. The container of claim 21, wherein the ribs are parallel to each other.

23. The container of claim 20, wherein the ribs incorporated therein have a rounded edge facing outwardly or inwardly relative to the interior of the container.

24. The container of claim 23, wherein the ribs are parallel to each other.

25. The container of claim 1, wherein the first controlled deflection flex panel has a region that is generally laterally outwardly curved.

26. The container of claim 1, wherein the second controlled deflection flex panel has a region that is generally laterally outwardly curved.

27. The container of claim 1, wherein the first controlled deflection flex panel is in a reverse position under vacuum pressure.

28. The container of claim 7, wherein the pair of first sidewall portions oppose each other and the pair of second sidewall portions oppose each other, the first controlled deflection flex panel being more reactive to pressure changes within the container than the second controlled deflection flex panel.

29. A container comprising a plastic body having a neck defining an opening and connected to a shoulder, wherein the shoulder extends downward and is connected to a sidewall that extends downward and is connected to a bottom that forms a base,

the side wall includes four panels and includes a vertical transition wall disposed between and connecting the panels, the four panels including:

a controllably deflectively-curved primary panel having a first degree of capability to react to pressure changes within the container, adapted to be inwardly collapsed by vacuum forces; and

a controlled deflection flex sub-panel having a second degree of capability to react to pressure changes within the container, adapted to be inwardly collapsed by vacuum force, wherein the first degree is different from the second degree; and

wherein the body is adapted to increase volumetric contraction and decrease pressure, and the primary panel and the secondary panel are adapted to contract inwardly in response to internal negative pressure generated by packaging or subsequent handling and storage.

30. The container of claim 29, wherein the internal negative pressure is generated in the container during a hot filling process or subsequent cooling of a hot liquid.

31. The container of claim 29, wherein the panels comprise a pair of opposing major panels and a pair of opposing minor panels.

32. The container of claim 31, wherein the primary panel comprises a smaller surface area than the secondary panel.

33. The container of claim 31, wherein the controlled deflection panel is convex, generally flat, or concave in shape (curved) and becomes less convex, generally flat, or more concave when collapsed.

34. A container according to claim 31, wherein the sub-panel is convex and becomes less convex or substantially flat when collapsed.

35. The container of claim 31, wherein the main panel is generally flat and becomes concave when collapsed.

36. The container of claim 31, wherein the main panel is convex and becomes concave when collapsed.

37. The container of claim 31, wherein the primary panel is adapted to absorb more internal negative pressure than the secondary panel.

38. The container of claim 31, wherein the main panel comprises an upper portion and a lower portion.

39. The container of claim 31, wherein the main panel comprises upper and lower panel walls.

40. The container of claim 29, further comprising an upper cushioning wall between the shoulder and the sidewall, and a lower cushioning wall between the sidewall and the bottom.

41. The container of claim 40, wherein the upper and lower cushioning walls extend continuously along a circumference of the container.

42. The container of claim 40, wherein the upper and lower portions of the main panel transition to the upper and lower cushioning walls, respectively.

43. The container of claim 31, further comprising horizontal transition walls defining the upper and lower portions of the main panel.

44. The container of claim 43, wherein the horizontal transition wall extends continuously along a circumference of the container.

45. The container of claim 31, wherein the secondary panel comprises at least one horizontal rib.

46. The container of claim 31, wherein the secondary panel comprises three horizontal ribs.

47. The container of claim 46, wherein the ribs are separated by intermediate regions.

48. The container of claim 47, wherein the ribs abut.

49. The container of claim 29, further comprising at least one recessed rib or groove between the sidewall and the shoulder, and/or at least one recessed rib or groove between the sidewall and the lower bottom.

50. A container according to claim 49, wherein the recessed ribs or grooves are continuous along the circumference of the container.

51. The container of claim 29, wherein the container is an approximately 8 to 64 ounce bottle

52. The container of claim 29, wherein the shoulder and the base are generally circular.

53. The container of claim 1, comprising a pair of the first controlled flex panels and a pair of the second controlled flex panels, each pair of controlled flex panels positioned equidistant from the longitudinal axis.

54. The container of claim 1, comprising a pair of the first controllably curved panels and a pair of the second controllably curved panels, each pair of controllably curved panels positioned at an unequal distance from the longitudinal axis.