Process for making a stretch-blow moulded container having an integrally moulded handle

Abstract

The present invention relates to a process for making a container having an integral handle, comprising the steps of: a) providing a preform ( 6 ) in a mould cavity ( 1 ); b) stretch-blow moulding the preform ( 6 ) to form an intermediate container ( 8 ) which comprises at least one, preferably two, convex bubble(s) ( 9 ); c) deforming the or each convex bubble ( 9 ) by means of an inwardly moving plug ( 5 ) to form one or more concave gripping region(s), whilst maintaining the pressure within the intermediate container ( 8 ) above 1 bar and whilst the temperature of the material in the gripping region of the intermediate container is maintained at a temperature between the glass transition temperature, T g , and the melt temperature, T m ; d) releasing excess pressure within the container, preferably prior to withdrawing the plug ( 5 ) from within the container; and e) ejecting the finished container from the mould cavity ( 1, 3 ).

1 . A process for making a container having an integral handle, comprising the steps of:
 a) providing a preform ( 6 ) in a mould cavity ( 1 );   b) stretch-blow moulding the preform ( 6 ) to form an intermediate container ( 8 ) which comprises at least one convex bubble ( 9 ) extending outwardly from the intermediate container, the convex bubble ( 9 ) having a surface area;   c) deforming the convex bubble ( 9 ) by means of an inwardly moving plug ( 5 ) to form a concave gripping region having an area, whilst maintaining a pressure within the intermediate container ( 8 ) above 1 bar, wherein the surface area of the convex bubble ( 9 ) is less than the area of the concave gripping region;   d) releasing the pressure within the container; and   e) ejecting the container from the mould cavity ( 1 ,  3 ).   
     
     
         2 . A process according to  claim 1  wherein step b) comprises stretch-blow moulding the preform ( 6 ) to form an intermediate container ( 8 ) that comprises two convex bubbles ( 9 ). 
     
     
         3 . The process according to  claim 1  wherein step d) comprises the pressure within the container prior to withdrawing the plug ( 5 ) from within the container. 
     
     
         4 . (canceled) 
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . The process according to  claim 1  wherein step b) and step c) are carried out in separate cavities. 
     
     
         8 . The process according to  claim 7  wherein the intermediate container ( 8 ) is reheated between step b) and step c). 
     
     
         9 . (canceled) 
     
     
         10 . The process according to  claim 1  wherein the plug ( 5 ) has an outer profile that corresponds to an interior profile of the concave gripping region. 
     
     
         11 . The process according to  claim 1  wherein the finished container is ejected from the mould cavity at step e) at a temperature below the glass transition temperature, T g . 
     
     
         12 . (canceled) 
     
     
         13 . The process according to  claim 1  wherein the gripping region of the finished container comprises a deep grip palm rest, x, ( 52 ); a deep grip finger rest, y, ( 54 ); and a deep grip recess depth, z, ( 56 ). 
     
     
         14 . The process according to  claim 13  wherein the sum of x+2y+2z is greater than 107 mm. 
     
     
         15 . The process according to  claim 13  wherein the deep grip recess depth, z, ( 56 ) is greater than 20 mm.