Preform base and method of making a delamination and crack resistant multilayer container base

1. A plastic container for pressurized applications having a crack resistant multilayer footed base, the container formed by a method comprising:

providing a molded preform having an end cap region including a multilayer wall, the end cap region including a generally spherical outer surface and a relatively flattened central inner surface providing an end cap thickness profile which includes extending radially outwardly from a central longitudinal axis of the preform:

a central thickened end cap region;

an intermediate end cap region which is thinner than the central region; and

an outer end cap region which is thicker than the intermediate region; and

blow molding the preform to form a plastic container for pressurized applications having a delamination and crack resistant multilayer footed base.

2. The plastic container of claim 1 , wherein the multilayer wall includes at least one layer of a polyester material.

3. The plastic container of claim 2 , wherein the multilayer wall includes, adjacent to the at least one polyester layer, a layer of a barrier material for one or more of oxygen, moisture, and carbon dioxide.

4. The plastic container of claim 1 , wherein the end cap thickness profile provides a reduction in base weight of the formed container for at least an equivalent pressure resistance compared to a spherical end cap profile having spherical inner and outer walls and the same upper base portion.

5. The plastic container of claim 1 , wherein the end cap thickness profile provides a reduction in container base weight for at least an equivalent delamination resistance compared to a spherical end cap profile having spherical inner and outer walls and the same upper base portion.

6. The plastic container of claim 2 , wherein the end cap thickness profile enables a reduction in intrinsic viscosity of the polyester polymer for at least an equivalent crack resistance compared to a spherical end cap profile having spherical inner and outer walls and the same upper base portion.

7. The plastic container of claim 1 wherein the container is a single-use beverage container for pressurized liquids.

8. The plastic container of claim 1 wherein the container is a single-use pasteurizable beer container.

9. The plastic container of claim 1 wherein the pressurized applications are: cold-filling with a carbonated beverage, pasteurization, retort and refill.

10. A molded preform for blow molding a plastic container for pressurized applications, the preform having a base with a multilayer wall for forming a delamination and crack resistant multilayer footed container base, the base comprising:

a generally cylindrical upper base portion;

an end cap portion having a generally spherical outer wall and a nonspherical inner wall, the nonspherical inner wall having a flattened central section joined by arcuate corner sections to a generally cylindrical outer section forming an extension of the cylindrical upper base portion, wherein the inner wall sections respectively provide a varying end cap thickness profile comprising:

a central thickened end cap region;

an intermediate end cap region which is thinner than the central region; and

an outer end cap region which is thicker than the intermediate region.

11. The preform of claim 10 , wherein the multilayer wall includes at least one layer of a polyester material.

12. The preform of claim 11 , wherein the multilayer wall includes, adjacent to the at least one polyester layer, a layer of a barrier material for one or more of oxygen, moisture, and carbon dioxide.

13. The preform of claim 10 , wherein the end cap thickness profile provides a reduction in base weight of the formed container for at least an equivalent pressure resistance compared to a spherical end cap profile having spherical inner and outer walls and the same upper base portion.

14. The preform of claim 10 , wherein the end cap thickness profile provides a reduction in container base weight for at least an equivalent delamination resistance compared to a spherical end cap profile having spherical inner and outer walls and the same upper base portion.

15. The preform of claim 11 , wherein the end cap thickness profile enables a reduction in intrinsic viscosity of the polyester polymer for at least an equivalent crack resistance compared to a spherical end cap profile having spherical inner and outer walls and the same upper base portion.

16. The preform of claim 10 , wherein the preform is adapted for blow molding a single-use beverage container for pressurized liquids.

17. The preform of claim 10 , wherein the preform is adapted for blow molding a single-use pasteurizable beer container.

18. The preform of claim 10 , wherein the pressurized applications are:

cold-filling with a carbonated beverage, pasteurization, retort and refill.

19. An improved injection-molded preform for blow molding a single-use plastic beverage container for pressurized liquids having a multilayer footed base, the preform having an end cap region including a multilayer wall with a layer of a polyester material and an adjacent layer of a different polyester or nonpolyester material, the improvement comprising:

providing a non-spherical preform end cap region to form a delamination and crack resistant pressurized container base of reduced weight, wherein the non-spherical end cap region has a thickness which includes:

a relatively flattened central inner surface forming a central thickened end cap region;

an intermediate region surrounding the central region which is thinner than the central region; and

an outer end cap region surrounding the intermediate region which is thicker than the intermediate region.

20. A method of making a delamination and crack resistant multilayer footed base of a plastic container for pressurized applications, the method comprising:

providing a molded preform having an end cap region including a multilayer wall, the end cap region including a generally spherical outer surface and a relatively flattened central inner surface providing an end cap thickness profile which includes extending radially outwardly from a central longitudinal axis of the preform:

a central thickened end cap region;

an intermediate end cap region which is thinner than the central region; and

an outer end cap region which is thicker than the intermediate region; and

blow molding the preform to form a plastic container for pressurized applications having a delamination and crack resistant multilayer footed base.

21. The method of claim 20 , wherein upon the blow molding, the central end cap region forms a central thickened portion of the base of the formed container, and the intermediate end cap region forms a transition region between the central portion and a plurality of foot pads on which the container rests.

22. The method of claim 21 , wherein the transition region has at least 10% greater orientation compared to a transition region of a container base made from a preform having a spherical end cap profile with spherical inner and outer surfaces.

23. The method of claim 22 , wherein the transition region includes an inner wall portion of each foot of the formed footed container and an inner rib portion between two feet.

24. The method of claim 20 , wherein the end cap thickness profile provides a weight reduction in the container base of at least 5% compared to a container base made from a preform having a spherical end cap profile with spherical inner and outer surfaces.

25. The method of claim 24 , wherein the weight reduction is at least 10%.

26. The method of claim 20 , wherein the preform is formed into a container having a pressurized shelf life of at least 8 weeks.

27. The method of claim 26 , wherein the pressurized shelf life is at least 16 weeks.

28. The method of claim 20 , wherein the preform is formed into a carbonated beverage container having a volume of 500 milliliters (ml) or less.

29. The method of claim 28 , wherein the volume is 250 ml or less.

30. The method of claim 20 , wherein the preform is formed into a 250 ml carbonated soft drink container having a minimum burst pressure of at least 150 pounds per square inch (psi).

31. The method of claim 30 , wherein the container has an average burst pressure of at least 175 psi.

32. The method of claim 31 , wherein the container has a base weight of no greater than 6 grams (g).

33. The method of claim 32 , wherein the base weight is no greater than 4 g.

34. The method of claim 20 , wherein the preform is formed into a carbonated beverage container having a volume of 1 to 3 liters (I).

35. The method of claim 20 , wherein the blow molding step includes stretch blow molding.

36. The method of claim 35 , wherein the stretch blow molding is performed with a stretch rod having a flattened tip that engages the intermediate end cap region.

37. The method of claim 20 , wherein the preform is formed into a single-use food or beverage container adapted for at least one of hot-filling, cold-filling, pasteurization.

38. The method of claim 20 , wherein the preform is formed into a pasteurizable beer container.

39. The method of claim 20 , wherein the preform is formed into a retortable or refillable container.

40. The method of claim 20 , wherein the preform is formed into a single-use beverage container for pressurized liquids.

41. The method of claim 40 , wherein the multilayer wall includes at least one layer of a polyester material and an adjacent layer of a nonpolyester material.

42. The method of claim 41 , wherein the nonpolyester material is a barrier material for one or more of oxygen, moisture and carbon dioxide.