Method for forming a variable thickness preform for a bottle

A method for forming a preform, comprising:

• closing a first preform mold comprising a first preform mold cavity that includes a first top opening and a first bottom opening;
• closing a second preform mold comprising a second preform mold cavity that includes a second top opening and a second bottom opening,
• wherein the first and second preform mold cavities:
• form a first space corresponding to an outer shape of an upper portion of the preform having a variable outer diameter;
• and
• comprise recesses in a shape of a handle that forms a closed handle pocket;
• disposing a third preform mold comprising a third preform mold cavity that includes a third top opening, and a third bottom opening below the closed first and second preform molds, the third preform mold cavity having a second space corresponding to an outer shape of a lower portion of the preform having a constant outer diameter;
• inserting a rod-shaped inner mold into the first, second, and third preform mold cavities,
• injecting molten plastic through the third bottom opening into the first, second, and third preform mold cavities, and around an outside of the rod-shaped inner mold;
• cooling the molten plastic to form a hardened plastic preform;
• removing the first, second, and third preform molds to expose an outside of the preform;
• and
• removing the rod-shaped inner mold from the preform, wherein the preform, which is formed by the first, second, and third preform mold cavities and the inserted rod-shaped inner mold, comprises:
• a hollow cylindrical main body having a first thickness;
• a hollow cylindrical first thick portion having a second thickness greater than the first thickness;
• a tapered transition portion formed between the main body and the first thick portion, such that a thickness of the preform in the tapered transition portion increases gradually from the first thickness of the main body to the second thickness of the first thick portion along a downward longitudinal direction of the preform;
• an integral handle that corresponds to the recesses formed in the first and second mold cavities, where the integral handle is directly attached to the main body at both an upper attachment point and at a lower attachment point disposed on a main body side of the tapered transition portion along the downward longitudinal direction,
• where the upper and lower attachment points are opposite ends of the integral handle that correspond to upper and lower bounds of the closed handle pocket on the main body and comprise the same first thickness of the main body, and
• where the lower attachment point is attached to the main body immediately above the tapered transition portion in an upward longitudinal direction;
• and
• a curved end portion, where inner surfaces of the main body, the first thick portion, and the curved end portion form a cavity that corresponds to the rod-shaped inner mold,
• wherein the first, second, and third preform mold cavities and the inserted rod-shaped inner mold are shaped to form:
• an outer diameter of the first thick portion that is greater than that of the main body, and
• an inner diameter of the first thick portion that is the same as that of a lower portion of the main body in the downward longitudinal direction.