U.S. patent application number 10/974385 was filed with the patent office on 2005-09-22 for insulated label.
This patent application is currently assigned to PepsiCo, Inc.. Invention is credited to Farha, Said.
Application Number | 20050208245 10/974385 |
Document ID | / |
Family ID | 34841242 |
Filed Date | 2005-09-22 |
United States Patent
Application |
20050208245 |
Kind Code |
A1 |
Farha, Said |
September 22, 2005 |
Insulated label
Abstract
The invention is an insulated label for maintaining the
temperature of the contents of a package, formed from a polymeric
thermoplastic closed cell foam having from about 5,000 to about
250,000 closed cells per cubic inch.
Inventors: |
Farha, Said; (Pleasantville,
NY) |
Correspondence
Address: |
RYNDAK & SURI
30 NORTH LASALLE STREET
SUITE 2630
CHICAGO
IL
60602
US
|
Assignee: |
PepsiCo, Inc.
|
Family ID: |
34841242 |
Appl. No.: |
10/974385 |
Filed: |
October 27, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10974385 |
Oct 27, 2004 |
|
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60554537 |
Mar 19, 2004 |
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Current U.S.
Class: |
428/36.5 |
Current CPC
Class: |
Y10T 428/1376 20150115;
Y10T 428/249976 20150401; Y10T 428/266 20150115; Y10T 156/10
20150115; G09F 3/10 20130101; Y10T 428/249921 20150401 |
Class at
Publication: |
428/036.5 |
International
Class: |
B65D 001/00 |
Claims
What is claimed:
1. An insulated label for maintaining the temperature of the
contents of a package, the insulated label comprising: a polymeric
thermoplastic closed cell foam having first and second surfaces and
from about 5,000 to about 250,000 closed cells per cubic inch.
2. The insulated label according to claim 1, wherein the polymeric
foam is a polymeric microfoam formed from a solution flash
extrusion process microfoam.
3. The insulated label according to claim 1, wherein the foam has
from about 25,000 to about 100,000 closed cells per in.sup.3.
4. The insulated label according to claim 1, wherein the foam has
from about 25,000 to about 75,000 closed cells per in.sup.3.
5. The insulated label according to claim 1, wherein the foam has
from about 40,000 to about 60,000 closed cells per in.sup.3.
6. The insulated label according to claim 1, wherein the foam has a
thickness of at least about 0.25 mm.
7. The insulated label according to claim 1, wherein the foam has a
thickness of from about 1 to about 4 mm.
8. The insulated label according to claim 1, wherein the foam
comprises extruded polypropylene, polyethylene, or mixtures
thereof.
9. The insulated label according to claim 1, further comprising a
printable film layer affixed to the first surface.
10. The insulated layer according to claim 9, further comprising a
layer of adhesive between the foam and the film layer.
11. The insulated layer according to claim 9, further comprising a
layer of adhesive on the second surface.
12. An insulated container, comprising the insulated label
according to claim 1.
13. A method of making an insulated package or container, the
method comprising obtaining a label according to claim 1, and
affixing the label onto a package or container.
14. A method of making an insulated package or container, the
method comprising obtaining a label according to claim 9, and
affixing the label onto a package or container.
Description
REFERENCE TO RELATED APPLICATION
[0001] This non-provisional application claims the benefit of U.S.
Provisional Patent Application No. 60/554,537, filed on Mar. 19,
2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention is directed to insulated labels for
packages. In particular, the present invention is directed to
insulated labels that decrease the rate of warming or cooling of
the contents of a package that has a temperature less than or
greater than ambient.
[0004] 2. Discussion of Related Art
[0005] Soft drinks consumed by the public are served chilled in a
variety of packaging materials of choice for a majority of beverage
applications. The chilled nature of the beverage is important to
the quality of the beverage and the ultimate consumer experience.
As chilled beverage packages are removed from the icebox or a
refrigerator, and exposed to warmer temperatures in the process of
consumption, the package and, hence, the beverage tends to absorb
heat, resulting in an increase in temperature, which can reduce the
quality of the taste of the beverage, possibly resulting in a
negative consumer experience. Additionally, in the case of
carbonated beverages, the beverage will go "flat" due to an
increased loss in the carbon dioxide from the beverage once an
opened package is exposed to the warmer temperatures. Similarly,
certain foods and beverages are preferably served at a temperature
warmer than ambient, and undergo an unacceptable cooling when
exposed to a sufficiently low temperature.
[0006] U.S. Patent Application Publication Nos. 2003/0003249 and
2003/0207059 A1 to Benim et al. disclose insulating label stocks
that include a thermal insulating layer, which may be a fiber-fill
batt, and is laminated to at least one layer of film, paper or
fabric. The applications disclose that the label stock can be
wrapped around a container, such as a can, bottle or pouch, and may
be coated with a coating material, so that it is printable, thereby
imparting both insulating properties and print capability to a
container. The disclosed label insulators have sufficient loft,
typically greater than 0.0075 inch, to provide insulation for the
container, but is reportedly thin enough to be easily wrapped
around a container for use as label stock, providing a label that
maintains the temperature of the contents of the container longer
than the use of a standard label alone. The disclosed thermal
insulating layer comprises an organic thermoplastic polyester,
polyethylene or polypropylene fiber-based material, such as
polyester fiber-fill batt. A fiber-fill batt sold as
THERMOLITE.RTM. Active Original by E.I. du Pont de Nemours and
Company is reportedly especially suitable. The disclosed fiber-fill
batt has an areal weight in the range of 10 gm/m.sup.2 to 200
gm/m.sup.2, and a bulk density of less than 0.3 gm/cm.sup.3.
Alternatively, the thermal insulating layer is formed from melt
blown fibers, such as melt blown polyolefins, sold as
THINSULATE.RTM. by 3M.
[0007] Materials disclosed for use as the thermal insulating layer
are polyurethane foams and other foam compositions known in the
art, but not specifically disclosed, an inorganic thermoplastic
fiber-based material comprising glass wool, borosilicate glass, or
rock wool, knit fabrics made from a tetra-channel or scalloped oval
fiber, sold under the trademark COOLMAX.RTM. by E.I. du Pont de
Nemours and Company of Wilmington, Del., woven or fleece material,
and non-woven materials, such as felt, or high-loft non-woven or
needled non-woven fabrics. However, based on the disclosure of the
patent, it is not believed that the label disclosed in the Benim
applications provide the desired degree of insulation.
[0008] U.S. Pat. No. 6,620,281 to Sommers discloses an insulating
label and wrap for beverage containers of various shapes,
manufactured by a continuous run process using a plurality of
printing stations to provide a high quality printed image on the
face of the label. The disclosed label or after-market beverage
container wrap produced by this process comprises a multi-layered
label having a layer of ink on the face of a paper stock substrate,
and adhesive layer on the back side of the stock substrate holds a
thin waterproof layer of foam. The printed face of the label is
protected by a clear film or coating covering the ink layer. The
label can be manufactured as an after-market wrap to be applied by
hand by the customer and fits containers of various sizes, or as a
label that is an integral part of the container as it comes from
the manufacturer. As with the Benim applications, based on the
disclosure of the Sommers patent, it is not believed that the label
disclosed in the patent provides the desired degree of
insulation.
[0009] U.S. Pat. No. 6,235,380 discloses a multi-layered article
comprising a closed-cell microcellular material, having an average
cell size of less than about 80 microns and a void fraction of at
least 90 percent, and a paper-based sheet material adhered directly
to the microcellular material. Such a foam would have on the order
of 1,000,000 cells per cubic centimeter.
[0010] U.S. Pat. No. 5,085,906 to Ast et al. discloses a
polypropylene container and an adhesive label for applying to such
a container. The adhesive label comprises a base layer, which
includes on its underside an adhesive layer and on its upper side
an imprint, and a film adhered to the upper side of the base layer
by means of a laminating adhesive. The base layer comprises a
foamed polypropylene core layer and a pair of oriented
polypropylene layers, where the foamed polypropylene layer is
covered on both sides with the polypropylene layers, and the film
consists essentially of polypropylene. There is no disclosure
regarding the specific foamed polypropylene or how it is
produced.
[0011] Hence, a need exists for methods and means of maintaining
the temperature of packages and their contents upon exposure to a
higher or lower ambient temperature for a period of time sufficient
to allow consumption of the contents at the desired temperature.
The present invention provides an insulated label that provides
such means and methods.
SUMMARY OF THE INVENTION
[0012] The present invention is directed to an insulated label for
maintaining the temperature of the contents of a package. The
insulated label comprises a polymeric thermoplastic closed cell
foam, preferably a polypropylene microfoam, typically having from
about 5,000 to about 250,000 closed cells per cubic inch.
Preferably, the foam is a solution process polymeric closed cell
microfoam, most preferably formed from polypropylene. Moreover, the
foam preferably has from about 25,000 to about 100,000 closed cells
per cubic inch (in.sup.3), more preferably, from about 25,000 to
about 75,000 closed cells per in.sup.3, and, most preferably, from
about 40,000 to about 60,000 closed cells per in.sup.3. A foam
useful in the invention preferably has a thickness of at least
about 0.25 mm, and, more preferably, from about 1 to about 4 mm.
Indicia may be printed directly on the microfoam, or a printable
layer may be affixed to the outer surface of the microfoam, either
directly or with an adhesive. Typically, the other surface of the
microfoam of the label is affixed to the container, preferably with
an adhesive layer, and, in contrast to the foam labels disclosed in
U.S. Pat. No. 5,085,906 to Ast et al., does not comprise a film
layer.
[0013] The present invention is further directed to an insulated
container, comprising the insulated label of the invention, and to
a method of making an insulated package, where the method comprises
obtaining a label according to the invention, and affixing the
label onto a package or container.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0014] FIG. 1 illustrates an insulated label of the invention;
and
[0015] FIG. 2 illustrates a container having an insulated label of
the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0016] The present invention relates to an insulated label that,
when applied to a package or container, insulates the package or
container, reducing the rate of temperature change in the contents
of the package or container when exposed to a temperature warmer or
colder than that of the contents. In contrast to conventional
labels that are based on sheet materials, such as non-foamed
polypropylene or paper, the label of the present invention is form
from a polymeric thermoplastic closed cell foam, where the
polymeric thermoplastic can be any polymeric material capable of
being foamed into a flexible foam that can be used as a label, such
as polyethylene and polypropylene, and is, preferably, a
polypropylene microfoam. Polymeric thermoplastic closed cell foams
useful in the invention generally have at least about 5,000 closed
cells per cubic inch (in.sup.3), about 305 closed cells per cubic
centimeter (cm.sup.3), and less than about 250,000 closed cells per
in.sup.3, from about 305 to about 6,100 closed cells per cm.sup.3,
more preferably, from about 25,000 to about 75,000 closed cells per
in.sup.3, from about 1,525 to about 4,575 closed cells per
cm.sup.3, and, most preferably, from about 40,000 to about 60,000
closed cells per in.sup.3, from about 2,440 to about 3,660 closed
cells per cm.sup.3. Preferably, the foam has a thickness of at
least about 0.25 mm (about 0.01 inch), more preferably, from about
1 to about 4 mm (about 0.04 to about 0.16 inch).
[0017] The foam is preferably a polypropylene microfoam formed in a
flash solution process, such as that disclosed in U.S. Pat. Nos.
3,584,090, 3,637,458, and 3,787,543 to Parrish, the contents of
which are incorporated herein in their entirety by reference. The
process essentially comprises preparing a solution of a film
forming polymer in an organic solvent having a boiling point
significantly lower than the melting point of the polymer. The
solution is extruded, and a closed cell microfoam of the polymer is
produced as the pressure on the solution is rapidly reduced as the
solution exits the extruder. The solvent flashes into a gas, and
the polymer foams and solidifies.
[0018] A polypropylene microfoam insulation material useful in the
invention is MICROFOAM.RTM., available commercially from Pactiv
Corporation, Lake Forest, Ill. MICROFOAM.RTM. is a foam having
approximately 50,000 closed cells per in.sup.3, about 3,050 closed
cells per cm.sup.3, and is available in several thicknesses,
including {fraction (1/32)} inch, 0.03125 inch (about 0.8 mm),
{fraction (1/16)} inch, 0.0625 inch (about 1.5 mm), and {fraction
(1/8)} inch, 0.125 inch (3.175 mm). Such a polypropylene microfoam,
as with other foams useful in labels in accordance with the
invention, can be used alone or in combination, such as by
lamination and coextrusion, with conventional label materials to
form a label. As foams, such as MICROFOAM.RTM., are effective
insulators, packages having a foam label in accordance with the
invention stay colder or warmer for longer periods of time than do
packages having prior art labels. Moreover, the preferred
polypropylene microfoam materials have a lower density and, thus,
weight than polyethylene or PET foams, and are more flexible,
facilitating handling and application. The preferred polypropylene
base allows the material to readily accept labels and tape for
laminated structures and enables the adhesives to stick better.
[0019] Polymeric thermoplastic closed cell foams useful in the
invention may also be blown with physical gaseous foaming and
blowing agents, i.e., gases or low boiling point liquids, or by
decomposing chemical foaming and blowing agents. The physical
foaming agents include, but are not limited to, inert gases, such
as nitrogen and carbon dioxide, hydrocarbons containing 3 to 5
carbon atoms, such as the isomers of the aliphatic hydrocarbons
propane, butane, and pentane, and chlorinated hydrocarbons, such as
methylene chloride, and the recently mandated "ozone-safe"
replacements for banned chlorofluorocarbons, such as
trichlorofluoromethane and dichlorodifluoromethane. Physical
blowing agents are typically dissolved or dispersed in a liquefied
plastic or melt polymer under pressure, either rapidly expanding or
flashing into the gaseous state and rapidly expanding as the
pressure is released, thereby forming the cellular structure in the
polymer, which rapidly cools and solidifies as the desired
foam.
[0020] In contrast, chemical blowing agents decompose at elevated
temperatures releasing an inert gas. Chemical blowing agents may be
conventional diazo blowing agents, which, on decomposition, yield
nitrogen. Chemical blowing agents useful in forming foams useful in
the invention include, but are not limited to, organic and
inorganic bicarbonates and oxylates, azo-chemicals, hydroxides, and
amine nitrates. The chemical blowing agent is typically mixed with
the thermoplastic materials in a process known in the art, such as
mixing the chemical blowing agents with pellets or powders of the
thermoplastic polymeric material, and introducing the blended
material into an extruder inlet. The gas released when the blowing
agent decomposes as a result of the heat in the extruder then forms
the cellular structure in the resulting foam in the manner
described above for physical blowing agents.
[0021] Other materials useful for the labels of the invention
include, but are not limited to, foams of the type described above
that are co-extruded with thermoplastic polymeric films that
comprise a layer of the foam and a layer of the polymeric film
material onto which indicia may be printed. Such co-extrusion and
methods are known in the art.
[0022] As discussed above, indicia, such as trademarks, text, and
designs, may be printed directly onto the surface of the foam to
provide a label, or a printed film, preferably a polyolefin, such
as polypropylene, may be affixed to the surface of the foam to form
the printed portion of the label. The film may be affixed directly
to the foam by, for example, extrusion, or an adhesive may be used
to affix the film and foam together. A layer of adhesive is also
typically used to affix the insulating label of the invention to a
container, such as a can, jar, or bottle. An insulated label 10 in
accordance with the invention is illustrated in FIG. 1. As
illustrated, the insulated label 10 has a layer of foamed
polypropylene 12 of the type described above, and an outer film 14
of polypropylene on which indicia 16 may be printed. The outer film
14 is optionally affixed to the foam layer 12 by a layer of
adhesive 18, and a layer of adhesive 20 is provided to affix the
label 10 to a container.
[0023] A bottle 22 having a label 24 in accordance with the
invention is illustrated in FIG. 2. As illustrated, the label 24
comprises a foam layer 26 and an outer film layer 28. As will be
recognized by those of ordinary skill in the art, indicia may be
printed on the outer surface of the film layer 28, or the outer
film layer 28 may be transparent, such that indicia printed on the
surface of foam layer 26 are visible. Optionally, the outer film
layer 28 may be affixed to the foam layer 26 by a layer of adhesive
(not shown).
[0024] These and other aspects of the present invention may be more
fully understood by reference to the following example. While the
example is meant to be illustrative of insulating labels according
to the present invention, the present invention is not meant to be
limited by the following example.
EXAMPLE
[0025] Insulating labels of the present invention were compared to
those of a type similar to those disclosed in U.S. Patent
Application Publication No. 2003/0207059 to Benim et al. (Benim).
The sample bottles were 20-ounce, polyethylene terephthalate
("PET") carbonated soft drink bottles, each having either an
insulated label in accordance with the invention or a prior art
insulated label. Each sample bottle was filled with 20 ounces of
water to the standard fill level of the bottle, and capped with a
lined plastic closure that was pre-drilled with a {fraction (1/16)}
inch hole for the introduction of a temperature monitoring
thermocouple.
[0026] The insulated-label bottles, each containing 20 ounces of
water, were prepared and stored in a temperature controlled chamber
at 5.degree. C. for a minimum of 24 hours prior to the initiation
of a given test sequence. An environmental chamber was set at a
temperature of 45.degree. C. to provide the requisite ambient
temperature condition.
[0027] The test sequence involved the placement of the 5 insulated
label bottles, pre-chilled to 5.degree. C., in the temperature
controlled chamber in direct contact with a metal surface in the
chamber. Immediately prior to transferring the samples from the
5.degree. C. chamber to the 45.degree. C. chamber, a temperature
reading of the water in each bottle was digitally recorded from the
thermocouple in each sample, and a timer was used to record the
elapsed time for each subsequent temperature reading. The
temperature of the liquid contents of each sample was recorded as a
function of elapsed time for each sample.
[0028] The temperature versus elapsed time data for the contents of
each bottle were recorded with the total elapsed time required for
the contents of each bottle to reach 12.8.degree. C., or 55.degree.
F. In addition, the temperature of the contents of the bottles
having insulating labels of the invention was recorded when the
contents of the bottles with the prior art label material reached
12.8.degree. C.
[0029] The difference in time required for the contents of the
prior art bottles and those of the bottles of the invention to
reach 12.8.degree. C. is set forth in Table 1.
1TABLE 1 TIME DIFFERENTIAL @ 12.8.degree. C. (55.degree. F.) Sample
No. Ambient T .degree. C. Label Type Time to 12.8.degree. C.
Minutes 1-A 45 Control 9 to 11 1-B 45 Invention 25 to 26 .DELTA.t
14 to 17
[0030] The temperature difference between the bottles having the
prior art labels and the bottles having labels of the invention
when the water in the prior art bottles reached 12.8.degree. C. was
-3.4.degree. C. That is, when the temperature of the water in the
prior art bottles reached 12.8.degree. C., the temperature in the
bottles with the labels of the invention was only 9.4.degree. C.
Therefore, the improvement in insulation by the labels of the
invention compared to those of the prior art is clear.
[0031] Although the invention has been disclosed in the context of
certain embodiments and examples, it will be understood by those
skilled in the art that the invention extends beyond the
specifically disclosed embodiments to other alternative embodiments
and/or uses and obvious modifications and equivalents thereof.
Accordingly, the invention is not intended to be limited by the
specific disclosures of preferred embodiments herein.
* * * * *