U.S. patent application number 14/080363 was filed with the patent office on 2014-05-15 for multilayer article and method for making a multilayer article, blank, and insulating cup.
This patent application is currently assigned to PACTIV LLC. The applicant listed for this patent is PACTIV LLC. Invention is credited to Edward BERNIER, Michael BORDARY, Liming CAI, David DINIUS.
Application Number | 20140131367 14/080363 |
Document ID | / |
Family ID | 50680702 |
Filed Date | 2014-05-15 |
United States Patent
Application |
20140131367 |
Kind Code |
A1 |
BORDARY; Michael ; et
al. |
May 15, 2014 |
MULTILAYER ARTICLE AND METHOD FOR MAKING A MULTILAYER ARTICLE,
BLANK, AND INSULATING CUP
Abstract
Method of making a multilayer article including providing a
first substrate and providing a second substrate. The method
further includes disposing an expandable insulating material on an
inner surface of at least one of the first substrate and the second
substrate, wherein the expandable insulating material is in a first
condition during disposing. The second substrate is adhered to the
first substrate with the expandable insulating material
therebetween to form a blank, wherein an insulating space is
defined between the first substrate and the second substrate with
the expandable insulating material therein and the insulating space
includes a first volume. The method further includes forming the
blank into the article and expanding the expandable insulating
material to a second condition by application of energy, wherein
the expandable insulating material in the second condition
increases the insulating space to a second volume.
Inventors: |
BORDARY; Michael;
(Downingtown, PA) ; DINIUS; David; (Glenmore,
PA) ; BERNIER; Edward; (Downingtown, PA) ;
CAI; Liming; (Westchester, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
PACTIV LLC |
Lake Forest |
IL |
US |
|
|
Assignee: |
PACTIV LLC
Lake Forest
IL
|
Family ID: |
50680702 |
Appl. No.: |
14/080363 |
Filed: |
November 14, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61726446 |
Nov 14, 2012 |
|
|
|
Current U.S.
Class: |
220/592.25 ;
156/79; 428/304.4; 428/317.1 |
Current CPC
Class: |
B65D 2581/3485 20130101;
Y10T 428/249982 20150401; Y10T 428/249953 20150401; B65D 81/3874
20130101 |
Class at
Publication: |
220/592.25 ;
428/304.4; 428/317.1; 156/79 |
International
Class: |
B65D 81/38 20060101
B65D081/38 |
Claims
1. A method of making a multilayer article, comprising: providing a
first substrate having an inner surface and an outer surface;
providing a second substrate having an inner surface and an outer
surface; disposing an expandable insulating material on the inner
surface of at least one of the first substrate and the second
substrate, wherein the expandable insulating material is in a first
condition during disposing; adhering the second substrate to the
first substrate with the expandable insulating material
therebetween to form a blank, wherein an insulating space is
defined between the first substrate and the second substrate with
the expandable insulating material therein and the insulating space
includes a first volume; forming the blank into the article; and
expanding the expandable insulating material of the article to a
second condition by application of energy, wherein the expandable
insulating material in the second condition increases the
insulating space to a second volume.
2. The method of claim 1, wherein the disposing includes printing
the expandable insulating material in a pattern on the inner
surface of the first substrate.
3. The method of claim 1, wherein the disposing includes printing
the expandable insulating material on an interior region of the
inner surface of the first substrate, wherein an outer margin of
the inner surface of the first substrate remains free of the
expandable insulating material.
4. The method of claim 1, wherein the adhering includes adhering
the second substrate along the inner surface of the first substrate
with an adhesive.
5. The method of claim 1, wherein the adhering includes coupling
the first substrate to the second substrate with adhesive along
surface areas of the first substrate and second substrate free of
expandable insulating material.
6. The method of claim 1, further comprising coating the outer
surface of the first substrate with substance.
7. The method of claim 1, further comprising coating the outer
surface of the second substrate with a substance.
8. The method of claim 1, wherein expanding the expandable
insulating material of the article to a second condition with
application of energy includes heating the article at approximately
400.degree. F. to approximately 500.degree. F. for a duration of at
least approximately 30 seconds to approximately 60 seconds.
9. The method of claim 1, wherein the disposing comprises at least
one of printing, coating, spraying, laminating, and extruding.
10. The method of claim 1, wherein the disposing the expandable
insulating material includes disposing the expandable insulating
material with a mesh screen ranging in dimension between
approximately 60 Mesh and approximately 110 Mesh.
11. The method of claim 1, wherein the disposing the expandable
insulating material includes disposing the expandable insulating
material in a ridge at an angle of approximately 45.degree. F. with
respect a center longitudinal axis of the article.
12. A multilayer article, comprising: a first substrate having an
inner surface and an outer surface; a second substrate having an
inner surface and an outer surface; and an expandable insulating
material applied to the inner surface of at least one of the first
substrate and the second substrate, wherein the expandable
insulating material includes a first condition at ambient
temperature and a second condition upon application of energy, and
wherein the second substrate is adhered to the first substrate with
the expandable insulating material therebetween to form a blank,
wherein an insulating space is defined between the first substrate
and the second substrate with the expandable insulating material
therein, the insulating space having a first volume when the
expandable insulating material is in the first condition and the
insulating space having a second volume when the expandable
insulating material is in the second condition.
13. The article of claim 12, wherein the expandable insulating
material includes an expandable material.
14. The article of claim 13, wherein the expandable material
includes microspheres.
15. The article of claim 13, wherein the expandable insulating
material further includes additives and is free of adhesive.
16. The article of claim 12, wherein the expandable insulating
material is in the second condition upon the application of energy
between approximately 400.degree. F. and approximately 500.degree.
F. and remains in the second condition thereafter.
17. The article of claim 12, wherein the second substrate is
adhered to the first substrate by adhesive.
18. The structure of claim 12, wherein the article includes a total
heat flux of approximately 1900 W/m.sup.2.
19. The article of claim 12, wherein the article transfers
approximately between approximately 70% and approximately 80% of
heat energy.
20. The article of claim 12, wherein the article has a stiffness
deflection that ranges from approximately 0.35 lbs. force to 1.2
lbs. force.
21. An insulating cup, comprising: a sidewall defining a top
opening and a bottom portion, the sidewall including a multilayer
article having: a first substrate having inner surface and an outer
surface, a second substrate having an inner surface and an outer
surface, and an expandable insulating material applied to the inner
surface of at least one of the first substrate and the second
substrate, wherein the expandable insulating material includes a
first condition at ambient temperature and a second condition upon
application of energy, and wherein the second substrate is adhered
to the first substrate with the expandable insulating material
therebetween, wherein an insulating space is defined between the
first substrate and the second substrate with the expandable
insulating material therein; and a base coupled to the bottom
portion of the sidewall when the expandable insulating material is
in the first condition.
22. The insulating cup of claim 21, wherein the insulating space
has a first volume when the expandable insulating material is in
the first condition and the insulating space has a second volume
when the expandable insulating material is in the second condition,
the expandable insulating material being expanded to the second
condition after forming the cup.
23. The insulating cup of claim 21, wherein the sidewall further
comprises a rolled top portion to define a rim about the top
opening.
24. The insulating cup of claim 23, wherein the rim is disposed
above a top edge of the second substrate of the structure.
25. The insulating cup of claim 21, wherein the base comprises a
skirt to define a surface-engaging edge with the sidewall.
26. The insulating cup of claim 21, wherein the expandable
insulating material is applied to the inner surface of at least one
of the first substrate and the second substrate in a ridge at an
angle of approximately 45.degree. F. with respect a center
longitudinal axis of the cup.
27. The insulating cup of claim 21, wherein the expandable
insulating material is applied to the inner surface of at least one
of the first substrate and the second substrate at a density
corresponding to a mesh screen size dimension ranging between
approximately 60 Mesh and approximately 110 Mesh.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Application No.
61/726,446, entitled "Multilayer Article and Method for Making a
Multilayer Article, Blank, and Insulating Cup" and filed on Nov.
14, 2012, the disclosure of which is incorporated herein by
reference in its entirety.
BACKGROUND
[0002] 1. Field
[0003] The presently disclosed subject matter relates to a
disposable cup for serving beverages, such as water and coffee, and
food items, such as soup or ice cream. Particularly, the presently
disclosed subject matter is directed to a blank having a multilayer
structure to provide improved insulating properties, among other
benefits.
[0004] 2. Description of Related Art
[0005] Some known types of disposable cups include those made from
polystyrene, expanded polystyrene or paper. Although polystyrene
cups can be aesthetically pleasing, such cups tend to not have an
outer surface more suitable for printing graphics or logos.
Further, polystyrene cups are generally not biodegradable or easily
recyclable.
[0006] Another type of cup, made from expanded polystyrene, or EPS
(e.g., a Styrofoam.RTM. cup), can have improved thermal insulation
properties compared to other cups, and thus can maintain the
temperature of a drink, either hot or cold, for a longer amount of
time. Expanded polystyrene cups can be relatively inexpensive, and
can be comfortable to handle as the exterior of the cup remains
relatively close to ambient temperature regardless of the
temperature of the item inside the cup. However, expanded
polystyrene is also generally not biodegradable or easily
recyclable. Additionally, as expanded polystyrene cups are
typically printed after they have been formed, and the relatively
rough surface of the cup can be incompatible with high-resolution
printing, relatively slow and costly processes are typically used
for printing on expanded polystyrene cups.
[0007] Yet another type of disposable cup, made from paper, is
generally recyclable and biodegradable, and thus can be considered
environmentally friendly. However, paper cups, particularly
single-layer paper cups, can have relatively poor thermal
insulation properties. Furthermore, paper cups constructed with a
single wall or layer can be susceptible to weakening after exposure
to liquids.
[0008] Multilayer paper cups can provide improved thermal
insulation and increased strength compared to single-layer paper
cups. Although relatively strong and thermally efficient,
multilayer cups generally are more expensive due to the complicated
manufacturing processes and excess material typically required.
Some examples of multilayer cups, including paper cups and paper
wrapped expanded polystyrene cups, that attempt to address these
concerns can be found in U.S. Pat. Nos. 7,552,841; 6,663,926;
6,598,786; and 6,193,098; U.S. Patent Application Publication Nos.
2008/0121681 and 2008/0041860; and International Publication No.
WO2011/003569, the disclosure of each of which is incorporated by
reference herein in its entirety. Other examples of cups include
U.S. Pat. No. 3,941,634; U.S. Pat. No. 4,477,518; U.S. Pat. No.
6,509,384; U.S. Pat. No. 6,749,913; U.S. Pat. No. 6,908,651; U.S.
Pat. No. 7,956,096; U.S. Publication 2007/0228134; U.S. Publication
2009/0321508, the contents of which each incorporated by reference
in their entirety. However, there remains an opportunity for
improvement for a disposable cup that is strong, well-insulated and
inexpensive to manufacture.
SUMMARY
[0009] The purpose and advantages of the disclosed subject matter
will be set forth in and apparent from the description that
follows, as well as will be learned by practice of the disclosed
subject matter. Additional advantages of the disclosed subject
matter will be realized and attained by the methods and systems
particularly pointed out in the written description and claims
hereof, as well as from the appended drawings.
[0010] To achieve these and other advantages and in accordance with
the purpose of the disclosed subject matter, as embodied and
broadly described, the disclosed subject matter includes a method
of making a multilayer article, comprising providing a first
substrate having an inner surface and an outer surface and
providing a second substrate having an inner surface and an outer
surface. The method further includes disposing an expandable
insulating material on the inner surface of at least one of the
first substrate and the second substrate, wherein the expandable
insulating material is in a first condition during disposing. The
second substrate is adhered to the first substrate with the
expandable insulating material therebetween to form a blank,
wherein an insulating space is defined between the first substrate
and the second substrate with the expandable insulating material
therein and the insulating space includes a first volume. The
method further includes forming the blank into the article and
expanding the expandable insulating material of the article to a
second condition by application of energy, wherein the expandable
insulating material in the second condition increases the
insulating space to a second volume.
[0011] As embodied herein, the disclosed subject matter further
includes a multilayer article, comprising a first substrate having
an inner surface and an outer surface and a second substrate having
an inner surface and an outer surface. The article further
including an expandable insulating material applied to the inner
surface of at least one of the first substrate and the second
substrate, wherein the expandable insulating material includes a
first condition at ambient temperature and a second condition upon
application of energy. The second substrate is adhered to the first
substrate with the expandable insulating material therebetween to
form a blank. An insulating space is defined between the first
substrate and the second substrate with the expandable insulating
material therein. The insulating space has a first volume when the
expandable insulating material is in the first condition and the
insulating space has a second volume when the expandable insulating
material is in the second condition.
[0012] In another embodiment, an insulating cup is provided. The
insulating cup, comprising a sidewall defining a top opening and a
bottom portion. The sidewall includes a multilayer article having a
first substrate having inner surface and an outer surface and a
second substrate having an inner surface and an outer surface. An
expandable insulating material is applied to the inner surface of
at least one of the first substrate and the second substrate,
wherein the expandable insulating material includes a first
condition at ambient temperature and a second condition upon
application of energy. The second substrate is adhered to the first
substrate with the expandable insulating material therebetween,
wherein an insulating space is defined between the first substrate
and the second substrate with the expandable insulating material
therein. The cup further includes a base coupled to the bottom
portion of the sidewall when the expandable insulating material is
in the first condition.
[0013] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and are intended to provide further explanation of the disclosed
subject matter claimed.
[0014] The accompanying drawings, which are incorporated in and
constitute part of this specification, are included to illustrate
and provide a further understanding of the method and system of the
disclosed subject matter. Together with the description, the
drawings serve to explain the principles of the disclosed subject
matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a top view of a multilayer blank according to a
representative embodiment of the disclosed subject matter, with a
printed pattern of insulating material featured for purposes of
understanding.
[0016] FIG. 2 is a cross-sectional view of the multilayer blank of
FIG. 1 along detail line A-A, according to the disclosed subject
matter.
[0017] FIG. 3A depicts a photograph of the expandable insulating
material printed in a diamond pattern on a first substrate of a
multilayer blank, according to an embodiment of the disclosed
subject matter.
[0018] FIG. 3B depicts an enlarged photograph of the expandable
insulating material of FIG. 3A after the application of energy,
according to an embodiment of the disclosed subject matter.
[0019] FIG. 4A depicts a photograph of the expandable insulating
material printed in a dot pattern on a first substrate of a
multilayer blank, according to an embodiment of the disclosed
subject matter.
[0020] FIG. 4B depicts an enlarged photograph of the expandable
insulating material of FIG. 4A after the application of energy,
according to an embodiment of the disclosed subject matter.
[0021] FIG. 5A depicts a photograph of the expandable insulating
material printed in a lined pattern on a first substrate of a
multilayer blank, according to an embodiment of the disclosed
subject matter.
[0022] FIG. 5B depicts an enlarged photograph of the expandable
insulating material of FIG. 5A after the application of energy,
according to an embodiment of the disclosed subject matter.
[0023] FIG. 6 is a schematic cross-sectional view of the multilayer
blank of FIG. 1 at ambient temperature along detail line A-A,
according to an embodiment of the disclosed subject matter.
[0024] FIG. 7 is a schematic cross-sectional view of the multilayer
blank of FIG. 6 after application of suitable energy, according to
an embodiment of the disclosed subject matter.
[0025] FIG. 8 is an exploded view of an insulating cup having a
multilayer blank, according to an embodiment of the disclosed
subject matter.
[0026] FIG. 9 is the insulating cup of FIG. 8, according to an
embodiment of the disclosed subject matter.
[0027] FIG. 10 depicts a flow chart of a method of making a
multilayer article, according to an embodiment of the disclosed
subject matter.
[0028] FIG. 11A depicts a photograph of an insulating cup formed
according to the disclosed subject matter, and FIG. 11B depicts a
photograph of the cup of FIG. 11A with the outer substrate removed,
according to an embodiment of the disclosed subject.
[0029] FIG. 12 depicts a table of samples and experiment data of
the samples, according to embodiments of the disclosed subject
matter.
[0030] FIG. 12A depicts an infrared image of the temperature of the
sidewall of a cup measured with a Flir I5 infrared camera,
according to embodiments of the disclosed subject matter.
[0031] FIG. 13 demonstrates the data means for the effects plot for
weight of the samples of FIG. 12, according to embodiments of the
disclosed subject matter.
[0032] FIG. 14 demonstrates the data means for the effects plot for
hold time in seconds of the samples of FIG. 12, according to
embodiments of the disclosed subject matter.
[0033] FIG. 15 demonstrates the data means for the effects plot for
the sidewall of the samples of FIG. 12, according to embodiments of
the disclosed subject matter.
[0034] FIG. 16 demonstrates the data means for the effects plot for
the average gauge of the samples of FIG. 12, according to
embodiments of the disclosed subject matter.
[0035] FIG. 17 demonstrates the data means for the effects plot for
the ridge gauge of the samples of FIG. 12, according to embodiments
of the disclosed subject matter.
[0036] FIG. 18 demonstrates the data means for the effects plot for
the appearance of the samples of FIG. 12, according to embodiments
of the disclosed subject matter.
[0037] FIG. 19 demonstrates the data means for the effects plot for
the strength of the samples of FIG. 12, according to embodiments of
the disclosed subject matter.
[0038] FIG. 20 shows a front view of the blank and corresponding
cup, according to embodiments of the disclosed subject matter.
[0039] FIG. 21 shows a back seam side view of the blank and
corresponding cup of FIG. 20, according to embodiments of the
disclosed subject matter.
[0040] FIG. 22 shows a front view of the blank and corresponding
cup, according to embodiments of the disclosed subject matter.
[0041] FIG. 23 shows a back seam side view of the blank and
corresponding cup of FIG. 22, according to embodiments of the
disclosed subject matter.
[0042] FIG. 24 depicts another embodiment of the disclosed subject
matter showing a blank, according to embodiments of the disclosed
subject matter.
[0043] FIG. 25 and FIGS. 25A-25C depict another embodiment of the
disclosed subject matter showing a cup made from a blank, according
to embodiments of the disclosed subject matter.
[0044] FIG. 26 demonstrates the insulation characteristics of an
article of the disclosed subject matter, according to embodiments
of the disclosed subject matter.
DETAILED DESCRIPTION
[0045] The products and methods presented herein may be used for
serving, storage and transportation of beverages and food items,
and other perishable and nonperishable products. The disclosed
subject matter is particularly suited for serving, storage, and
transportation of hot or cold beverages or food items, wherein the
multi-layer configuration of the cup provides improved insulating
properties to maintain the temperature of the beverage or food item
contained therein during consumption, storage and/or
transportation.
[0046] In accordance with the disclosed subject matter herein, the
disclosed subject matter includes a method of making a multilayer
article, comprising providing a first substrate having an inner
surface and an outer surface and providing a second substrate
having an inner surface and an outer surface. The method further
includes disposing an expandable insulating material on the inner
surface of at least one of the first substrate and the second
substrate, wherein the expandable insulating material is in a first
condition during disposing. The second substrate is adhered to the
first substrate with the expandable insulating material
therebetween to form a blank, wherein an insulating space is
defined between the first substrate and the second substrate with
the expandable insulating material therein and the insulating space
includes a first volume. The method further includes forming the
blank into the article and expanding the expandable insulating
material of the article to a second condition by application of
energy, wherein the expandable insulating material in the second
condition increases the insulating space to a second volume.
[0047] As embodied herein, the disclosed subject matter further
includes a multilayer article, comprising a first substrate having
an inner surface and an outer surface and a second substrate having
an inner surface and an outer surface. The article further
including an expandable insulating material applied to the inner
surface of at least one of the first substrate and the second
substrate, wherein the expandable insulating material includes a
first condition at ambient temperature and a second condition upon
application of energy. The second substrate is adhered to the first
substrate with the expandable insulating material therebetween to
form a blank. An insulating space is defined between the first
substrate and the second substrate with the expandable insulating
material therein. The insulating space has a first volume when the
expandable insulating material is in the first condition and the
insulating space has a second volume when the expandable insulating
material is in the second condition.
[0048] In another embodiment, an insulating cup is provided. The
insulating cup, comprising a sidewall defining a top opening and a
bottom portion. The sidewall includes a multilayer article having a
first substrate having inner surface and an outer surface and a
second substrate having an inner surface and an outer surface. An
expandable insulating material is applied to the inner surface of
at least one of the first substrate and the second substrate,
wherein the expandable insulating material includes a first
condition at ambient temperature and a second condition upon
application of energy. The second substrate is adhered to the first
substrate with the expandable insulating material therebetween,
wherein an insulating space is defined between the first substrate
and the second substrate with the expandable insulating material
therein. The cup further includes a base coupled to the bottom
portion of the sidewall when the expandable insulating material is
in the first condition.
[0049] Reference will now be made in detail to the various
exemplary embodiments of the disclosed subject matter, exemplary
embodiments of which are illustrated in the accompanying drawings.
The structure and corresponding method of operation of the
disclosed subject matter will be described in conjunction with the
detailed description of the system.
[0050] The accompanying figures, where like reference numerals
refer to identical or functionally similar elements throughout the
separate views, serve to further illustrate various embodiments and
to explain various principles and advantages all in accordance with
the disclosed subject matter. For purpose of explanation and
illustration, and not limitation, exemplary embodiments of the
multilayer blank in accordance with the disclosed subject matter
are shown in FIGS. 1-2. The multilayer blank is suitable for the
manufacture of articles such as containers, cups, bowls, and the
like. Such articles incorporating the multilayer blank can be used
with a wide variety of perishable and nonperishable goods. However,
for purpose of understanding, reference will be made to the use of
the multilayer blank as an insulating cup disclosed herein with
beverages, wherein the insulating cup can be used for transporting,
serving, storing, preparing and/or re-using such beverages. As
described in further detail below, the insulating cup has suitable
insulating properties to assist in maintaining the temperature of a
beverage therein. For purpose of illustration, and not limitation,
reference will made herein to a multilayer blank and an insulating
cup incorporating a multilayer blank that is intended to contain a
relatively hot food or beverage, such as hot water or coffer or
other similar beverage, wherein the insulating cup has a multilayer
structure to provide improved insulating properties, among other
benefits.
[0051] The multilayer blank generally includes a first substrate,
an expandable insulating material, and a second substrate. However,
the subject matter of the application further contemplates a blank
having a plurality of substrates and expandable insulating
materials and is not herewith limited to two substrates and one
insulating material. For example, the multilayer blank could
include four substrates and three insulating materials.
[0052] As shown FIG. 1, a first substrate 110 and an insulating
material 200 of a multilayer blank 100 are depicted, according to
an embodiment of the subject matter. For purpose of illustration,
FIG. 1 depicts a pattern of insulating material 200 that is
positioned between the first substrate 110 and the second substrate
120 of the multilayer blank 100. In the embodiment of FIG. 1, the
insulating material is printed between the first substrate 110 and
the second substrate 120. However, other application methods of
coupling the insulating material to the first substrate and/or the
second substrate include, but are not limited to, coating,
spraying, laminating, and extruding, as further discussed
herein.
[0053] FIG. 2 is a cross-section of a multilayer blank that
includes the first substrate 110 and insulating material 200 of
FIG. 1, the cross-section taken along lines A-A of FIG. 1. As
depicted in FIG. 2, the first substrate 110 has an outer surface
112 and an inner surface 114. The first substrate 110 defines a
thickness T.sub.1 between the outer surface 112 and the inner
surface 114. The thickness T.sub.1 of the first substrate 110 can
be any suitable dimension, depending on the material used. For
example, in one embodiment the thickness T.sub.1 can range between
0.002 inches and 0.020 inches. Other embodiments include the first
substrate 110 as having a value of the thickness T.sub.1 between
approximately 8 to approximately 15 pts and in particular
approximately 10 to approximately 11 pts, where a conventional
paperboard is used.
[0054] The multilayer blank 100 further includes a second substrate
120. The second substrate 120 has an inner surface 122 and an outer
surface 124. The second substrate 120 defines a thickness T.sub.2
between the inner surface 122 and the outer surface 124. The
thickness T.sub.2 of the second substrate 120 can be any suitable
dimension and can be the same or different than the thickness
T.sub.1 of the first substrate 110. For example, in one embodiment
the thickness T.sub.2 can range between 0.002 inches and 0.020
inches. As embodied herein in one embodiment, the thickness of the
second substrate is less than that of the first substrate. In one
embodiment, the second substrate 120 has a value of the thickness
T.sub.2 between approximately 3 to 8 pts. In another embodiment,
the second substrate 120 has a value of the thickness T.sub.2 of
approximately 6 pts.
[0055] As depicted in FIG. 2, the first substrate 110 and the
second substrate 120 are coupled together such that the inner
surface 122 of the second substrate 120 faces the inner surface 114
of the first substrate 110. As such, in one embodiment, the inner
surface 122 of the second substrate 120 is coupled to at least a
portion of the inner surface 114 of the first substrate to form the
blank 100. The first substrate 110 and the second substrate 120
define an insulating space 300 therebetween with the expandable
insulating material 200 therein, as further discussed herein. The
insulating space 300 can additionally be filled with a suitable
gas, such as air, or can be filled with a variety of suitable
materials to achieve desired insulating properties. The insulating
space 300 can further include an adhesive applied randomly or in a
pattern within the insulating space, as further discussed herein.
Furthermore, the adhesive can be applied about the entire surface
area of each of the first substrate and second substrate, if
desired.
[0056] The first substrate 110 and the second substrate 120 can be
coupled together by a plurality of suitable methods. In one
embodiment, the first substrate 110 and the second substrate 120
are coupled together along the margin 116 with an adhesive. In
another aspect of the disclosed subject matter, the first substrate
110 and the second substrate 120 are coupled together along the
surface areas of the first substrate and the second substrates,
respectively, including within the insulating space 300. A
plurality of suitable adhesives can be used including, but not
limited to, pressure sensitive adhesive, glue, thermal bond, and
the like. When the adhesive comprises a glue, certain kinds of glue
can be used depending on the level of thickness and material of
construction of each of the first and second substrates. For
example, for substrates of a smaller thickness dimension, a glue
having low moisture content, a non water-based glue, or a glue
having a higher solids content can be better suited for such
application. With any kind of suitable adhesive, the adhesive can
prevent leaching and be compatible with the insulating material.
With respect to the embodiment of FIG. 2, the adhesion of the first
substrate 110 with the second substrate 120 about the margin 116
allows for the expandable insulating material 200 to expand
independently within the insulation space 300, as described further
below. The blank 110 need not be limited to just a single margin
about the entire perimeter of the blank. In additional embodiments,
perimeter margins and interior channel breaks are also herein
contemplated. The first substrate 110 and the second substrate 120
can be coupled together prior to the application of energy to the
blank 100, further discussed herein.
[0057] In another embodiment, the first substrate 110 and the
second substrate 120 can be adhered together by adhesion in
alternate patterns. For example, the adhesive can be positioned on
the first substrate and/or the second substrate in channels
alternating with the insulating material adhered thereto. In
another example, the adhesive can be positioned within the pattern
of the insulating material, such as for purposes of example, within
the diamond pattern of the embodiment of FIG. 1. Such embodiments
can accommodate for a more controlled expansion of the insulating
material. As such, the adhesive can include an adhesive pattern or
can have an overall application about the surface area of the first
substrate and/or the second substrate. In another aspect of the
disclosed subject matter, the adhesive can be applied in a
registered application. In registered applications, the adhesive
may bond the first substrate with the second substrates in areas
devoid of or with limited expandable insulating material in
addition to or alternative to the application of adhesive to the
margins of the substrates.
[0058] The first substrate 110 and the second substrate 120 can
have any suitable shape and dimension for the intended purpose. For
example, the first substrate 110 and the second substrate 120 can
have geometric shapes, such as cylindrical, rectangular,
triangular, or any suitable geometrical shape. Generally, although
not necessarily, the shape and dimension of the first substrate 110
and the second substrate 120 are substantially similar. In
alternative embodiments, the shape and dimension of the first
substrate 110 and the second substrate 120 vary dependent on the
use of the blank. As depicted in FIG. 1 for purposes of
illustration, the first substrate 110 has a semi-rectangular shape
with arcuate edges for use in making a cup, such as a wrapped cup.
In other embodiments as discussed herein, the first substrate and
the second substrate each can comprise a web of material that is
later machined, cut, and processed into suitable shapes and
dimensions for articles, such as cups and the like as previously
disclosed.
[0059] The first substrate 110 and the second substrate 120 can
also include any suitable material. Examples of such suitable
materials include paperboard, polymeric sheets, foil or metalized
film, foam sheets (e.g., expanded polystyrene), a water-soluble
(e.g., starch-based) material, a foamed heat-insulating layer or
coating (e.g., polyethylene, polyolefin, polyvinylchloride,
polystyrene, polyester, or nylon), unscored paperboard such as
chipboard (plain chip or bending chip), linerboard, virgin
paperboard, paperboard with recycled content, SBS board, SUS board,
corrugated paper or board, polymeric solid sheets, combinations
thereof, or the like. The first substrate and the second substrate
can further include foil or metalized film laminated paperboard,
porous sheets, foam sheets (e.g., expanded polystyrene),
combinations thereof, or the like.
[0060] Suitable substances and coatings can be applied to the blank
as desired. For example, the outer surface 112 of the first
substrate 110 can include a coating such as a wax or polyethylene
that can cooperate with a liquid such as coffee or a soup, when the
blank is incorporated into a cup. For example, the first substrate
110 can include approximately between one-half to 1 mil of
polyethylene coating to create a seal in the interior of the cup.
Further, the outer surface 124 of the second substrate 120 can
include a coating to improve printing graphics on the blank or to
improve gripping of the blank. Alternatively or additionally, the
blank can be coated with a waterproof coating including, for
example, polyethylene. Other suitable coatings such as e.g.,
polyethylene, polyolefin, polyvinylchloride, polystyrene,
polyester, or nylon, combinations thereof, or the like are
furthermore contemplated as known in the art. The blank can
furthermore be coated with ink or graphics, as known in the
art.
[0061] Turning back to FIG. 1 and FIG. 2, the blank 100 includes an
insulating material 200 applied between the first substrate 110 and
the second substrate 120 in the insulating space 300. The
expandable insulating material 200 is applied on the inner surface
of at least one of the inner surface of the 114 of the first
substrate and the inner surface 122 of the second substrate 120.
The expandable insulating material 200 can be applied to at least
one of the inner surface 114 of the first substrate and the inner
surface 122 of the second substrate 120 in a plurality of suitable
ways and processes, as further discussed herein. For example, and
not by limitation, in one embodiment, the expandable insulating
material 200 is printed on the inner surface 114 of the first
substrate 110 in a pattern. For example, a mesh can be utilized to
print the expandable insulating material 200 on at least one of the
first substrate 110 and the second substrate 120. In another aspect
of the disclosed subject matter, the expandable insulating material
200 is applied by at least one of printing, coating, spraying,
laminating, and extruding, as further discussed herein.
[0062] A variety of suitable patterns of the expandable insulating
material can suffice, such as, but not limited to, dots, chevrons,
diamonds, lines, zigzags, spirals, and the like. The pattern can be
an ordered pattern or can be random, such as a camouflage pattern.
If desired, the pattern can define individual cells, wherein each
individual cell of the pattern can be sufficiently spaced from an
adjacent cell. In an embodiment, the first substrate can include a
pattern on an inner surface area of the substrate whereas the
second substrate can include a complementary pattern on the outer
surface area of the second substrate for a complementary fit
between the first and second substrates. In other embodiments and
as depicted herein, the pattern can be printed on an inner surface
area of the inner surface of the first substrate while leaving an
outer margin surrounding the expandable insulating material, as
shown in FIG. 1. Other embodiments do not include a margin free of
expandable insulating material. For purposes of illustration, FIG.
1 depicts a diamond pattern of the expandable insulating material
200.
[0063] As previously discussed, the adhesive can be applied within
the diamonds on either the first substrate and/or the second
substrate. The pattern of the expandable insulating material can
influence the shape of the overall container after expansion of the
expandable insulating material. The pattern can furthermore
influence the structure of the container such as the rigidity and
dimensional stability. The pattern can also create an aesthetically
pleasing design and decorative graphic. The pattern can also
provide different areas of insulation that can be application
specific for the intended use of the container. For example, with
embodiments of the container used as a hot coffee cup, the center
of the cup can include a dense pattern of the insulating material
thereabout, whereas the peripheral areas at the top and bottom of
the cup include a less dense pattern or can be lacking insulating
material.
[0064] The expandable insulating material 200 of the disclosed
subject matter is formed of expandable beads or microspheres, which
expand in size upon the application of sufficient energy, such as
heat. As embodied herein, one such suitable expandable insulating
material is available from Akzo Nobel, under the trademark
Expancel.RTM.. Such expandable insulating material can be combined
with inks, solution binders, carrier medium, or other additives to
allow for disposing onto a substrate surface. The binder can have
flexible characteristics and not be a rigid substance. A carrier
medium of the insulating material can include a variety of suitable
characteristics such as being dry to touch after application, but
not cured to the extent to lock in any beads of the expandable
insulating material and prevent expansion. The carrier medium can
have a predetermined viscosity and predetermined drying time based
on the method of disposing the expandable insulating material on
the substrate(s).
[0065] The expandable insulating material 200 can have certain
expansion properties upon the application of energy. Thus, the
expandable insulating material 200 can be printed or disposed in a
first condition at a first temperature on the substrate(s), the
first and second substrates can be adhered to each other and dried
to form a blank and, after forming an article from the blank, can
subsequently be processed with energy, such as but not limited to
radio frequency (RF), infrared, convection, conduction, laser,
heat, microwaves, or the like , such that the expandable insulating
material 200 includes a second condition. Depending on the desired
article of manufacture, different energy or heating applications of
the expandable insulating material have different advantages. For
articles having a poly-coated applications, the application of the
energy to the article need not exceed the melting point of the poly
coating.
[0066] In an example embodiment, at ambient temperature the
expandable insulating material 200, such as an expandable ink with
microspheres, can include microspheres having pre-expansion
diameters ranging from approximately 6 to approximately 12 microns,
i.e, the first condition. However, another embodiment contemplates
a bead having a pre-expansion diameter ranging from approximately
10 to approximately 16 microns, such as for purposes of example,
Akzo Nobel, 031WUF40 Expancel bead used in hot cup applications.
The expandable insulating material 200 can be printed or disposed
on the substrate in the first condition with the thickness
dimension of the expandable insulating material 200 based on the
density of the microspheres. For example, but not limited to, the
thickness of the expandable insulating material 200 can be printed
with a thickness dimension between approximately 0.001 inches to
0.008 inches. For applications desiring more stiffness and less
insulation, the thickness dimension of the expandable insulating
material 200 can be printed or disposed with a thickness dimension
of approximately 0.0005 inches in the first condition. For hot cup
articles such as hot coffee cups, the thickness dimension of the
expandable insulating material 200 can be printed or disposed with
a thickness of approximately 0.0015 inches to approximately 0.003
inches, in the first condition.
[0067] Upon the application of energy to the microspheres to e.g.,
approximately 100-500 degrees Fahrenheit (hereinafter, ".degree.
F.") and for a duration ranging between approximately 5 to
approximately 120 seconds, the microspheres permanently expand to
increase the original diameter of the microspheres, i.e., the
second condition. The expansion of the insulating material can be a
function of the application of energy and the associated duration
time. For example, in a hot cup application using the Akzo Nobel,
031WUF40 Expancel bead, convective heat can be applied at
approximately 400.degree. F. to approximately 500.degree. F. for
approximately 30 to approximately 90 seconds, and in some
embodiments for approximately 60 seconds. Such expansion can be
generally uniform across the surface of the substrate so as to
increase the dimension or distance between the inner surfaces of
the substrates and thus the volume of the insulation space. For
example, the microspheres can expand up to 10 times the original
diameter and volume. In another example, the printed microspheres
can have a thickness dimension of 0.0005 inches in the first
condition at ambient temperature and expand to 0.012 inches or
greater in the second condition, depending at least on the kind and
construction of bead.
[0068] In an example of the disclosed subject matter, the
expandable insulating material, inclusive of the expandable beads
with a carrier medium/coating, can be applied using screen printing
technology with a mesh ranging from approximately 60 mesh to
approximately 200 mesh size, and in one example, approximately 60
mesh to approximately 100 mesh. With screens of greater mesh
dimensions, the lower the amount of insulation material is applied
on the substrate. Another factor that can affect the thickness of
the expanded insulation material is the ratio of beads to the
carrier medium (i.e., the density of the beads within the carrier
medium/coating). With a higher density of beads in the carrier
medium, the expansion of the beads can be limited due to the lack
of space for the bead to expand. However, with a lower density of
beads in the carrier medium, there may not be enough expansion of
the beads for the insulation of the article and the desired use
thereof. Other factors that can affect the expansion of the beads,
include but are not limited to, the application of the adhesive
material and the flexibility and construction of the
substrates.
[0069] The spacing of the pattern of the expandable insulating
material can accommodate the expansion of the microspheres.
Similarly, the first and second substrates are joined or coupled
together in a matter to allow for such expansion. Furthermore, a
pleat or embossment can be provided in one or both substrates to
allow for such expansion. After the energy is applied, the
expandable insulating material 200 can be allowed to cure for a
suitable time, for example, but not limited to, between
approximately 20 and approximately 60 hours. However, curing after
the energy is applied is not necessary. It is noted however that
the energy can be applied at a suitable time after the insulating
material is applied. Long delays between application of insulating
material and energizing the insulating material can cause the
carrier medium to lock or become rigid, which can be adverse to the
expansion of the material. In one embodiment, the blank is allowed
to dry up to approximately 2 days, as further discussed herein
[0070] FIGS. 3A-5B depict various examples of the expandable
insulating material 200 printed on at least one of the inner
surface 114 of the first substrate and the inner surface 122 of the
second substrate 120. For purpose of illustration and description
only, each embodiment depicts the blank with the second substrate
removed and the insulating material expanded prior to forming a
corresponding article from the blank. FIG. 3A depicts a photograph
of the expandable insulating material 200, embodied as
microspheres, in an uniform diamond pattern at ambient temperature,
similar to the embodiment of FIG. 1. FIG. 3B depicts an enlarged
view of the microspheres of FIG. 3A after the application of
energy. As shown in FIG. 3B, upon the application of suitable
energy, the microspheres have increased in diameter and volume. The
expansion of the expandable insulating material 200 further
supplements the insulation properties of the blank, such as by
increasing the dimension or distance between the facing inner
surfaces of the first and second substrates and thus the volume of
the insulating space 300.
[0071] FIG. 4A depicts the expandable insulating material 200,
embodied as microspheres, in an ordered dot pattern at ambient
temperature. FIG. 4B depicts an enlarged view of the microspheres
of FIG. 4A at a maximized view after the application of energy. As
shown in FIG. 4B, upon the application of suitable energy, the
microspheres have increased in diameter and volume.
[0072] FIG. 5A depicts the expandable insulating material 200,
embodied as microspheres, in an ordered lined pattern at ambient
temperature. FIG. 5B depicts an enlarged view of the microspheres
of FIG. 5A at a maximized view after the application of energy. As
shown in FIG. 5B, upon the application of suitable energy, the
microspheres have increased in diameter and volume.
[0073] The expandable insulating material 200 can also include
suitable additives to further enhance the properties of the
expandable insulating material. The additives may include suitable
binders and/or adhesive substances that do not hinder the
subsequent expansion of the expandable insulating material upon the
application of energy. The additives may include those as known and
customary in the art.
[0074] The selective expansion of the article can have additional
benefits. For example, the portions of the article with the
insulating material can be disposed at any suitable location such
as in the bottom of a carton to create wells, as further discussed
herein. The insulating material can furthermore be used to increase
rigidity at select portions of a container and can facilitate
stacking
[0075] For purpose of illustration only, FIG. 6 and FIG. 7 show
cross-sections of a multilayer blank 100 prior to the application
of suitable energy and after the application of suitable energy,
respectively. Again, it is understood that such expansion
generally, although not necessarily, would be performed after first
forming the multilayer blank into a corresponding article. FIG. 6
is substantially similar to FIG. 2, but reproduced for comparative
purposes with FIG. 7.
[0076] As depicted in FIG. 6, the blank 100 includes a margin
thickness T.sub.S along the margin 116 at ambient temperature. The
margin thickness T.sub.S generally is the sum of the thickness
T.sub.1 of the first substrate 110, the thickness T.sub.S of the
second substrate 120, and the thickness of any adhesive and
additives between the first substrate 110 and the second substrate
120. The margin thickness T.sub.S can be any suitable dimension
such as, but not limited to, for example, 0.002 inches to 0.040
inches.
[0077] The blank 100 further includes an original thickness T.sub.O
between the margins 116 along the inner surface area. The original
thickness T.sub.O is the sum of the thickness T.sub.1 of the first
substrate 110, the thickness T.sub.S of the second substrate 120,
and the thickness of the expandable insulating material 300 at
ambient temperature. The thickness of the expandable insulating
material 200 generally defines the dimension or height of the
insulating space 300 between the facing inner surfaces of the first
and second substrates. As depicted in FIG. 6, the dimensional value
of the insulating space 300 is defined by the original blank
thickness T.sub.O minus the thickness T.sub.1 of the first
substrate 110 and the thickness T.sub.2 of the second substrate
120. The original thickness T.sub.O can be any suitable dimension
such as, but not limited to, for example, approximately 0.001 to
0.008 inches, and particularly approximately 0.0015 to 0.003
inches.
[0078] FIG. 7 shows a cross-section of a multilayer blank 100 after
the application of suitable energy. As depicted, the margin
thickness T.sub.S of the margins 116 stays substantially the same
thickness. In other words, the thickness T.sub.1 of the first
substrate 110 and the thickness T.sub.2 of the second substrate 120
remains unchanged and furthermore the adhesive with any additives
that binds the first substrate 110 to the second substrate 120 at
the margins 116, remains substantially nonreactive to any
application of energy.
[0079] As previously discussed, the expandable insulating material
200 expands upon the application of suitable energy to increase the
dimension, and thus the volume, of the insulating space 300.
[0080] As shown by FIG. 7, the thickness of the blank 100 defined
at the inner surface area, i.e. between margins 116 of FIG. 7,
changes with the application of suitable energy due to the material
characteristics of the expandable insulating material 200. Thus,
the original thickness T.sub.O of the blank 100 increases to a
second thickness T.sub.H upon application of suitable energy due to
the change in size of the expandable insulating material 200
disposed between margins 116. In other words, the second thickness
T.sub.H of the blank 100 is greater than the original thickness
T.sub.S of the blank 100 between the margins 116. The second
thickness T.sub.H can be any suitable range, for example, but not
limited to, from about 0.007 inches to 0.090 inches. As depicted in
FIG. 6 and FIG. 7 for purposes of illustration, the second
thickness T.sub.H of the blank 100 is two times the size of the
original thickness T.sub.O of the blank 100 whereas the thickness
T.sub.S of the margins 116 remains the same before and after
application of suitable energy. Although FIG. 7 depicts the
expansion of the insulating space 300 outwardly such that the first
substrate 110 deforms relative the second substrate 120, the
application further includes embodiments in which both the first
substrate 110 and the second substrate 120 deform together and in
which the second substrate 120 deforms inwardly with respect to the
first substrate 110.
[0081] In FIG. 7 after the application of suitable energy, the
dimension of the insulating space 300 has increased from its
original dimension and is defined by the second thickness T.sub.H
minus the thickness T.sub.1 of the first substrate 110 and the
thickness T.sub.2 of the second substrate 120. In one example, an
insulating cup including the blank 110 had an original thickness
T.sub.O of approximately 0.020 inches at the first condition and a
second thickness T.sub.H of approximately 0.080 inches at the
second condition such that the thickness increased approximately 4
times. Other embodiments contemplate increases of approximately 0
to 10 times.
[0082] As previously noted, and in accordance with another aspect,
the blank 100 of the embodiments discussed above can be used to
make a plurality of suitable articles, for example, but not limited
to, an insulating cup. Particularly, the multilayer blank disclosed
herein can be formed into a corresponding article using
conventional manufacture techniques, such as rim rolling and the
like, and can expanded by the application of energy to form an
insulated article. For purpose of illustration and not limitation,
the insulating cup comprises a sidewall defining a top opening and
a bottom portion. The sidewall includes a multilayer article having
a first substrate having inner surface and an outer surface and a
second substrate having an inner surface and an outer surface. An
expandable insulating material is applied to the inner surface of
at least one of the first substrate and the second substrate,
wherein the expandable insulating material includes a first
condition at ambient temperature and a second condition upon
application of energy. The second substrate is adhered to the first
substrate with the expandable insulating material therebetween,
wherein an insulating space is defined between the first substrate
and the second substrate with the expandable insulating material
therein. The cup further includes a base coupled to the bottom
portion of the sidewall when the expandable insulating material is
in the first condition.
[0083] FIG. 8 and FIG. 9 depict an embodiment of the subject matter
wherein a blank 100 of the embodiments discussed herein is used to
form a sidewall of an insulating cup 400. For purpose of
illustration and not limitation, as shown in FIG. 9, the insulating
cup 400 comprises a sidewall 415 and a base 435. The sidewall 415
includes a multilayer blank 100 that can include any of the
characteristics as previously disclosed. The sidewall 415 is
configured, for example, by wrapping a multilayer blank 100 about
itself prior to the application of energy to expand the expandable
insulating material, such that the blank 100 forms the sidewall 415
of the cup in which the first substrate 110 forms an interior of
the insulating cup 400 and the second substrate 120 forms an
exterior of the insulating cup 400. Because the article is formed
prior to expanding the expandable insulating layer, any of a
variety of known manufacturing techniques or processes can be used
for each component of cup and assembly of the cup therefrom.
[0084] As shown in FIG. 9, the multilayer blank wraps about itself
such that a longitudinal portion of the first substrate 110 adheres
to a longitudinal portion of the second substrate 120 to form a
seam of the insulating cup 400. The sidewall 415 defines a top
opening 420 and bottom portion 430, as embodied herein. The
sidewall 415 can further comprise a rolled top portion to define a
rim 417 about the top opening 420. The rim 417 can be disposed
above a top edge of the second substrate 120 of the blank which
forms the exterior of the insulating cup 400. Although not shown in
the illustrated embodiments, the insulating cup 400 and the
sidewall 415 can include additional surface features, such as ribs,
dimples, corrugations, scores, pleats, embossing, or the like and
combinations thereof, or the like for aesthetics, gripping or other
desired characteristics. For example, such characteristics can be
formed by the pattern of the insulating material after expansion,
as shown in FIG. 11A.
[0085] The bottom portion 430 of the sidewall 415 can be folded
toward the interior of the cup to form an inwardly folded segment
for connection with the base 435 of the insulating cup. The base
435 is coupled to the bottom portion 430 of the sidewall. The base
435 can be spaced from a bottom of the cup such that a bottom
circumferential periphery of the sidewall supports the cup and the
base is suspended from the bottom of the cup.
[0086] The base can include a substantially flat planar portion
with a skirt depending therefrom to define a surface-engaging edge
with the sidewall 415. The skirt of the base 435 can cooperate with
the inwardly folded segment of the sidewall 415 for adhering the
base to the sidewall 415 to form the insulating cup 400. The first
substrate 110 together with the flat planar portion of the base 435
define the inner volume of the insulating cup 400.
[0087] The base 435 can be formed from the blank material or other
suitable material, as known in the art. The base 435 can include
any suitable material and can be a single substrate or can
alternatively include a plurality of substrates. Examples of such
suitable materials include paperboard, polymeric sheets, foil or
metalized film, foam sheets (e.g., expanded polystyrene), a
water-soluble (e.g., starch-based) material, a foamed
heat-insulating layer or coating (e.g., polyethylene, polyolefin,
polyvinylchloride, polystyrene, polyester, or nylon), combinations
thereof, or the like. The base can further include suitable
coatings such as the coatings previously disclosed in relation to
the blank.
[0088] Once the insulating cup is assembled, the insulating
material can be expanded by the application of energy as described
in detail above to expand the insulating space 300 and thus
provides a region of insulation between the contents of the
insulating cup 400 and the air surrounding the sidewall to reduce
thermal flow therebetween. In one example, an insulating cup of an
embodiment of the disclosed subject matter containing a hot
beverage can insulate the heat such that only approximately 50-70%
of the heat is transferred to the exterior of the insulating cup.
For example, a person holding an insulating cup of the disclosed
subject matter containing coffee at 190.degree. F. can only feel
the insulating cup at approximately 70% to approximately 80% of the
coffee temperature, such as at a range of approximately 133.degree.
F. to approximately 152.degree. F., and in particular approximately
140.degree. F. to approximately 145.degree. F., such that
approximately 30% to approximately 20% of the temperature is
diffused by the insulating properties of the insulating cup. For
purposes of example, a person holding a solid paper cup containing
coffee at 190.degree. F. can feel the exterior surface of the paper
cup at a temperature of approximately 162.degree. F., such that
only 15% is diffused by the paper cup. In an embodiment of the
disclosed subject matter, the multilayer blank includes a total
heat flux of approximately 1800 W/m.sup.2 to 2000 W/m.sup.2. For
purposes of example, an 18 pt paper cup will have a total heat flux
of approximately 6890 W/m.sup.2.
[0089] As illustrated, the insulating cup 400 can have a generally
frustoconical shape. Alternatively, the cup can have other
geometric shapes, such as cylindrical, rectangular, triangular, or
any suitable geometrical shape. The insulating cup can include a
suitable stiffness to support a hot substance or a cold substance.
For example, but not limited to, the stiffness deflection can range
from approximately 0.35 lbs. force of deflection to approximately
1.2 lbs. force of deflection.
[0090] In accordance with the disclosed subject matter herein, a
method of making a multilayer article, comprising providing a first
substrate having an inner surface and an outer surface and
providing a second substrate having an inner surface and an outer
surface. The method further includes disposing an expandable
insulating material on the inner surface of at least one of the
first substrate and the second substrate, wherein the expandable
insulating material is in a first condition during disposing. The
second substrate is adhered to the first substrate with the
expandable insulating material therebetween to form a blank,
wherein an insulating space is defined between the first substrate
and the second substrate with the expandable insulating material
therein and the insulating space includes a first volume. The
method further includes forming the blank into the article and
expanding the expandable insulating material of the article to a
second condition by application of energy, wherein the expandable
insulating material in the second condition increases the
insulating space to a second volume.
[0091] FIG. 10 depicts a flow chart of the method of making a
multilayer article, according to an embodiment of the disclosed
subject matter. The first substrate is provided, as depicted in
step 501. The first substrate can be provided on a roll or web of
material suitable for inline processing and downstream
manufacturing by an apparatus.
[0092] The method further includes providing a second substrate as
depicted in step 503 of FIG. 10. The second substrate can be
provided in a conventional manner similar to the first substrate,
i.e. on a roll or web of material as known in the art.
[0093] As depicted in step 505 of FIG. 10, an expandable insulating
material is printed on the inner surface of at least one of the
first substrate and the second substrate. As previously disclosed,
the expandable insulating material in a first condition can be
printed on the at least portion of the inner surface of at least
one of the first substrate and the second substrate, as the webs of
the first substrate and the second substrate are transported
downstream. The disposing can be in a pattern on the portion of the
inner surface of the first substrate, as previously disclosed
above. The expandable insulating material can be printed on an
inner surface area of the substrates such that an outer margin of
the substrates remain free of the expandable insulating
material.
[0094] As depicted in step 507, the second substrate is adhered to
the first substrate. The second substrate can be coupled with the
first substrate along the outer margin of the inner surface of the
first substrate with an adhesive to form the blank. However, other
embodiments of the disclosed subject matter as further discussed
herein, contemplate the first substrate coupled with the second
substrate along the entire surface areas thereof. In such
embodiments, the adhesion can be between any pattern of expandable
insulating material attached thereto. The second substrate can be
coupled with the first substrate by conventional methods as known
in the art, for example, pressure sensitive adhesion, glue, thermal
bonding, or the like. The first substrate and the second substrate
define an insulating space therebetween with the expandable
insulating material therein wherein the insulating space includes a
first volume when the first substrate and the second substrate are
adhered together. As previously discussed, the adhesive can be
positioned within the insulating space.
[0095] The method can also include forming the blank into an
article, as depicted in step 509 of FIG. 10. For example, the
multilayer blank can be manufactured to a desired shape or
dimension as known in the art. Furthermore, a method of making an
insulating cup including the multilayer blank as disclosed is also
herewith contemplated. Conventional methods of making a cup are
known. For example, the following patents include such conventional
methods, the contents of which are herein incorporated by reference
in their entirety: U.S. Pat. No. 5,569,143; U.S. Pat. No.
5,624,367; and U.S. Pat. No. 5,556,364. In one embodiment, the
application further includes embodiments where a mandrel, heated or
otherwise, fits within the insulating cup to form the structure of
the cup. In other embodiments, the application further includes
embodiments where a mandrel, heated or otherwise, fits exterior to
the insulating cup to form the structure of the cup and further
embodiments include using a system of mandrels, heated or
otherwise, fits within and exterior to the insulating cup to form
the structure of the cup.
[0096] As depicted in step 511 of FIG. 10, the method further
includes the application of energy to expand the expandable
insulating material in the insulating space to a second condition.
The expandable insulating material in the second condition
increases the insulating space to a second volume. The application
of energy can be applied by any conventional methods as known in
the art, for example but not limited to, by use of an open/closed
oven, hot air application, microwave, laser device, heated mandrel,
radio frequency (RF), infrared, convection, conduction or the
like.
[0097] The method can further include coating the blank with a
substance, such as a coating material. For instance, the outer
surface of the first substrate can be coated with coating
substance, as previously discussed. The method can also include
coating the blank with ink or graphics, as known in the art.
[0098] Solely for purpose of illustration, FIGS. 11A-B depicts an
insulating cup 400, according to an embodiment of the disclosed
subject matter. In this example, the insulating cup 400 was formed
by wrapping, in lieu of the line processing described with respect
to FIG. 10, to show the different phases and substrates of an
insulating cup 400 for purposes of illustration. FIG. 11A depicts a
final article of an insulating cup 400 having a sidewall 415 of the
multilayer blank with the expandable insulating material 200 in the
second condition having the first substrate 110 coupled to the
second substrate 120.
[0099] FIG. 11B depicts the insulating cup 400 of FIG. 11A after
the application of suitable energy, with the second substrate
removed for purposes of illustration. The insulating cup 400 was
baked in an oven at approximately 230.degree. F., in this
embodiment. In this FIG. 11B, the expandable insulating material
200 is in the second condition. In other embodiments of the
disclosed subject matter, the article is placed in a convective
heat tunnel at approximately 400.degree. F. to approximately
500.degree. F. for a duration of approximately 60 seconds.
EXPERIMENTS
[0100] The disclosed subject matter is further described by means
of the examples and experiments, presented below. The use of such
examples is illustrative only and in no way limits the scope and
meaning of the disclosed subject matter or of any exemplified term.
Likewise, the disclosed subject matter is not limited to any
particular preferred embodiments described herein. Indeed, many
modifications and variations of the disclosed embodiments will be
apparent to those skilled in the art upon reading this
specification.
[0101] Experimentation was conducted to determine optimal
characteristics of the article and blanks, specifically for a hot
cup application, according to the embodiments of the disclosed
subject matter. A plurality of variables can affect the performance
and characteristics of the article and blank, including but not
limited to dimension of the screen mesh, the content of the beads
and carrier medium, the pattern of the expandable insulating
material upon the substrates inclusive of any width dimension
between stripes of expandable insulating material, the length of
the drying time of the article or blank prior to the application of
energy, the kind of energy applied, the intensity of the energy
applied including the temperature of heat application, the duration
of the energy or heat applied, whether the articles were loosely
stacked during application of energy, whether the articles were
stacked as a compressed unit during application of energy, the
positioning of the adhesive upon the substrate(s), the thickness
dimension of the adhesive upon the substrate(s), and the like.
[0102] In an embodiment of the disclosed subject matter, the
expandable insulation material can be disposed on the substrate(s)
by using a screen mesh of at least one of approximately 60 Mesh,
approximately 86 Mesh, approximately 110 Mesh, and any Mesh
dimension therebetween, wherein the higher the Mesh screen
dimension, the lower the density of the beads within the carrier
medium of the expandable insulating material, as previously
discussed. In another embodiment, the expandable insulating
material includes a bead content of at least one of approximately
15 percent of the expandable insulating material, approximately 20
percent of the expandable insulating material, approximately 25
percent of the expandable insulating material, or combinations
thereof. In another embodiment, the substrate(s) include stripes of
expandable insulating material having a width dimension of at least
one of approximately 0.23 inches, approximately 0.30 inches,
approximately 0.45 inches, or combinations thereof. In another
embodiment, the stripes of the expandable insulating material are
spaced at a width dimension of at least one of approximately 0.04
inches, approximately 0.07 inches, approximately 0.09 inches, or
combinations thereof. In another embodiment, the adhesive(s) are
applied at a setting range between approximately 3 mil gap to
approximately 7.5 mil gap, and in particular at least one of
approximately 4 mil gap, approximately 5 mil gap, approximately 6
mil gap, or any setting therebetween. As such, a thickness
dimension of the adhesive can range according to the setting
parameter, and in particular for purposes of example, the adhesive
can have a thickness dimension of approximately 2.4 mil,
approximately 2.9 mil, and approximately 3.5 mil for a glue
adhesive having approximately 54% solids. In another embodiment of
the disclosed subject matter, the article or blank is allowed to
dry up to approximately 2 days prior to the application of
energy.
[0103] In another embodiment, heat energy is applied to the article
or blank at a temperature of at least one of approximately
400.degree. F., approximately 450.degree. F., approximately
500.degree. F., or anywhere therebetween for a duration of at least
one of approximately 40 seconds, approximately 60 seconds,
approximately 90 seconds or anywhere therebetween. In another
embodiment, the articles are stacked after the application of
energy to minimize distortion whereas other embodiments of the
disclosed subject matter contemplate unstacked articles during the
application of energy.
[0104] Based on the plurality of combinations of the embodiments
discussed above, the article and blank can be customized for a
variety of articles and blanks of varying needs. For example, by
combining any of the plurality of combinations of the embodiments
discussed above, the following characteristics can be customized:
weight of the article or blank, strength of the article or blank,
the thickness dimension of the glue, the sidewall gauge of the
article, the average sidewall temperature of an article, the
average temperature at the portions of insulating material, the
duration of time the article can be handled with a substance
contained within the article at 185.degree. F., the appearance of
the article or blank such as but not limited to a person of
ordinary skill in the art judgment regarding aesthetics, wrinkles,
distortion, and delamination. Based on the plurality of
combinations of the embodiments discussed above, fractional
factorial design experiments were conducted to demonstrate the
customized characteristics of articles produced, according to
aspects of the disclosed subject matter.
[0105] FIG. 12 provides characteristics of 36 samples of articles
of the disclosed subject matter, in particular cups, and a sampling
of data from experiments conducted thereto. As evident from FIG.
12, controlling certain variables provides certain characteristics,
which can be used for article and blank customization, as desired.
The test protocols include gauge of the sidewall in which an
automated equipment measures 18 thickness points starting 1 inch
from the bottom of the article spaced 3/16 of an inch apart. The
average gauge is an average of all points along the sidewall,
whereas the ridge gauge is a maximum gauge measured along the
sidewall of the cup. The strength protocol includes strength
wherein the force required to deflect a cup 0.25 inch at a location
1/3 of the total cup height from the top using JS-1 rigidity tester
is measured. The sidewall and temperature protocol is measured with
a Flir I5 infrared camera and water at a temperature of
approximately 185.degree. F. is placed in an un-lidded cup and the
sidewall temperature image is taken from a 20 inch distance from
the cup after a duration of approximately 60 seconds. The average
temperature is within approximately a 1 inch by 1 inch square (15
pixels by 15 pixels) in a center of the cup opposite the seam, as
shown in the example of FIG. 12A. The hold time protocol test
includes a cup handled from above the area where the sidewall
temperature measurement was conducted, picked up and held such that
the hand of the tester did not contact the seam. The cup was held
until a tester determined the cup was too uncomfortable to hold by
a reasonable hand sensitivity of the tester. The appearance
protocol includes a qualitative evaluation of cup appearance,
wherein the 0 signal is the best and the 3 signal is the worst,
such that a good quality is marked for the 0 signal, wrinkles
appear on the inner and/or outer surface of the cup for a 1 signal,
the cup is distorted for the 2 signal, and the cup experienced
delamination of glued areas for the 3 signal.
[0106] FIG. 13-FIG. 19 demonstrate various trends of the data
gathered from experimentation of the 36 samples of FIG. 12. FIG. 13
demonstrates the data means for the effects plot for weight of the
samples, wherein the dimension of the screen mesh and the thickness
dimension of the glue weight exhibit the greatest variable changes.
As understood by persons of ordinary skill in the art, the data
means referred to herein and in the figures is the mean value of
the data collected. FIG. 14 demonstrates the data means for the
effects plot for hold time in seconds of the samples containing a
substance of 185.degree. F., wherein the temperature of the oven,
the dimension of the screen mesh and the duration of the articles
in the oven exhibit the greatest variable changes. FIG. 15
demonstrates the data means for the effects plot for the sidewall
of the samples containing a substance of 185.degree. F., wherein
the dimension of the screen mesh, the density of the Expancel beads
of the expandable insulating material, and the duration of the
articles in the oven exhibit the greatest variable changes.
[0107] FIG. 16 demonstrates the data means for the effects plot for
the average gauge of the samples, wherein the dimension of the
screen mesh, the density of the Expancel beads of the expandable
insulating material, and the duration of the articles in the oven
exhibit the greatest variable changes. FIG. 17 demonstrates the
data means for the effects plot for the ridge gauge of the samples,
wherein the dimension of the screen mesh, the density of the
Expancel beads of the expandable insulating material, and the
duration of the articles in the oven exhibit the greatest variable
changes. FIG. 18 demonstrates the data means for the effects plot
for the appearance of the samples such as distortion, delamination
and the like, wherein the dimension of the screen mesh, the density
of the Expancel beads of the expandable insulating material, and
the duration of the articles in the oven exhibit the greatest
variable changes. FIG. 19 demonstrates the data means for the
effects plot for the strength of the samples, wherein the thickness
dimension of the stripe of expandable insulating material, the
dimension of the screen mesh, the density of the Expancel beads of
the expandable insulating material, and the duration of the
articles in the oven exhibit the greatest variable changes.
[0108] As evident from the plots of FIG. 13-FIG. 19, by controlling
certain variables and varying other variables of the samples,
customized articles are contemplated with the aspects of
embodiments of the disclosed subject matter.
[0109] FIG. 20-FIG. 21 depict an embodiment of the disclosed
subject matter showing a blank juxtaposed with a frustroconical cup
made from the blank. For purposes of illustration only, the blank
is shown with only a first substrate and the second substrate is
not shown in the figure. FIG. 20 shows a front view of the blank
and corresponding cup and FIG. 21 shows a back seam side view of
the blank and corresponding cup of FIG. 20. As depicted, the
expandable insulating material is disposed in ridges at an angle of
approximately 45.degree. F. with respect an axis perpendicular to
the center longitudinal axis of the frustroconical cup. FIG. 21
depicts the back seam side view of the frustroconical cup and blank
of FIG. 20. Due to the frustroconical shape of the cup and the
positioning of the ridges having no degrees of curvature, the angle
of the striped expandable insulation material ridges is
approximately 29.3.degree. F. on the left side of the cup and
60.7.degree. F. on the right side of the cup. The parallelograms of
expandable insulating material disposed at the bottom of the cup
can comprise stacking lugs and can facilitate stacking and/or
securement of cups.
[0110] FIG. 22-FIG. 23 depict another embodiment of the disclosed
subject matter showing a blank juxtaposed with a frustroconical cup
made from the blank. For purposes of illustration only, the blank
is shown with only a first substrate and the second substrate is
not shown in the figure. FIG. 22 shows a front view of the blank
and corresponding cup and FIG. 23 shows a back seam side view of
the blank and corresponding cup of FIG. 22. As depicted, the
expandable insulating material is disposed in ridges at an angle of
approximately 45.degree. F. with respect the center longitudinal
axis of the frustroconical cup and disposed at a substantially
constant radius of curvature of approximately 17.13 inches. The
substantially constant curve line can be generated and manipulated
based on an involute curve of the blank. The involute curve can in
turn be used to design a curve on the top of the teeth for the
machine gears of the apparatus manufacturing the blank and/or
corresponding article. For purposes of example, in manufacturing a
16 ounce cup according to an embodiment of the disclosed subject
matter, the expansion cell curve line of the blank can have an
increment of approximately 0.26 inch in the radius, every time the
angle turns approximately 0.784.degree. F. However, the increment
can have any suitable range dimension depending on the blank and
article being manufactured, as different size articles and blanks
can have different angles and shapes which impact the
specifications of the involute curves and any matching
substantially constant curve lines.
[0111] FIG. 23 depicts the back seam side view of the
frustroconical cup and blank of FIG. 22. Due to the frustroconical
shape of the cup and the degree of curvature of the ridges of
expandable insulating material, the angle of the striped expandable
insulation material ridges at the seam is still approximately
45.degree. F. Such embodiment can facilitate better aesthetic
appearance than the embodiment of FIG. 20-21 and can increase
strength for the cup.
[0112] FIG. 24 depicts another embodiment of the disclosed subject
matter showing a blank, similar to the embodiment of FIG. 22-23.
The ridges of FIG. 24 are disposed at a predetermined radius of
curvature, as shown.
[0113] FIG. 25 and detail FIGS. 25A-25C depict another embodiment
of the disclosed subject matter showing a cup made from a blank.
The ridges of FIG. 25 are disposed at a predetermined radius of
curvature, as shown. The cup is depicted after the application of
energy to the cup such that the expandable insulating material has
expanded to the second condition. As shown in the details FIGS.
25A-25C and along the side of cup of FIGS. 25A and 25B, adhesive
has been disposed between the ridges of the insulating material
such that the first and second substrate are coupled to each other
at areas lacking the insulating material. According to the
embodiment of FIG. 25, the cup has a rolled rim and there is no
insulating material at the top of the cup, as apparent in detail A.
The insulating ridges create a unique topography about the surface
area of the sidewalls of the cup.
[0114] FIG. 26 demonstrates the insulation characteristics of the
article of the disclosed subject matter of FIGS. 20-21, in
comparison with an economy level cup and in comparison with an
ultra premium cup. An example of an ultra premium cup can be found
in the disclosure of U.S. Pat. No. 7,552,841, entitled "Reinforced
plastic foam cup, method of and apparatus for manufacturing same",
the contents of which is incorporated herein by reference in its
entirety.
[0115] While the disclosed subject matter is described herein in
terms of certain preferred embodiments, those skilled in the art
will recognize that various modifications and improvements may be
made to the disclosed subject matter without departing from the
scope thereof. Moreover, although individual features of one
embodiment of the disclosed subject matter may be discussed herein
or shown in the drawings of the one embodiment and not in other
embodiments, it should be apparent that individual features of one
embodiment may be combined with one or more features of another
embodiment or features from a plurality of embodiments.
[0116] In addition to the specific embodiments claimed below, the
disclosed subject matter is also directed to other embodiments
having any other possible combination of the dependent features
claimed below and those disclosed above. As such, the particular
features presented in the dependent claims and disclosed above can
be combined with each other in other manners within the scope of
the disclosed subject matter such that the disclosed subject matter
should be recognized as also specifically directed to other
embodiments having any other possible combinations. Thus, the
foregoing description of specific embodiments of the disclosed
subject matter has been presented for purposes of illustration and
description. It is not intended to be exhaustive or to limit the
disclosed subject matter to those embodiments disclosed.
[0117] It will be apparent to those skilled in the art that various
modifications and variations can be made in the method and system
of the disclosed subject matter without departing from the spirit
or scope of the disclosed subject matter. Thus, it is intended that
the disclosed subject matter include modifications and variations
that are within the scope of the appended claims and their
equivalents.
* * * * *