EP3395705A1 - Methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom - Google Patents
Methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom Download PDFInfo
- Publication number
- EP3395705A1 EP3395705A1 EP18169772.3A EP18169772A EP3395705A1 EP 3395705 A1 EP3395705 A1 EP 3395705A1 EP 18169772 A EP18169772 A EP 18169772A EP 3395705 A1 EP3395705 A1 EP 3395705A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- edge
- adhesive
- band
- paperboard
- shrinkable film
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D3/00—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines
- B65D3/22—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines with double walls; with walls incorporating air-chambers; with walls made of laminated material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
- B31B50/60—Uniting opposed surfaces or edges; Taping
- B31B50/62—Uniting opposed surfaces or edges; Taping by adhesives
- B31B50/624—Applying glue on blanks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/38—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
- B65D81/3865—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation drinking cups or like containers
- B65D81/3869—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation drinking cups or like containers formed with double walls, i.e. hollow
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B2105/00—Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs
- B31B2105/001—Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs made from laminated webs, e.g. including laminating the webs
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B2105/00—Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs
- B31B2105/002—Making boxes characterised by the shape of the blanks from which they are formed
- B31B2105/0022—Making boxes from tubular webs or blanks, e.g. with separate bottoms, including tube or bottom forming operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B2110/00—Shape of rigid or semi-rigid containers
- B31B2110/10—Shape of rigid or semi-rigid containers having a cross section of varying size or shape, e.g. conical or pyramidal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B2110/00—Shape of rigid or semi-rigid containers
- B31B2110/20—Shape of rigid or semi-rigid containers having a curved cross section, e.g. circular
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
- B31B50/26—Folding sheets, blanks or webs
- B31B50/28—Folding sheets, blanks or webs around mandrels, e.g. for forming bottoms
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
- B31D5/00—Multiple-step processes for making three-dimensional articles ; Making three-dimensional articles
- B31D5/0086—Making hollow objects
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
- B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
- B31F1/008—Shaping of tube ends, e.g. flanging, belling, closing, rim-rolling or corrugating; Fixing elements to tube ends
- B31F1/0093—Fixing elements to tube ends
Definitions
- the shrinkable film 103 may be uniaxially or biaxially oriented. In at least one specific example, the shrinkable film 103 may be a biaxially oriented, heat shrinkable polymeric film. In at least one specific example, the shrinkable film 103 may be a uniaxially oriented, heat shrinkable polymeric film.
- the shrinkable film 103 may be a mono-layer film or a multi-layer film. A multilayer film 103 may have 2, 3, 4, 5, 6, 7, 8, or more layers.
- the film 103 may include a core layer or intermediate layer, and one or more outer layers or skin layers such as a first outer layer and a second outer layer.
- the film 103 may include a core layer or intermediate layer one or more tie layers, and one or more outer layers.
- the film 103 may include a core layer, a first tie layer and a second tie layer disposed on opposing sides of the core layer, a first outer layer disposed on the first tie layer, and a second outer layer disposed on the second tie layer.
- a surface area of the shrinkable film 103 may shrink or reduce from an original or starting surface area to a second or final surface area in an amount of about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, or about 60% based on the original or starting surface area.
- the surface area of the shrinkable film 103 may shrink or reduce from an original or starting surface area to a second or final surface area in an amount of about 10% to about 30%, about 15% to about 30%, about 8% to about 20%, about 15% to about 35%, about 12% to about 33%, about 25% to about 35%, or about 10% to about 40%.
- a heat shrink film having a surface area of about 100 cm 2 may be reduced to about 95 cm 2 , about 90 cm 2 , about 85 cm 2 , about 80 cm 2 , about 75 cm 2 , about 70 cm 2 , about 65 cm 2 , about 60 cm 2 , about 55 cm 2 , about 50 cm 2 , about 45 cm 2 , or about 40 cm 2 when subjected to a temperature of about 40°C to about 100°C.
- the first area 320 between the shrinkable film 303 and the paperboard substrate 305 may be free to move away from the paperboard substrate 305 as the shrinkable film 303 shrinks. For example, if the paperboard blank 300 has been formed into a container and the shrinkable film 303 shrinks a gap may be formed between the film 303 and the paperboard substrate 305 as discussed and described in further detail below with reference to Figure 6 .
- the width of the band of adhesive 315 or glue line along each edge 307, 309, 311, and 313 of the paperboard substrate 305 may be the same or different with respect to one another.
- the width of the first portion 316, the width of the second portion 317, the width of the third portion 318, and the width of the fourth portion 319 of the band of adhesive 315 may be the same or different with respect to one another.
- the width of the band of adhesive 315 along the first edge 307 may be less than the width of the band of adhesive 315 along the second edge 309, less than the width of the band of adhesive 315 along the third edge 311, and/or less than the width of the band of adhesive 315 along the fourth edge 313.
- the second area 722 may have a length that extends from the first portion 716 of the band of adhesive 715 to the second portion 717 of the band of adhesive 715.
- the first portion 716, the second portion 717, and the third portion 718 of the band of adhesive 715 may form or otherwise provide a continuous layer or band of the adhesive 715 that extends from the first edge 707 to the second edge 709 that includes the second area 722 partially disposed therein.
- the second area 722 may extend for a distance that is less than the distance between the first portion 716 of the band of adhesive 715 and the second portion 717 of the band of adhesive 715.
- the first area 720 between the shrinkable film 703 and the paperboard substrate 705, may be free to move away from the paperboard substrate 705 as the shrinkable film 703 shrinks. For example, if the paperboard blank 700 has been formed into a container and the shrinkable film 703 shrinks, a gap may be formed between the film 703 and the paperboard substrate 705 as discussed and described in detail above with reference to Figure 6 .
- the band of adhesive 115 located along the first edge 107 of the blank 1000 extends from side to side, i.e. all the way from the third edge 111 to the fourth edge 113.
- at least a portion of the band of adhesive 115 located along the second edge 109 of the blank 1000 extends from side to side, i.e. all the way from the third edge 111 to the fourth edge 113.
- the second region 1022 that is substantially free of adhesive is thus formed along the third edge 111, but does not extend all the way to the first and second edges 107, 109, as shown in Figure 10 .
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Packages (AREA)
Abstract
Description
- This application is continuation-in-part of co-pending
U.S. Patent Application No. 14/979,191, filed on December 22, 2015 U.S. Provisional Patent Application No. 62/096,349, filed on December 23, 2014 - Embodiments described generally relate to methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom.
- Paperboard is used to make a wide variety of paper products, such as plates, bowls, and cups. Paper products may be insulated in a variety of ways to provide an insulated product, such as an insulated cup for hot or cold beverages. For example, the paper product may be insulated by forming an air gap within a sidewall of the container. The air gap, for example, may be located between a film that forms an inner surface of the sidewall and a paperboard substrate that forms an outer surface of the sidewall. The film may be a shrinkable film that may shrink, e.g., a heat shrinkable film, to form the gap between the film and the paperboard substrate as the film shrinks.
- Typically the paperboard blank that the shrinkable film is adhered to includes an outer and an inner coating of low density polyethylene or other polymer. When a composite structure includes paperboard and a shrink film to form an insulated container, a potential defect is that a shrink force induced by the shrink film may cause delamination within the paperboard component of the substrate. The layer of paperboard fibers which are adhered to the shrink film are peeled away as the film shrinks, producing an effect generally referred to as "peel back." Once the film peels back, the paperboard fibers are exposed and will begin to absorb liquid, e.g., coffee, if present in the container. The absorption and migration of the liquid into the paperboard blank used to form the container is generally referred to as "edge wicking." The absorption of the liquid may reduce the structural integrity of the paperboard blank, is not aesthetically pleasing, and is generally undesirable.
- There is a need, therefore, for improved methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom that have a reduced degree of peel back of the shrinkable film along an inner sidewall seam thereof.
- Methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom are provided. In at least one specific embodiment, a method for making a paper container may include applying a band of adhesive about a perimeter of a paperboard substrate having a first edge and a second edge opposed to one another and a third edge and a fourth edge opposed to one another. The band of adhesive may at least partially surround a first area that is substantially free from the adhesive. A second area that is substantially free from the adhesive may be located between the third edge and the first area. The first area and the second area may be separated by the band of adhesive. A shrinkable film may be secured to the paperboard substrate with the adhesive to produce a paperboard blank. The third edge and the fourth edge may be overlapped to form a sidewall. The sidewall may include an inner surface that includes the shrinkable film and an outer surface that includes the paperboard substrate, the first edge, and the second edge. A bottom panel may be secured to the sidewall at or adjacent the second edge. The first edge may be curled to form a brim.
- In at least one specific embodiment, a method for making a paper container may include applying a band of adhesive about a perimeter of a paperboard substrate having a first edge and a second edge opposed to one another and a third edge and a fourth edge opposed to one another. The band of adhesive may surround a first area that is substantially free of the adhesive. A second area that is substantially free of the adhesive may be formed between the third edge and the first area. The first area and the second area may be separated by the band of adhesive. A shrinkable film may be secured to the paperboard substrate with the adhesive to produce a paperboard blank. The third edge and the fourth edge may be overlapped to form a sidewall. The sidewall may include an inner surface that includes the shrinkable film and an outer surface that includes the paperboard substrate, the first edge, and the second edge. A bottom panel may be secured to the sidewall at or adjacent the second edge of the sidewall. The first edge of the sidewall may be curled to form a brim.
- In at least one specific embodiment, a method for making a paper container may include applying a band of adhesive about a perimeter of a paperboard substrate having a first edge and a second edge opposed to one another and a third edge and a fourth edge opposed to one another. The band of adhesive may at least partially surround a first area that is substantially free from the adhesive. A second area that is substantially free from the adhesive may be located between the third edge and the first area. The first area and the second area may be separated by at least a portion of the band of adhesive. A shrinkable film may be secured to the paperboard substrate with the adhesive to produce a paperboard blank. The third edge and the fourth edge may be overlapped with one another. The third edge and the fourth edge may be heat sealed to one another to form a sidewall. A bottom panel may be secured to the sidewall at or adjacent the second edge. The first edge may be curled to form a brim.
- In at least one specific embodiment, a method for making a paper container may include applying a band of adhesive about a perimeter of a paperboard substrate having a first edge and a second edge opposed to one another and a third edge and a fourth edge opposed to one another. The band of adhesive may at least partially surround a first area that is substantially free from the adhesive. A second area that is substantially free from the adhesive may be located along a portion of the third edge between the first and second edges. The first area and the second area may be separated by at least a portion of the band of adhesive. A shrinkable film may be secured to the paperboard substrate with the adhesive to produce a paperboard blank. The third edge and the fourth edge may be overlapped with one another. The third edge and the fourth edge may be heat sealed to one another to form a sidewall. A bottom panel may be secured to the sidewall at or adjacent the second edge. The first edge may be curled to form a brim.
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Figure 1 depicts a schematic view of an illustrative paperboard blank for making a cup, according to one or more embodiments described. -
Figure 2 depicts a schematic cross-sectional view of the paperboard blank depicted inFigure 1 along line 2-2, according to one or more embodiments described. -
Figure 3 depicts a schematic view of another illustrative paperboard blank for making a cup, according to one or more embodiments described. -
Figure 4 depicts a schematic cross-sectional view of the paperboard blank depicted inFigure 3 along line 4-4, according to one or more embodiments described. -
Figure 5 depicts a partial cut away, perspective view of an illustrative paper cup, according to one or more embodiments described. -
Figure 6 depicts a cross-section side view of a paper cup having a brim curl, a shrunk film, and a gap formed or located between the shrunk film and the paperboard substrate, according to one or more embodiments described. -
Figure 7 depicts a schematic view of another illustrative paperboard blank for making a cup, according to one or more embodiments described. -
Figure 8 depicts a schematic cross-sectional view of the paperboard blank depicted inFigure 7 along line 8-8, according to one or more embodiments described. -
Figure 9 depicts a schematic cross-sectional view of the paperboard blank depicted inFigure 7 along line 9-9, according to one or more embodiments described. -
Figure 10 depicts a schematic view of yet another illustrative paperboard blank for making a cup, according to one or more embodiments described. -
Figure 11 depicts a schematic cross-sectional view of the paperboard blank depicted inFigure 10 along line 11-11, according to one or more embodiments described. -
Figure 1 depicts a schematic view of an illustrative paperboard blank 100 for making a cup, according to one or more embodiments, andFigure 2 depicts a schematic cross-sectional view of the paperboard blank 100 depicted inFigure 1 along line 2-2. Referring toFigures 1 and 2 , thepaperboard blank 100 may include a first layer orfilm 103 and a second layer orsubstrate 105. Thefilm 103 and thesubstrate 105 may be secured to one another using any suitable method. For example, thefilm 103 and thesubstrate 105 may be at least partially bonded, coupled, affixed, joined, fastened, attached, connected, or otherwise secured to one another with an adhesive 115. In another example, thefilm 103 and thesubstrate 105 may be at least partially bonded, coupled, affixed, joined, fastened, attached, connected, or otherwise secured to one another via ultrasonic bonding. In one or more embodiments, thefilm 103 may be a shrinkable film and thesubstrate 105 may be a paperboard substrate. For simplicity and ease of description, embodiments provided herein will be further described with reference to ashrinkable film 103 and apaperboard substrate 105. When thesubstrate 105 is a paperboard substrate, thepaperboard blank 100 may be formed into a paper product, such as a bowl, plate, container, tray, platter, deep dish container, fluted product, or cup. The terms "paper product," "paper containers," "paperboard products," and "paperboard containers" are intended to be interchangeable. For simplicity and ease of description, embodiments provided herein will be further described with reference to a paper cup. - The
paperboard blank 100 may have a first or "top"edge 107, a second or "bottom"edge 109, a third or "left"edge 111, and a fourth or "right"edge 113. The particular shape of thepaperboard blank 100 may depend, at least in part, on the particular container to be made from thepaperboard blank 100. For example, the paperboard blank 100 depicted inFigure 1 has arcuate first andsecond edges fourth edges second edges fourth edges - The adhesive 115 may be disposed between the
shrinkable film 103 and thepaperboard substrate 105. For example, theshrinkable film 103 may be secured to thepaperboard substrate 105 with the adhesive 115 about at least a portion of an area or region along a perimeter, e.g., edges 107, 109, 111, and 113, of thepaperboard substrate 105. In at least one example, the adhesive 115 may be applied about or along thefirst edge 107, thesecond edge 109, thethird edge 111, and thefourth edge 113 to form a band of adhesive 115 about the perimeter of the paperboard substrate. As used herein, the term "band" refers to a generally thin and generally flat strip of material, e.g., a generally thin and a generally flat strip of the adhesive 115. - The adhesive 115 along the
first edge 107 may extend from thethird edge 111 to thefourth edge 113 and toward thesecond edge 109 to form afirst portion 116 of the band of adhesive 115. The adhesive 115 along thesecond edge 109 may extend from thethird edge 111 to thefourth edge 113 and toward thefirst edge 107 to form asecond portion 117 of the band of adhesive 115. The adhesive 115 along thethird edge 111 may extend from thefirst portion 116 of the band of adhesive 115 to thesecond portion 117 of the band of adhesive 115 and toward thefourth edge 113 to form athird portion 118 of the band of adhesive 115. The adhesive 115 along thefourth edge 113 may extend from thefirst portion 116 of the band of adhesive 115 to thesecond portion 117 of the band of adhesive 115 and toward thethird edge 111 to form afourth portion 119 of the band of adhesive 115. Accordingly, thefirst portion 116, thesecond portion 117, thethird portion 118, and thefourth portion 119 may form a continuous band of adhesive 115 about the perimeter of thepaperboard substrate 105. - The
first portion 116, thesecond portion 117, thethird portion 118, and thefourth portion 119 of the band of adhesive 115 may surround or at least partially surround a first region orarea 120 that may be free or substantially free from the adhesive 115. The adhesive 115 along thethird edge 111, e.g., thethird portion 118 of the band of adhesive 115, may include a second region orarea 122 between thefirst edge 107 and thesecond edge 109 that may be free or substantially free from any adhesive 115. Thesecond area 122 may be located within thethird portion 118 of the band of adhesive 115 (as shown inFigures 1 and 2 ) or adjacent to thethird portion 118 of the band of adhesive 115 (not shown). It should be noted that thefirst portion 116, thesecond portion 117, and/or thefourth portion 119 of the band of adhesive 115 may include one or more interior areas similar to thesecond area 122 that may be located within and/or adjacent to thefirst portion 116, thesecond portion 117, and/or thefourth portion 119 of the band of adhesive 115. - The
second area 122 may have a length that extends from thefirst portion 116 of the band of adhesive 115 to thesecond portion 117 of the band of adhesive 115. As such, thefirst portion 116, thesecond portion 117, and thethird portion 118 of the band of adhesive 115 may form or otherwise provide a continuous layer or band of the adhesive 115 that extends from thefirst edge 107 to thesecond edge 109 that includes thesecond area 122 disposed therein. In one or more embodiments, thesecond area 122 may extend for a distance that is less than the distance between thefirst portion 116 of the band of adhesive 115 and thesecond portion 117 of the band of adhesive 115. For example, the length of thesecond area 122 may range from a low of about 50%, about 55%, or about 60% to a high of about 90%, about 95%, or about 99% of the distance between thefirst portion 116 of the band of adhesive 115 and thesecond portion 117 of the band of adhesive 115. In one or more embodiments, thesecond area 122 may extend from thefirst edge 107 to thesecond portion 117 of the band of adhesive 115, from thesecond edge 109 to thefirst portion 116 of the band of adhesive 115, or from thefirst edge 107 to thesecond edge 109. - In one or more embodiments, the width of the
second area 122 may range from a low of about 0.5 mm, about 1 mm, about 2 mm, or about 3 mm to a high of about 5 mm, about 8 mm, about 10 mm, or about 12 mm or more. In one or more embodiments, the side of thesecond area 122 adjacent or proximate to thethird edge 111 may be located from the third edge 111 a distance ranging from a low of about 0.5 mm, about 1 mm, or about 2 mm to about 3 mm, about 4 mm, about 6 mm, about 8 mm, or about 10 mm or more. The side of thesecond area 122 closest to thefourth edge 113 may be located from the third edge 111 a distance ranging from a low of about 1 mm, about 3 mm, or about 5 mm to a high of about 7 mm, about 9 mm, about 11 mm, about 13 mm, or about 15 mm or more. The width of thethird portion 118 of the band of adhesive 115 located between thesecond area 122 and thefirst area 120 may range from a low of about 1 mm, about 2 mm, or about 3 mm to a high of about 5 mm, about 7 mm, about 9 mm, about 11 mm, about 13 mm, or about 15 mm or more. - As noted above, the
second area 122 may be located within or adjacent thefourth portion 119 of the band of adhesive 115 rather than, or in addition to, being located within thethird portion 118 of the band of adhesive 115. If thesecond area 122 is located within thefourth portion 119, thesecond area 122 may have the same dimensions as those discussed and described for thesecond area 122 located within thethird portion 118 of the band of adhesive 115. Similarly, if thesecond area 122 is located within thefourth portion 119, thesecond area 122 may be located within thefourth portion 119 of the band of adhesive 115 relative to thefourth edge 113 in the same manner as discussed and described for thesecond area 122 located within thethird portion 118 of the band of adhesive 115. - The first interior or first
inner region 120 between theshrinkable film 103 and thepaperboard substrate 105, similar to the second interior or secondinner region 122, may be free or substantially free from the adhesive 115 such that theshrinkable film 103 may be free to move away from thepaperboard substrate 105 as theshrinkable film 103 shrinks. When thepaperboard blank 100 has been formed into a container and theshrinkable film 103 shrinks, a gap may be formed between thefilm 103 and thepaperboard substrate 105 as discussed and described in further detail below with reference toFigure 6 . - As shown in
Figure 1 , the adhesive 115 may be disposed between theshrinkable film 103 and thepaperboard substrate 105 along the perimeter of thepaperboard blank 100. The width of the band of adhesive 115 or "glue line" disposed between theshrinkable film 103 and thepaperboard substrate 105 and along thefirst edge 107, thesecond edge 109, thethird edge 111, and thefourth edge 113 may range from a low of about 1 mm, about 2 mm, or about 3 mm to a high of about 5 mm, about 10 mm, about 20 mm, or about 30 mm or more. - The width of the band of adhesive 115 or glue line along each
edge paperboard substrate 105 may be the same or different with respect to one another. Said another way, the width of thefirst portion 116, the width of thesecond portion 117, the width of thethird portion 118, and the width of thefourth portion 119 of the band of adhesive 115 may be the same or different with respect to one another. For example, the width of the band of adhesive 115 along thefirst edge 107 may be less than the width of the band of adhesive 115 along thesecond edge 109, less than the width of the band of adhesive 115 along thethird edge 111, and/or less than the width of the band of adhesive 115 along thefourth edge 113. In another example, the width of the band of adhesive 115 along thethird edge 111 may be less than the width of the band of adhesive 115 along thefirst edge 107, less than the width of the band of adhesive 115 along thesecond edge 109 and/or less than the width of the band of adhesive 115 along thefourth edge 113. In another example, the width of the band of adhesive 115 along thefourth edge 113 may be less than the width of the band of adhesive 115 along thefirst edge 107, less than the width of the band of adhesive 115 along thesecond edge 109 and/or less than the width of the band of adhesive 115 along thethird edge 111. In another example, the width of the band of adhesive 115 along thefirst edge 107 may be less than the width of the band of adhesive 115 along thethird edge 111, which may be less than the width of the band of adhesive 115 along thefourth edge 113, which may be less than the width of the band of adhesive 115 along thesecond edge 109. - In one or more embodiments, the first layer or
shrinkable film 103 may shrink when subjected to one or more predetermined triggers or conditions. For example, theshrinkable film 103 may be a heat shrinkable film, i.e., a film that shrinks when heated to a sufficient temperature. For example, theshrinkable film 103 may shrink when heated to a temperature of about 40°C or more, about 80°C or more, about 90°C, about 100°C or more. In at least one example, thefilm 103 may shrink when exposed to a hot liquid. In at least one other example, thefilm 103 may shrink when heated in an oven, by contact with a flow of heated gas, or other heating means. In at least one other example, thefilm 103 may shrink when exposed to infrared light, microwaves, or a combination thereof. - The shrink force exerted by the
shrinkable film 103 during and after shrinking may pull or otherwise exert a force on thepaperboard substrate 105. The adhesive 115 may have a tack or bond strength sufficient to maintain theshrinkable film 103 secured to thepaperboard substrate 105. In one or more embodiments, the adhesive 115 may have a tack or bond sufficient to maintain theshrinkable film 103 secured to thepaperboard substrate 105 along thefirst portion 116, thesecond portion 117, and thefourth portion 119 of the band of adhesive 115, but may permit theshrinkable film 103 secured to thethird portion 118 of the band of adhesive 115 between thethird edge 111 and thesecond area 122 to pull up while maintaining theshrinkable film 103 secured to thepaperboard substrate 105 via thethird portion 118 of the band of adhesive 115 between thesecond area 122 and thefirst area 120. The portion of theshrinkable film 103 secured to thethird portion 118 of the band of adhesive 115 between thethird edge 111 and thesecond area 122 may pull cleanly away from thepaperboard substrate 105 and/or may physically separate or tear fibers away from thepaperboard substrate 105 when theshrinkable film 103 shrinks. - It has been surprisingly and unexpectedly discovered that applying the adhesive 115 along the
third edge 111 in a configuration or pattern that forms or provides thesecond area 122 located at, adjacent, or proximate thethird edge 111 may significantly reduce or prevent the physical separation or tearing of fibers away from the paperboard substrate when theshrinkable film 103 shrinks. The presence of thesecond area 122 may permit the portion of theshrinkable film 103 secured to the adhesive 115 located between thethird edge 111 and thesecond area 122, if any, to pull away from or otherwise become unsecured to thepaperboard substrate 105, while the remaining portion of theshrinkable film 103 secured to thepaperboard substrate 103 between thesecond area 122 and thefirst area 120 may remain secured to thepaperboard substrate 103. - The adhesive 115 may be applied onto the
shrinkable film 103 and/or thepaperboard substrate 105 to provide thesecond area 122 and thefirst area 120 that may be free or substantially free of any adhesive 115 using any suitable method or combination of methods known in the art. For example, the adhesive 115 may be applied to thepaperboard substrate 105 via spraying, brushing, flexographic printing, rotogravure printing, offset printing, screen printing, or any other suitable coating method. Suitable methods for applying the adhesive 115 to theshrinkable film 103 and/or thepaperboard substrate 105 may also include those discussed and described inU.S. Patent Nos.: 6,536,657 ;6,729,534 ;7,464,856 ;7,614,993 ;7,600,669 ;7,464,857 ;7,913,873 ;7,938,313 ;7,513,386 ;7,510,098 ;7,841,974 ;8,622,232 andU.S. Patent Application Publication Nos. 2011/0031305 ;2012/0312869 ; and2013/0341387 . - The adhesive 115 may be a single or one part adhesive or glue. As used herein, the terms "single part" and "one part," when used in conjunction with "adhesive" or "glue," refer to an adhesive or an adhesive system that does not require the addition of a hardener, catalyst, accelerant, or other cure component or agent required to make the adhesive curable. Said another way, the adhesive 115 may include two or more different components, but the adhesive may be of a type that does not require adding a second component to the adhesive to form a curable adhesive. As such, the adhesive 115 may be storage stable for weeks, months, or even years and upon application of the adhesive 115 to the first or second layer, the adhesive 115 may be cured without the need for a hardener, catalyst, accelerator, or other cure agent.
- The adhesive 115 may be or include a polyethylene vinyl acetate resin, or any other suitable adhesive or mixture of adhesives. The adhesive 115 may include one or more additives. Illustrative additives may include, but are not limited to, one or more tackifiers. Suitable tackifiers may include, but are not limited to, ethyl p-toluene sulfonamide. In one or more embodiments, the amount of the additive, e.g., the tackifier, if present, may range from a low of about 1 wt%, about 3 wt%, or about 5 wt% to a high of about 10 wt%, about 12 wt%, or about 15 wt%, based on the total weight of the adhesive.
- Commercially available adhesives suitable for use as the adhesive 115 discussed and described above and elsewhere herein may include, but are not limited to, AQUENCE® FB 9192 VELOCITY® and AQUENCE® FB 9080 VELOCITY®, both available from Henkel Corporation. It is believed that the AQUENCE® FB 9192 VELOCITY® and AQUENCE® FB 9080 VELOCITY® adhesives are both polyethylene vinyl acetate resins, with the AQUENCE® FB 9192 VELOCITY® including the addition of ethyl p-toluene sulfonamide (tackifier) in an amount of about 5 wt% to about 10 wt%, based on the total weight of the adhesive.
- In one or more embodiments, the peel strength required to separate the
shrinkable film 103 from thepaperboard substrate 105 when secured thereto with the adhesive 115 may be less than about 340 g/2.54 cm, less than about 280 g/2.54 cm, or less than about 220 g/2.54 cm at a temperature of about 23°C. For example, the peel strength required to separate theshrinkable film 103 from thepaperboard substrate 105 when secured thereto with the adhesive 115 may range from a low of about 100 g/2.54 cm, about 150 g/2.54 cm, about 200 g/2.54 cm, about 215 g/2.54 cm, or about 235 g/2.54 cm to a high of about 255 g/2.54 cm, about 270 g/2.54 cm, or about 285 g/2.54 cm at a temperature of about 23°C. - The peel strength may be measured according to the following procedure. The
shrinkable film 103 and thepaperboard substrate 105 may be secured to one another with the adhesive 115 and a 1 inch wide sample may be cut therefrom. Theshrinkable film 103 and thepaperboard substrate 105 at the end of a sample (not adhered to one another with the adhesive or separated from one another if adhered) may be secured in opposing clamps and pulled apart from one another at an angle of 180°, at a rate of 1 inch per minute, while at a temperature of 23°C. An Instron tensile tester Model 5943 may be used to measure the force with a frequency of 25 data points per second throughout the peel. The average value of the force measured is the peel strength required to separate theshrinkable film 103 from thepaperboard substrate 105 when secured thereto with the adhesive 115. - The pattern or configuration of the adhesive 115 discussed and described herein may be used to form
blanks 100 suitable for making a paperboard product in which theshrinkable film 103 has a reduced amount of peel back along thethird edge 111 from thepaperboard substrate 105 when theshrinkable film 103 shrinks as compared to a comparative blank that is the same except thesecond area 122 is absent. More particularly, theshrinkable film 103 of the comparative blank will exhibit a significantly greater amount of peel back from thepaperboard substrate 105 as compared to the amount of peel back theshrinkable film 103 secured to thepaperboard substrate 105 with thesecond area 122 free or substantially free from the adhesive 115. - The
shrinkable film 103 may be uniaxially or biaxially oriented. In at least one specific example, theshrinkable film 103 may be a biaxially oriented, heat shrinkable polymeric film. In at least one specific example, theshrinkable film 103 may be a uniaxially oriented, heat shrinkable polymeric film. Theshrinkable film 103 may be a mono-layer film or a multi-layer film. Amultilayer film 103 may have 2, 3, 4, 5, 6, 7, 8, or more layers. Thefilm 103 may include a core layer or intermediate layer, and one or more outer layers or skin layers such as a first outer layer and a second outer layer. Thefilm 103 may include a core layer or intermediate layer one or more tie layers, and one or more outer layers. For example, thefilm 103 may include a core layer, a first tie layer and a second tie layer disposed on opposing sides of the core layer, a first outer layer disposed on the first tie layer, and a second outer layer disposed on the second tie layer. - Orientation in the direction of extrusion is known as the machine direction (MD) orientation. Orientation perpendicular to the direction of extrusion is known as the transverse direction (TD) orientation. Orientation may be accomplished by stretching or pulling a film first in the MD followed by the TD orientation. Blown films or cast films may also be oriented by a tenter-frame orientation subsequent to the film extrusion process, again in one or both directions. Orientation may be sequential or simultaneous, depending upon the desired film features. Typical commercial orientation processes may include the biaxially oriented polypropylene (BOPP) tenter process, the blown film process, and the linear motor simultaneous stretching (LISIM) process.
- The
shrinkable film 103 may be or include a polyolefin film. For example, theshrinkable film 103 may be or include a polyethylene film, a polypropylene film, a polyethylene terephthalate film, a cellophane film, a polyamide film, or any combination thereof. In another example, theshrinkable film 103 may be or include a butylene polymer, ethylene polymer, high density polyethylene (HDPE) polymer, medium density polyethylene (MDPE) polymer, low density polyethylene (LDPE) polymer, linear low density polyethylene (LLDPE), propylene (PP) polymer, isotactic polypropylene (iPP) polymer, high crystallinity polypropylene (HCPP) polymer, ethylene-propylene (EP) copolymers, ethylene-propylene-butylene (EPB) terpolymers, propylene-butylene (PB) copolymer, an ethylene elastomer, ethylene-based plastomer, propylene elastomer and combinations or blends thereof. In another example, theshrinkable film 103 may be or include polyethylene, polypropylene, polyvinylchloride (PVC), polymethylpentene, polybutene-1, polyolefin elastomers, polyisobutylene, ethylene propylene rubber, or any mixture or combination thereof. - The polyolefin film may also include one or more additives. Illustrative additives may include, but are not limited to, tackifiers, waxes, functionalized polymers such as acid modified polyolefins and/or anhydride modified polyolefins, antioxidants, oils, compatabilizers, fillers, adjuvants, adhesion promoters, plasticizers, low molecular weight polymers, blocking agents, antiblocking agents, anti-static agents, release agents, anti-cling additives, colorants, dyes, pigments, processing aids, UV stabilizers, heat stabilizers, neutralizers, lubricants, surfactants, nucleating agents, flexibilizers, rubbers, optical brighteners, colorants, diluents, viscosity modifiers, oxidized polyolefins, and any combination or mixture thereof. Commercially available films that may be used as the
shrinkable film 103 may include, but are not limited to, CLYSAR® HPG (HP Gold), CLYSAR® LLGT, CLYSAR® VEZT, CLYSAR® LLG, CLYSAR® ABL, available from Clysar, Clinton, Iowa. - The total thickness of the resulting monolayer and/or
multilayer shrinkable film 103 may vary. For example, a total film thickness of about 5 µm to about 50 µm or about 10 µm to about 30 µm may be suitable for most paperboard containers. In another example, theshrinkable film 103 may have a thickness from a low of about 5 µm, about 10 µm, or about 15 µm to a high of about 20 µm, about 25 µm, about 30 µm, or about 35 µm. In one or more embodiments, the thickness of theshrinkable film 103 may be sufficient to reduce or prevent theshrinkable film 103 from breaking, tearing, ripping, or otherwise forming holes therethrough. - In one or more embodiments, a surface area of the
shrinkable film 103 may shrink or reduce from an original or starting surface area to a second or final surface area in an amount of about 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about 55%, or about 60% based on the original or starting surface area. For example, the surface area of theshrinkable film 103 may shrink or reduce from an original or starting surface area to a second or final surface area in an amount of about 10% to about 30%, about 15% to about 30%, about 8% to about 20%, about 15% to about 35%, about 12% to about 33%, about 25% to about 35%, or about 10% to about 40%. In another example, a heat shrink film having a surface area of about 100 cm2 may be reduced to about 95 cm2, about 90 cm2, about 85 cm2, about 80 cm2, about 75 cm2, about 70 cm2, about 65 cm2, about 60 cm2, about 55 cm2, about 50 cm2, about 45 cm2, or about 40 cm2 when subjected to a temperature of about 40°C to about 100°C. In at least one specific example, the surface area of theshrinkable film 103 may shrink in an amount of about 30% to about 45%, about 35% to about 50%, about 35% to about 45%, about 40% to about 50%, about 45% to about 55%, about 50% to about 60%, or about 40% to about 60% when heated to a temperature of about 102°C for a time of 10 minutes. The shrinkage of theshrinkable film 103 may be measured according to ASTM D1204. - The
second layer 105 may be or include any paperboard material capable of forming a desired paper container. It should be noted that thesecond layer 105 may be or include non-paperboard or non-paper based materials such as one or more polymers, e.g., polyolefins, and/or metals, e.g., aluminum. In one or more embodiments, paperboard materials suitable for use as the second layer orsubstrate 105 may have a basis weight ranging from a low of about 163 grams, about 210 grams, or about 275 grams to a high of about 325 grams, about 400 grams, or about 500 grams per square meter of paperboard substrate. In one or more embodiments, the paperboard material may have a thickness ranging from a low of about 175 µm, about 225 µm, or about 250 µm to a high of about 350 µm, 450 µm, about 600 µm, about 750 µm, or about 1,000 µm. - If the
second layer 105 is or includes paperboard, the paperboard may be uncoated or coated with one or more additional materials. For example, the paperboard may be uncoated, e.g., free or substantially free from wax, clay, polyethylene, and other coating material. In another example, a suitable paperboard may be or include paperboard coated with one or more waxes, one or more clays, and/or one or more polyolefins on one or both sides. A paperboard may be coated with polyethylene, for example, using any suitable process. In one example, a polyethylene coating may be applied to the paperboard via an extrusion process. Polyethylene and/or other polymeric materials may be coated onto the paperboard to provide liquid resistance properties and/or serve as a heat sealable coating. A paperboard may be at least partially coated with one or more additional materials on one side or both sides thereof. Suitable polymeric materials that may be used to coat the paperboard may include, but are not limited to, polyethylene, polypropylene, polyester, or any combination thereof. If the paperboard is coated with a material, e.g., wax or polymeric material, the coating may have a thickness ranging from a low of about 0.002 mm, about 0.01 mm, or about 0.1 mm to a high of about 0.15 mm, about 0.2 mm, or about 0.35 mm. - Commercially available paperboard material that may be used as the
second layer 105 may include, but is not limited to, solid bleached sulfate (SBS) cupstock, bleached virgin board, unbleached virgin board, recycled bleached board, recycled unbleached board, or any combination thereof. For example, SBS cupstock available from Georgia-Pacific LLC may be used as thesecond layer 105. - In one or more embodiments, at least a portion of the surface(s) of the
shrinkable film 103 and/or thesecond layer 105, e.g., a paperboard substrate, may be oxidized via corona treatment and/or flame discharge treatment. Oxidizing the surface of theshrinkable film 103 and/or thesecond layer 105 may increase or raise the surface energy of the treated surface. In one or more embodiments, theshrinkable film 103 may have a surface energy, treated or untreated, greater than about 30 dyne/cm, greater than about 35 dyne/cm, greater than about 38 dyne/cm, greater than about 40 dyne/cm, greater than about 42 dyne/cm, greater than about 44 dyne/cm, or greater than about 46 dyne/cm. In at least one embodiment, the surface of theshrinkable film 103 that contacts the adhesive 115, the surface of thesecond layer 105 that contacts the adhesive 115, and/or the surface of thesecond layer 105 that may be coated with ink may be subjected to corona and/or flame treatment. - The method for securing the
shrinkable film 103 to the paperboard substrate orsecond layer 105 may include applying the adhesive 115 to theshrinkable film 103 and/or thesecond layer 105. Theshrinkable film 103 and thesecond layer 105 may be contacted with one another such that the adhesive 115 may at least partially secure theshrinkable film 103 to thesecond layer 105. In one or more embodiments, the amount of adhesive 115 applied to theshrinkable film 103 and/or thesecond layer 105 may range from a low of about 0.04 kg, about 0.1 kg, about 0.5 kg, or about 1.3 kg to a high of about 2 kg, about 3.5 kg, or about 5.5 kg of adhesive 115 per 279 square meters of theshrinkable film 103 orsecond layer 105. Multiple coatings of the adhesive 115 may be applied to achieve the aforementioned amounts. - The
paperboard blank 100 may be formed as part of a paperboard roll (not shown) that includes a plurality ofpaperboard blanks 100 formed therein. Thepaperboard blank 100 may be cut from the paperboard roll. A paperboard roll may be formed that includes any suitable number of paperboard blanks formed therein. -
Figure 3 depicts a schematic view of another illustrative paperboard blank 300 for making a cup, according to one or more embodiments, andFigure 4 depicts a schematic cross-sectional view of the paperboard blank 300 depicted inFigure 3 along lines 4-4. Referring toFigures 3 and 4 , thepaperboard blank 300 may include a first layer orfilm 303 and a second layer orsubstrate 305. Thefilm 303 and thesubstrate 305 may be secured to one another using any suitable method. For example, thefilm 303 and thesubstrate 305 may be at least partially bonded, coupled, affixed, joined, fastened, attached, connected, or otherwise secured to one another with an adhesive 315. In another example, thefilm 103 and thesubstrate 305 may be at least partially bonded, coupled, affixed, joined, fastened, attached, connected, or otherwise secured to one another via ultrasonic bonding. In one or more embodiments, thefilm 303 may be a shrinkable film and thesubstrate 305 may be a paperboard substrate. The first layer orfilm 303, the second layer orsubstrate 305, and the adhesive 315 may be the same or similar to the first layer orfilm 103, the second layer orsubstrate 105, and the adhesive 115 discussed and described above with reference toFigures 1 and 2 . - The
paperboard blank 300 may have a first or "top"edge 307, a second or "bottom"edge 309, a third or "left"edge 311, and a fourth or "right"edge 313. The particular shape of thepaperboard blank 300 may depend, at least in part, on the particular container to be made from thepaperboard blank 300. For example, the paperboard blank 300 depicted inFigure 3 has arcuate first andsecond edges fourth edges second edges fourth edges - The adhesive 315 may be disposed between the
shrinkable film 303 and thepaperboard substrate 305. For example, theshrinkable film 303 may be secured to thepaperboard substrate 305 with the adhesive 315 about at least a portion of an area or region about a perimeter, e.g., at or adjacent to theedges paperboard substrate 305. In at least one example, the adhesive 315 may be applied about thefirst edge 307, thesecond edge 309, thethird edge 311, and the fourth edge 314 to form a band of adhesive 315 about the perimeter of thepaperboard substrate 305. The adhesive 315 may surround or at least partially surround afirst area 320 that may be free or substantially free from the adhesive 315. - As shown in
Figure 3 , the adhesive 315 along thefirst edge 307, thesecond edge 309, and thefourth edge 313 may be at the outer edge or perimeter of thepaperboard substrate 305, and the adhesive 315 along thethird edge 311 may be set back from, e.g., near but not at, thethird edge 311. As such, a second region orarea 322 between thethird edge 311 and the band of adhesive 315 along thethird edge 311 may be free or substantially free from any adhesive. Although not shown, any one or more of thefirst portion 316, thesecond portion 317, and thefourth portion 319 of the band of adhesive 315 may also be set back from, e.g., near but not at, thefirst edge 307, thesecond edge 309, and thefourth edge 313, respectively. - As shown in
Figure 3 , the adhesive 315 along thefirst edge 307 may extend from thesecond area 322 along thethird edge 311 that may be free or substantially free from the adhesive 315 to thefourth edge 313 and toward thesecond edge 309 to form afirst portion 316 of the band of adhesive 315. The adhesive 315 along thesecond edge 309 may extend from thesecond area 322 along thethird edge 311 that may be free or substantially free from the adhesive 315 to thefourth edge 313 and toward thefirst edge 307 to form asecond portion 317 of the band of adhesive 315. The adhesive 315 along thethird edge 311 may extend from thefirst portion 316 of the band of adhesive 315 to thesecond portion 317 of the band of adhesive 315 and from thesecond area 322 toward thefourth edge 313 to form athird portion 318 of the band of adhesive 315. The adhesive 315 along thefourth edge 313 may extend from thefirst portion 316 of the band of adhesive 315 to thesecond portion 317 of the band of adhesive 315 and from thefourth edge 313 toward thethird edge 311 to form afourth portion 319 of the band of adhesive 315. Accordingly, thefirst portion 316, thesecond portion 317, thethird portion 318, and thefourth portion 319 of the band of adhesive 315 may form a continuous band of adhesive 315 along or about the perimeter of thepaperboard substrate 305. Although not shown, it should be appreciated that the band of adhesive 315 does not have to be a continuous band, but may include one or more breaks or discontinuities in the adhesive. As such, thefirst portion 316, thesecond portion 317, thethird portion 318, and thefourth portion 319 of the band of adhesive 315 may surround or at least partially surround thefirst area 320 that may be free or substantially free from the adhesive 315. - In one or more embodiments, the width of the
area 322, i.e., a distance from theedge 311 to thethird portion 318 of the band of adhesive 315, may range from a low of about 0.5 mm, about 1 mm, about 2 mm, or about 3 mm to a high of about 5 mm, about 8 mm, about 10 mm, or about 12 mm or more. In one or more embodiments, the width of thethird portion 318 of the band of adhesive 318 located between thefirst area 320 and thesecond area 322 may range from a low of about 1 mm, about 2 mm, or about 3 mm to a high of about 5 mm, about 7 mm, about 9 mm, about 11 mm, about 13 mm, or about 15 mm or more. - In one or more embodiments, the
second area 322 may be set back from, e.g., near but not at, thefourth edge 313 rather than, or in addition to, being set back from thethird edge 311. If thesecond area 322 is located along thefourth edge 313, thesecond area 322 may have the same dimensions as those discussed and described for thesecond area 322 located along thethird edge 311. - The
first area 320 between theshrinkable film 303 and thepaperboard substrate 305, may be free to move away from thepaperboard substrate 305 as theshrinkable film 303 shrinks. For example, if thepaperboard blank 300 has been formed into a container and theshrinkable film 303 shrinks a gap may be formed between thefilm 303 and thepaperboard substrate 305 as discussed and described in further detail below with reference toFigure 6 . - As shown in
Figure 3 , the adhesive 315 may be disposed between theshrinkable film 303 and thepaperboard substrate 305 along thefirst edge 307, thesecond edge 309, and thefourth edge 313 and along thethird edge 311, but set back from thethird edge 311 to provide thesecond area 322 between thethird edge 311 and the adhesive 315. As shown inFigure 4 , theshrinkable film 303 may extend to theedge 311 of thepaperboard substrate 305. One skilled in the art, however, will appreciate that theshrinkable film 303 may stop or terminate at the edge of thethird portion 318 of the band of adhesive 315. One skilled in the art will also appreciate that theshrinkable film 303 may stop or terminate between the edge of thepaperboard substrate 305 and the edge of thethird portion 318 of the band of adhesive 315. - In one or more embodiments, the width of the band of adhesive 315 or "glue line" disposed between the
shrinkable film 303 and thepaperboard substrate 305 and along thefirst edge 307, thesecond edge 309, and thefourth edge 313 and along, but set back from thethird edge 311 may range from a low of about 1 mm, about 2 mm, or about 3 mm to a high of about 5 mm, about 10 mm, about 20 mm, or about 30 mm or more. - In one or more embodiments, the width of the band of adhesive 315 or glue line along each
edge paperboard substrate 305 may be the same or different with respect to one another. Said another way, the width of thefirst portion 316, the width of thesecond portion 317, the width of thethird portion 318, and the width of thefourth portion 319 of the band of adhesive 315 may be the same or different with respect to one another. For example, the width of the band of adhesive 315 along thefirst edge 307 may be less than the width of the band of adhesive 315 along thesecond edge 309, less than the width of the band of adhesive 315 along thethird edge 311, and/or less than the width of the band of adhesive 315 along thefourth edge 313. In another example, the width of the band of adhesive 315 along thethird edge 311 may be less than the width of the band of adhesive 315 along thefirst edge 307, less than the width of the band of adhesive 315 along thesecond edge 309 and/or less than the width of the band of adhesive 315 along thefourth edge 313. In another example, the width of the band of adhesive 315 along thefourth edge 313 may be less than the width of the band of adhesive 315 along thefirst edge 307, less than the width of the band of adhesive 315 along thesecond edge 309 and/or less than the width of the band of adhesive 315 along thethird edge 311. In another example, the width of the band of adhesive 315 along thefirst edge 307 may be less than the width of the band of adhesive 315 along thethird edge 311, which may be less than the width of the band of adhesive 315 along thefourth edge 313, which may be less than the width of the band of adhesive 315 along thesecond edge 309. - The
shrinkable film 303 may shrink when subjected to one or more predetermined triggers or conditions, the same as or similar to theshrinkable film 103 discussed and described above with reference toFigures 1 and 2 . The shrink force exerted by theshrinkable film 303 during and after shrinking may pull or otherwise exert a force on thepaperboard substrate 305 and the adhesive 315 may have a tack or bond strength sufficient to maintain theshrinkable film 303 secured to thepaperboard substrate 305, as discussed and described above with reference toFigures 1 and 2 . - It has been surprisingly and unexpectedly discovered that applying the adhesive 315 along the
third edge 311 in a configuration or pattern that forms or provides thesecond area 322 located betweenthird edge 311 and thethird portion 318 of the band of adhesive 315 may significantly reduce or prevent the tendency for theshrinkable film 303 to peel back from thepaperboard substrate 305 when theshrinkable film 303 shrinks. - The adhesive 315 may be applied onto the
shrinkable film 303 and/or thepaperboard substrate 305 to provide thesecond area 322 and thefirst area 320 that may be free or substantially free from any adhesive 315 using any suitable method or combination of methods known in the art. For example, the adhesive 315 may be applied to thepaperboard substrate 305 via spraying, brushing, flexographic printing, rotogravure printing, offset printing, screen printing, or any other suitable coating method. Suitable methods for applying the adhesive 315 to theshrinkable film 303 and/or thepaperboard substrate 305 may also include those discussed and described inU.S. Patent Nos.: 6,536,657 ;6,729,534 ;7,464,856 ;7,614,993 ;7,600,669 ;7,464,857 ;7,913,873 ;7,938,313 ;7,513,386 ;7,510,098 ;7,841,974 ;8,622,232 andU.S. Patent Application Publication Nos.: 2011/0031305 ;2012/0312869 ; and2013/0341387 . -
Figure 5 depicts a partial cut away perspective view of apaper cup 500, according to one or more embodiments. The paperboard blank 100 (shown) or 300 (not shown) may be formed, e.g., rolled, folded, bent, curled, or otherwise configured to form a frusto-conical sidewall 505. For example, the third andfourth edges conical sidewall 505 having aseam 510. Theshrinkable film 103 may form or provide at least a portion of an inner surface of the frusto-conical sidewall 505 and thepaperboard substrate 105 may form or provide at least a portion of the outer surface of thesidewall 505. As shown inFigure 5 , theshrinkable film 103 has not been shrunk to provide a shrunkfilm 103. - The
sidewall 505 may be formed by rolling, curling, folding, bending, or otherwise placing the third andfourth edges Figure 1 in contact with one another to form theseam 510. For example, thepaperboard blank 100 may be formed around a mandrel to form theseam 510. As such, thefirst edge 107 may form a first or "top" edge of thesidewall 505 and thesecond edge 109 may form a second or "bottom" edge of thesidewall 505. If thepaperboard substrate 105 is coated with a polymeric material, e.g., polyethylene, thesidewall 505 may be heat sealed or ultrasonically welded to provide a sealedseam 510. Theseam 510 may also be sealed with one or more adhesives, e.g., the adhesive 115 or any other adhesive suitable for sealing the third andfourth edges shrinkable film 103 to thepaperboard substrate 105 along the third andfourth edges seam 510. - The
first edge 107 may be rolled, folded, curled, bent, or otherwise configured to form a brim or "brim curl" 515, which becomes an edge or "top" edge of thesidewall 505. More particularly, to form the brim curl, theedge 107 of thepaperboard blank 100 may be rolled, urged, or curled such that the outer or distal end of the edge turns and contacts thepaperboard substrate 105 and maintains this position. The brim curl may traverse the perimeter or circumference or only a portion thereof of a first or "top" edge of the paperboard product. - The
second edge 109 of thepaperboard blank 100 may form a second or "bottom" edge of thesidewall 505. Abottom panel 520 of thepaper cup 500 may be disposed on or otherwise secured to thesidewall 505, e.g., proximate or adjacent the second edge of the sidewall, such that thesidewall 505 and thebottom panel 520 define acontainer volume 530. Thebottom panel 520 may be coupled, affixed, joined, fastened, attached, connected, or otherwise secured to thesidewall 505 with the adhesive 115, another adhesive, and/or via other means such as by heat sealing. For example, similar to thepaperboard substrate 105, thebottom panel 520 may be coated in a polymeric material capable of forming a seal between the polymeric material, if present, on the paperboard substrate. In one or more embodiments, thesecond edge 109 may be folded inward and may overlap a rim or one or more tabs extending downward form thebottom panel 520. - The outer and/or inner surface of the
sidewall 505 may include one or more printed patterns that may be applied to thepaperboard substrate 105. "Printed patterns" and like terminology may refer to ink-printed patterns for aesthetics. Such features, however, may have a functional aspect such as indicating a fill line. - The
paper cup 500 may have anysuitable container volume 530. For example, thecontainer volume 530 may range from a low of about 20 mL, about 40 mL, about 60 mL, about 80 mL, or about 100 mL to a high of about 120 mL, about 200 mL, about 300 mL, about 400 mL, about 500 mL, about 750 mL, about 1,000 mL, about 1,300 mL, or about 1,500 mL or more. For example, thecontainer volume 530 may be from about 150 mL to about 500 mL, about 450 mL to about 1,000 mL, about 400 mL to about 900 mL, or about 800 mL to about 1,300 mL. -
Figure 6 depicts a cross-sectional elevation view of apaper cup 600 having a shrunkfilm 103 and agap 604 formed or located between the shrunkfilm 103 and thepaperboard substrate 105, according to one or more embodiments. Thepaper cup 600 may also include abrim curl 615 and abottom panel 620. As theshrinkable film 103 shrinks, thegap 604 may be formed between the non-secured portions of theshrinkable film 103 and thepaperboard substrate 105. Thegap 604 may provide an insulating property to thepaper cup 600. For example, a heated liquid having a temperature from a low of about 70°C, about 75°C, or about 80°C to a high of about 90°C, about 95°C, about 100°C, or about 110°C or more may be added to thepaper cup 600 to cause theshrinkable film 103 to shrink and form the insulatinggap 604. The formation or presence of thegap 604 may provide an outer surface of thepaper cup 600 that may be insulated from the hot liquid therein. The temperature of the outer surface of thepaper cup 600 may be less than about 70°C, less than about 65°C, less than about 60°C, less than about 55°C, less than about 50°C, less than about 45°C, less than about 40°C, or less than about 35°C, when a liquid at a temperature of 95°C to about 100°C is contained within thepaper cup 600. As such, a person may hold thepaper cup 600 containing the heated liquid therein about the outer surface of the container without being burned or otherwise experiencing an unsatisfactory level of discomfort due to the heated liquid within thepaper cup 600. - The time required for the
shrinkable film 103 to shrink or transition between an initial state to a shrunk state may vary based on one or more factors such as the area of the shrinkable film, the thickness of the shrinkable film, the temperature of the hot fluid placed into contact or otherwise in a heat exchanging relationship with theshrinkable film 103, an amount or flow rate of air or other fluid into a volume or space or "gap" formed between theshrinkable film 103 and thesecond layer 105 as theshrinkable film 103 shrinks, or combinations of these and/or other factors. As used herein, the term "initial state" refers to theshrinkable film 103 after being secured to thepaperboard substrate 105 and after thepaper cup 600 has been formed. It should be noted that theshrinkable film 103 may be annealed or otherwise treated or processed during manufacture of theshrinkable film 103 and annealing or otherwise treating theshrinkable film 103 may cause the shrinkable film to shrink some, but not shrink to a maximum amount theshrinkable film 103 is capable of being shrunk. - In one or more embodiments, the amount of time required for the
shrinkable film 103 to go from the initial state to the shrunk state may be about 10 seconds or less, about 9 seconds or less, about 8 seconds or less, about 7 seconds or less, about 6 seconds or less, about 5 seconds or less, about 4 seconds or less, about 3 seconds or less, about 2 seconds or less, about 1 second or less, or about 0.5 seconds or less per 100 mL ofcontainer volume 530, when a fluid at a temperature of about 70°C to about 100°C contacts theshrinkable film 103. For example, theshrinkable film 103 may transition from the initial state to the shrunk state in a time of about 0.5 seconds to 2 seconds per 100 mL ofcontainer volume 530, when a fluid at a temperature of about 80°C to about 100°C contacts theshrinkable film 103. For example, if the container volume is about 600 mL theshrinkable film 103 may transition from the initial state to the shrunk state in about 3 seconds to about 12 seconds when a fluid at a temperature of about 90°C contacts theshrinkable film 103. - As shown in
Figure 6 , the paperboard substrate 105 (shown) and/or the paperboard substrate 305 (not shown) may include one or more vents (two are shown 606) formed or defined therethrough. Thevent 606 may serve as a flow path for air or other gas to flow from a location exterior thepaperboard substrate 105 and into thegap 103. While theshrinkable film 103 may shrink without the presence of one ormore vents 606, the one ormore vents 606 may help theshrinkable film 103 shrink. As theshrinkable film 103 shrinks, a vacuum may be formed between thepaperboard substrate 105 and theshrinkable film 103. The presence of a vacuum may reduce and/or prevent theshrinkable film 103 from shrinking or fully shrinking. Having the one ormore vents 606 formed through the paperboard substrate may permit air or other fluid to flow into thegap 604 as theshrinkable film 103 shrinks. As such, the formation of the one ormore vents 606 through thepaperboard substrate 105 may provide a plurality of paper containers, e.g., thepaper cup 600, that haveshrinkable films 103 that shrink in a more consistent and reliable manner. Reliable and consistent shrinkage of theshrinkable film 103 may provide a more commercially desirable product for sale to consumers. - The
vent 606 may be cut through thepaperboard substrate 105 using a knife, punch, pin, or other rigid apparatus capable of puncturing thepaperboard substrate 105. Suitable shapes of the one ormore vents 606 may include, but are not limited to, U-shaped vents, large flaps, small flaps, slits, perforations, x-shaped cut-outs, round holes, or any other shape. If two ormore vents 606 are formed through thepaperboard substrate 105, the shape or configuration and/or size of the two ormore vents 606 may be the same or different with respect to one another. In one or more embodiments, thevents 606 may also be formed via burning. Suitable methods form forming thevents 606 via burning may include those discussed and described inU.S. Patent Application Publication No. 2012/0312869 . - As the
shrinkable film 103 shrinks, the amount of liquid the paperboard container may hold may be reduced. As shown inFigure 6 , thegap 604 occupies a space or volume within thepaper cup 600 that would not contain any liquid if liquid were present within theinternal volume 630. For example, thecontainer volume 630 may be reduced by about 35% or less, about 30% or less, about 25% or less, about 20% or less, about 15% or less about 10% or less, or about 5% or less with theshrinkable film 103 shrunk and the gap formed 604 as compared to thecontainer volume 630 before theshrinkable film 103 shrinks. Accordingly, thepaper cup 600 may be oversized in order to provide apaper cup 600 capable of containing a desired amount of a hot liquid. -
Figure 7 depicts a schematic view of another illustrative paperboard blank 700 for making a cup, according to one or more embodiments, andFigures 8 and 9 depict schematic cross-sectional views of the paperboard blank 700 depicted inFigure 7 along lines 8-8 and lines 9-9, respectively. Referring toFigures 7-9 , thepaperboard blank 700 may include a first layer orfilm 703 and a second layer orsubstrate 705. Thefilm 703 and thesubstrate 705 may be secured to one another using any suitable method. For example, thefilm 703 and thesubstrate 705 may be at least partially bonded, coupled, affixed, joined, fastened, attached, connected, or otherwise secured to one another with an adhesive 715. In another example, thefilm 703 and thesubstrate 705 may be at least partially bonded, coupled, affixed, joined, fastened, attached, connected, or otherwise secured to one another via ultrasonic bonding. In one or more embodiments, thefilm 703 may be a shrinkable film and thesubstrate 705 may be a paperboard substrate. The first layer orfilm 703, the second layer orsubstrate 705, and the adhesive 715 may be the same or similar to the first layers orfilms substrates adhesives Figures 1-4 . - The
paperboard blank 700 may have a first or "top"edge 707, a second or "bottom"edge 709, a third or "left"edge 711, and a fourth or "right"edge 713. The particular shape of thepaperboard blank 700 may depend, at least in part, on the particular container to be made from thepaperboard blank 700. For example, the paperboard blank 700 depicted inFigure 7 has arcuate first andsecond edges fourth edges second edges fourth edges - The adhesive 715 may be disposed between the
shrinkable film 703 and thepaperboard substrate 705. For example, theshrinkable film 703 may be secured to thepaperboard substrate 705 with the adhesive 715 about at least a portion of an area or region about a perimeter, e.g., at or adjacent to theedges paperboard substrate 705. In at least one example, the adhesive 715 may be applied about thefirst edge 707, thesecond edge 709, thethird edge 711, and the fourth edge 714 to form a band of adhesive 715 about the perimeter of thepaperboard substrate 705. The adhesive 715 may surround or at least partially surround afirst area 720 that may be free or substantially free from the adhesive 715. - The adhesive 715 along the
first edge 707 may extend from thethird edge 711 to thefourth edge 713 and toward thesecond edge 709 to form afirst portion 716 of the band of adhesive 715. The adhesive 715 along thesecond edge 709 may extend from thethird edge 711 to thefourth edge 713 and toward thefirst edge 707 to form asecond portion 717 of the band of adhesive 715. The adhesive 715 along thethird edge 711 may extend from thefirst portion 716 of the band of adhesive 715 to thesecond portion 717 of the band of adhesive 715 and toward thefourth edge 713 to form athird portion 718 of the band of adhesive 715. The adhesive 715 along thefourth edge 713 may extend from thefirst portion 716 of the band of adhesive 715 to thesecond portion 717 of the band of adhesive 715 and toward thethird edge 711 to form afourth portion 719 of the band of adhesive 715. Accordingly, thefirst portion 716, thesecond portion 717, thethird portion 718, and thefourth portion 719 may form a continuous band of adhesive 715 about the perimeter of thepaperboard substrate 705. - As shown in
Figure 7 , the adhesive 715 along thefirst edge 707, thesecond edge 709, and thefourth edge 713 may be at the outer edge or perimeter of thepaperboard substrate 705. A portion of the adhesive 715 along thethird edge 711 may be at the outer edge or perimeter of thethird edge 711 and a portion of the adhesive 715 along thethird edge 711 may be set back from, e.g., near but not at, a portion of thethird edge 711. The adhesive 715 along thethird edge 711, e.g., thethird portion 718 of the band of adhesive 715, may include a second region orarea 722 between thefirst edge 707 and thesecond edge 709 that may be free or substantially free from any adhesive 715. As shown inFigure 7 , a portion of thesecond area 722 may be located within thethird portion 718 of the band of adhesive 715 along thethird edge 711 at which the adhesive 715 is at the outer edge or perimeter and a portion of thesecond area 722 may extend from thethird edge 711 to the band of adhesive 715. Said another way, a portion of thesecond area 722 may extend from thethird edge 711 to thethird portion 718 of the band of adhesive 715 and a portion of thesecond area 722 may be located within thethird portion 718 of the band of adhesive 715 along thethird edge 711 of thepaperboard substrate 700 and between thefirst edge 707 and thesecond edge 709. The portion of thesecond area 722 that may extend from thethird edge 711 to thethird portion 718 of the band of adhesive 715 may be closer to thefirst edge 707 than thesecond edge 709. Thesecond area 722 may have a shape similar to an upside down and reversed letter "L", e.g., a "┐" shape. Thesecond area 722 may be seen as a combination of thesecond area 122 shown inFigure 1 and thesecond area 322 shown inFigure 3 . - The
second area 722 may have a length that extends from thefirst portion 716 of the band of adhesive 715 to thesecond portion 717 of the band of adhesive 715. As such, thefirst portion 716, thesecond portion 717, and thethird portion 718 of the band of adhesive 715 may form or otherwise provide a continuous layer or band of the adhesive 715 that extends from thefirst edge 707 to thesecond edge 709 that includes thesecond area 722 partially disposed therein. In one or more embodiments, thesecond area 722 may extend for a distance that is less than the distance between thefirst portion 716 of the band of adhesive 715 and thesecond portion 717 of the band of adhesive 715. For example, the length of thesecond area 722 may range from a low of about 50%, about 55%, or about 60% to a high of about 90%, about 95%, or about 99% of the distance between thefirst portion 716 of the band of adhesive 715 and thesecond portion 717 of the band of adhesive 715. In one or more embodiments, thesecond area 722 may extend from thefirst edge 707 to thesecond portion 717 of the band of adhesive 715, from thesecond edge 709 to thefirst portion 716 of the band of adhesive 715, or from thefirst edge 707 to thesecond edge 709. - The
first area 720 between theshrinkable film 703 and thepaperboard substrate 705, may be free to move away from thepaperboard substrate 705 as theshrinkable film 703 shrinks. For example, if thepaperboard blank 700 has been formed into a container and theshrinkable film 703 shrinks, a gap may be formed between thefilm 703 and thepaperboard substrate 705 as discussed and described in detail above with reference toFigure 6 . - In one or more embodiments, the width of the band of adhesive 715 or "glue line" disposed between the
shrinkable film 703 and thepaperboard substrate 705 and along thefirst edge 707, thesecond edge 709, thethird edge 711, and thefourth edge 713 may range from a low of about 1 mm, about 2 mm, or about 3 mm to a high of about 5 mm, about 10 mm, about 20 mm, or about 30 mm or more. In one or more embodiments, the width of the band of adhesive 715 or glue line along eachedge paperboard substrate 705 may be the same or different with respect to one another. - The
shrinkable film 703 may shrink when subjected to one or more predetermined triggers or conditions, the same as or similar to theshrinkable films Figures 1-4 . The shrink force exerted by theshrinkable film 703 during and after shrinking may pull or otherwise exert a force on thepaperboard substrate 705 and the adhesive 715 may have a tack or bond strength sufficient to maintain theshrinkable film 703 secured to thepaperboard substrate 705, as discussed and described above with reference toFigures 1-4 . - It has been surprisingly and unexpectedly discovered that applying the adhesive 715 along the
third edge 711 in a configuration or pattern that forms or provides thesecond area 722 that may include a first portion partially within thethird portion 718 of the band of adhesive 715 and that may include a second portion that extends from thethird edge 711 to thethird portion 718 of the band of adhesive may significantly reduce or prevent the tendency for theshrinkable film 703 to peel back from thepaperboard substrate 705 when theshrinkable film 703 shrinks. Additionally, it appears that the shrink forces exerted by thefilm 703, when thepaperboard blank 700 has been formed into a container, e.g., a cup, and thefilm 703 has been shrunk, allow for increased vertical edge wicking, particularly when a lid is placed on the container. Without wishing to be bound by theory, it is also believed that the configuration or pattern of thesecond area 722 may reduce or prevent coffee or other liquids from climbing up the sidewall of a formed container, e.g., cup, and over the rim thereof. - The adhesive 715 may be applied onto the
shrinkable film 703 and/or thepaperboard substrate 705 to provide thesecond area 722 and thefirst area 720 that may be free or substantially free from any adhesive 715 using any suitable method or combination of methods known in the art. For example, the adhesive 715 may be applied to thepaperboard substrate 705 via spraying, brushing, flexographic printing, rotogravure printing, offset printing, screen printing, or any other suitable coating method. Suitable methods for applying the adhesive 715 to theshrinkable film 703 and/or thepaperboard substrate 705 may also include those discussed and described inU.S. Patent Nos.: 6,536,657 ;6,729,534 ;7,464,856 ;7,614,993 ;7,600,669 ;7,464,857 ;7,913,873 ;7,938,313 ;7,513,386 ;7,510,098 ;7,841,974 ;8,622,232 andU.S. Patent Application Publication Nos.: 2011/0031305 ;2012/0312869 ; and2013/0341387 . -
Figure 10 depicts a schematic view of yet another illustrative paperboard blank 1000 for making a cup, according to one or more embodiments described.Figure 11 depicts a schematic cross-sectional view of the paperboard blank 1000 depicted inFigure 10 along line 11-11, according to one or more embodiments described. Thepaperboard blank 100 represents another embodiment of theblanks second area 1022 that is substantially free of adhesive 115 may be located within thethird portion 118, between the band of adhesive 115 located along thefirst edge 107 of the blank 1000 and the band of adhesive 115 located along the oppositesecond edge 109 of the blank 1000. Accordingly, at least a portion of the band of adhesive 115 located along thefirst edge 107 of the blank 1000 extends from side to side, i.e. all the way from thethird edge 111 to thefourth edge 113. Similarly, at least a portion of the band of adhesive 115 located along thesecond edge 109 of the blank 1000 extends from side to side, i.e. all the way from thethird edge 111 to thefourth edge 113. Thesecond region 1022 that is substantially free of adhesive is thus formed along thethird edge 111, but does not extend all the way to the first andsecond edges Figure 10 . - The
second region 1022 is an outer area that is substantially free from the adhesive. It is believed that this non-adhesive location effectively reduces wicking and liquid climb during use of the cup. Thesecond region 1022 can extend inward from thethird edge 111 of the substrate toward the middle of the blank 1000. The width of thesecond region 1022 can vary depending on many design considerations, such as the size of the blank 1000. For example, the width of thesecond region 1022 can vary from about 1 mm to about 20 mm; about 2 mm to about 16 mm; about 3 mm to about 14 mm; about 5 mm to about 15 mm; or about 8 mm to about 12 mm. Thesecond region 1022 is surrounded by adhesive 115 on three sides, whereas theinner region 120 is surrounded by adhesive on all four sides. - This adhesive pattern resembles that shown and described with reference to
Figure 3 . The adhesive pattern of blank 1000 differing in that there is adhesive 115 located in the upper left and lower left corners of the blank 1000, whereas thesecond region 322 that is substantially free of adhesive of the blank 300 inFigure 3 extends along thethird edge 311 from top to bottom, i.e., from the very top of thefirst edge 307 to the very bottom of thesecond edge 309. - As shown in
Figure 10 , the band of adhesive 115 can be continuous about all four sides of the blank 1000. Although continuous about each of the four sides of the blank, the band of adhesive 115 does not cover the entirethird edge 111 of the blank 1000, leaving a substantial portion of thethird edge 111 adhesive free. For example, the adhesive 115 can cover less than 20% of the overall length of thethird edge 111, or less than 15%, or less than 10%, or less than 5%, meaning at least 80%, 85%, 90% or 95% of the length of thethird edge 111 is free of adhesive. The adhesive can cover, for example, 3% to 20% of the length of thethird edge 111, or 5% to 15%, or 10% to 20%. - Along the first, second and
third edges adhesive band 115 or "glue line" can be consistent or it can vary about the perimeter of the blank 1000. For example, the width may range from about 1 mm, about 2 mm, or about 3 mm to about 5 mm, about 10 mm, about 20 mm, or about 30 mm or more. The width of the adhesive 115 proximate thethird edge 111 can be the same as the others. To accomplish this, the glue line proximate theedge 111 can be moved over toward to the middle of the blank 1000 to create room for thesecond region 1022. Alternatively, less adhesive 115 (i.e. a narrower strip) can be applied proximate thethird edge 111. As used herein, the "width" of theadhesive band 115 refers to the width of the adhesive band in the machine direction as well as the width of the adhesive band in the cross direction. - Embodiments of the present disclosure further relate to any one or more of the following paragraphs:
- 1. A method for making a paper container, comprising: applying a band of adhesive about a perimeter of a paperboard substrate having a first edge and a second edge opposed to one another and a third edge and a fourth edge opposed to one another, wherein the band of adhesive at least partially surrounds a first area that is substantially free from the adhesive, wherein a second area that is substantially free from the adhesive is located between the third edge and the first area, and wherein the first area and the second area are separated by the band of adhesive; securing a shrinkable film to the paperboard substrate with the adhesive to produce a paperboard blank; overlapping the third edge and the fourth edge to form a sidewall, wherein the sidewall comprises: an inner surface comprising the shrinkable film and an outer surface comprising the paperboard substrate, the first edge, and the second edge; securing a bottom panel to the sidewall at or adjacent the second edge; and curling the first edge to form a brim.
- 2. The method according to paragraph 1, wherein the second area extends from the third edge to the band of adhesive.
- 3. The method according to
paragraph 2, wherein the second area has a width extending from the first edge to the band of adhesive of about 1 mm to about 12 mm. - 4. The method according to paragraph 1, wherein the second area is located within the band of adhesive along the third edge of the paperboard substrate and between the first edge and the second edge.
- 5. The method of according to paragraph 4, wherein the band of adhesive has a width extending from the third edge to an edge of the second area that is closest to the third edge of about 1 mm to about 4 mm.
- 6. The method according to paragraph 4 or 5, wherein the second area has a width of about 1 mm to about 12 mm.
- 7. The method according to any one of paragraphs 4 to 6, wherein the band of adhesive has a width extending from the third edge to an edge of the second area that is closest to the third edge of about 1 mm to about 4 mm, wherein the second area has a width extending from the edge closest to the third edge to an edge that is closest to the first area of about 1 mm to about 12 mm, and wherein the band of adhesive along the third edge located between the first area and the second area has a width of about 1 mm to about 15 mm.
- 8. The method according to any one of paragraph 1 to 7, wherein the band of adhesive along the third edge located between the first area and the second area has a width of about 1 mm to about 15 mm.
- 9. The method according to any one of paragraph 1 to 8, wherein the shrinkable film comprises a biaxially oriented heat shrinkable polymeric material.
- 10. The method according to any one of paragraph 1 to 9, wherein the shrinkable film comprises polyethylene, polypropylene, or a mixture thereof.
- 11. The method according to any one of paragraph 1 to 10, wherein the paperboard substrate comprises a first coating and a second coating disposed on opposing sides of a paperboard layer, and wherein the first and second coatings comprise a polyolefin.
- 12. The method according to any one of paragraph 1 to 11, wherein the adhesive is applied along the perimeter of the substrate by flexographic printing, rotogravure printing, offset printing, screen printing, or any combination thereof.
- 13. The method according to any one of paragraph 1 to 12, further comprising forming at least one aperture through the paperboard substrate prior to securing the shrinkable film to the paperboard substrate.
- 14. A method for making a paper container, comprising: applying a band of adhesive about a perimeter of a paperboard substrate having a first edge and a second edge opposed to one another and a third edge and a fourth edge opposed to one another, wherein the band of adhesive surrounds a first area that is substantially free of the adhesive, and wherein a second area that is substantially free of the adhesive is formed between the third edge and the first area, and wherein the first area and the second area are separated by the band of adhesive; securing a shrinkable film to the paperboard substrate with the adhesive to produce a paperboard blank; overlapping the third edge and the fourth edge to form a sidewall, wherein the sidewall comprises: an inner surface comprising the shrinkable film and an outer surface comprising the paperboard substrate, the first edge, and the second edge; securing a bottom panel to the sidewall at or adjacent the second edge of the sidewall; and curling the first edge of the sidewall to form a brim.
- 15. The method according to paragraph 14, wherein the first area and the second area are separated by the band of adhesive such that the second area that is substantially free of the adhesive extends about the perimeter of the paperboard substrate.
- 16. The method according to paragraph 14, wherein the first area and the second area are separated by a portion of the band of adhesive that extends from the first edge to the second edge such that the second area extends from the third edge to the portion of the band of adhesive that extends from the first edge to the second edge.
- 17. The method according to paragraph 14, wherein the second area extends from the third edge to the band of adhesive that is between the first edge and the second edge a distance of about 1 mm to about 12 mm.
- 18. The method according to paragraph 14, where the second area is located within the band of adhesive along the third edge of the paperboard substrate and between the first edge and the second edge.
- 19. A method for making a paper container, comprising: applying a band of adhesive about a perimeter of a paperboard substrate having a first edge and a second edge opposed to one another and a third edge and a fourth edge opposed to one another, wherein the band of adhesive at least partially surrounds a first area that is substantially free from the adhesive, wherein a second area that is substantially free from the adhesive is located between the third edge and the first area, and wherein the first area and the second area are separated by at least a portion of the band of adhesive; securing a shrinkable film to the paperboard substrate with the adhesive to produce a paperboard blank; overlapping the third edge and the fourth edge with one another; heat sealing the third edge and the fourth edge to one another to form a sidewall; securing a bottom panel to the sidewall at or adjacent the second edge; and curling the first edge to form a brim.
- 20. The method according to paragraph 19, wherein the second area is located within the band of adhesive along the third edge of the paperboard substrate and between the first edge and the second edge.
- 21. The method according to any one of paragraphs 1 to 20, wherein the paper container is a paper cup.
- 22. The method according to any one of paragraphs 1 to 21, wherein the sidewall is frusto-conical.
- 23. The method according to any one of paragraphs 1 to 22, wherein a portion of the second area extends from the third edge to the band of adhesive and a portion of the second area is located within the band of adhesive along the third edge of the paperboard substrate and between the first edge and the second edge.
- 24. The method according to paragraph 23, wherein the portion of the second area that extends from the third edge to the band of adhesive is closer to the first edge than the second edge.
- Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges including the combination of any two values, e.g., the combination of any lower value with any upper value, the combination of any two lower values, and/or the combination of any two upper values are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are "about" or "approximately" the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.
- Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.
- While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
Claims (15)
- A method for making a paper container, comprising:applying a band of adhesive about a perimeter of a paperboard substrate having a first edge and a second edge opposed to each another and a third edge and a fourth edge opposed to each another, wherein the band of adhesive surrounds an inner region that is substantially free from the adhesive and the adhesive is applied entirely along the first, second and fourth edges of the perimeter but not entirely along the third edge of the perimeter, creating a second area that is substantially free from the adhesive between the first and second edges, and wherein the first area and the second area are separated by the adhesive disposed along the third edge;securing a shrinkable film to the paperboard substrate with the adhesive to produce a paperboard blank;overlapping the third edge and the fourth edge to form a sidewall, wherein the sidewall comprises:an inner surface comprising the shrinkable film and an outer surface comprising the paperboard substrate,the first edge, andthe second edge;securing a bottom panel to the sidewall at or adjacent the second edge; andcurling the first edge to form a brim.
- The method of claim 1, wherein the second area extends inward from the third edge toward the band of adhesive.
- The method of claim 2, wherein a corner between the first and third edges has adhesive applied thereto, and a corner between the second and third edges also has adhesive applied thereto.
- The method of claim 3, wherein the second area is located within the band of adhesive along the third edge of the paperboard substrate and between the first edge and the second edge.
- The method of claim 2, wherein the second area has a width of about 1 mm to about 12 mm.
- The method of claim 1, wherein the band of adhesive has a width of about 1 mm to about 4 mm along the first, second and fourth edges.
- A method for making a paper container, comprising:applying a band of adhesive about a perimeter of a paperboard substrate having first and second sides opposed to each another and third and fourth sides opposed to each another,wherein the band of adhesive is applied along the first, second and fourth sides of the perimeter but not entirely along the third side of the perimeter, creating an inner region that is substantially free from the adhesive, and an outer area that is substantially free from the adhesive along the third side between the first and second sides, wherein the outer area that is substantially free from the adhesive extends inward from the edge of the third side of the substrate toward the band of adhesive;securing a shrinkable film to the paperboard substrate with the adhesive to produce a paperboard blank;overlapping the third edge and the fourth edge to form a sidewall, wherein the sidewall comprises:an inner surface comprising the shrinkable film and an outer surface comprising the paperboard substrate,the first edge, andthe second edge;securing a bottom panel to the sidewall at or adjacent the second edge; andcurling the first edge to form a brim.
- The method of claim 12, wherein the first and second sides are arcuate and the third and fourth sides are straight.
- The method of claim 1 or 7, wherein the band of adhesive has a width of about 1 mm to about 4 mm along the first, second and fourth edges.
- The method of claim 1 or 7, wherein the shrinkable film comprises a biaxially oriented heat shrinkable polymeric material.
- The method of claim 1 or 7, wherein the shrinkable film comprises polyethylene, polypropylene, or a mixture thereof.
- The method of claim 1 or 7, wherein the paperboard substrate comprises a first coating and a second coating disposed on opposing sides of a paperboard layer, and wherein the first and second coatings comprise a polyolefin.
- The method of claim 1 or 7, wherein the adhesive is applied to the substrate by flexographic printing, rotogravure printing, offset printing, screen printing, or any combination thereof.
- The method of claim 1 or 7, further comprising forming at least one aperture through the paperboard substrate prior to securing the shrinkable film to the paperboard substrate.
- A method for making a paper container, comprising:applying a band of adhesive about a perimeter of a paperboard substrate having first and second sides opposed to each another that are arcuate and third and fourth sides opposed to each another that are generally straight, wherein the band of adhesive is applied along the first, second and fourth sides but not entirely along the third side, creating an inner region that is substantially free from the adhesive and an outer area that is substantially free from the adhesive along the third side between the first and second sides, wherein the outer area that is substantially free from the adhesive extends inward from the edge of the third side of the substrate toward the band of adhesive and is surrounded by adhesive on three sides, and wherein the inner region is surrounded by adhesive on all four sides;securing a shrinkable film to the paperboard substrate with the adhesive to produce a paperboard blank;overlapping the third edge and the fourth edge to form a sidewall, wherein the sidewall comprises:an inner surface comprising the shrinkable film and an outer surface comprising the paperboard substrate,the first edge, andthe second edge;securing a bottom panel to the sidewall at or adjacent the second edge; andcurling the first edge to form a brim.
Applications Claiming Priority (1)
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US15/499,509 US20170225423A1 (en) | 2014-12-23 | 2017-04-27 | Methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom |
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EP3395705A1 true EP3395705A1 (en) | 2018-10-31 |
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EP18169772.3A Withdrawn EP3395705A1 (en) | 2017-04-27 | 2018-04-27 | Methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom |
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EP (1) | EP3395705A1 (en) |
CA (1) | CA3002768A1 (en) |
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US20160176143A1 (en) * | 2014-12-23 | 2016-06-23 | Dixie Consumer Products Llc | Methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom |
US20170225423A1 (en) * | 2014-12-23 | 2017-08-10 | Dixie Consumer Products Llc | Methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom |
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2018
- 2018-04-25 CA CA3002768A patent/CA3002768A1/en not_active Abandoned
- 2018-04-27 EP EP18169772.3A patent/EP3395705A1/en not_active Withdrawn
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US20110031305A1 (en) | 2005-06-30 | 2011-02-10 | Dixie Consumer Products Llc | Method of making a container employing inner liner and vents for thermal insulation |
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US7510098B2 (en) | 2005-06-30 | 2009-03-31 | Dixie Consumer Products Llc | Container employing inner liner and vents for thermal insulation and methods of making same |
US20120312869A1 (en) | 2005-06-30 | 2012-12-13 | Dixie Consumer Products Llc | Methods for making paperboard blanks and paperboard products therefrom |
US8622232B2 (en) | 2005-06-30 | 2014-01-07 | Dixie Consumer Products Llc | Method of making a container employing inner liner and vents for thermal insulation |
US20130341387A1 (en) | 2012-06-25 | 2013-12-26 | Dixie Consumer Products Llc | Paperboard blanks having a shrinkable film adhered thereto and paperboard container made therefrom |
US20160176143A1 (en) * | 2014-12-23 | 2016-06-23 | Dixie Consumer Products Llc | Methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom |
US20170225423A1 (en) * | 2014-12-23 | 2017-08-10 | Dixie Consumer Products Llc | Methods for securing a shrinkable film to a paperboard substrate and methods for making paperboard containers therefrom |
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