US20140262916A1 - Container - Google Patents

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Publication number
US20140262916A1
US20140262916A1 US14/211,553 US201414211553A US2014262916A1 US 20140262916 A1 US20140262916 A1 US 20140262916A1 US 201414211553 A US201414211553 A US 201414211553A US 2014262916 A1 US2014262916 A1 US 2014262916A1
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United States
Prior art keywords
vessel
collapse
polymeric layer
cellular
force required
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.)
Abandoned
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US14/211,553
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English (en)
Inventor
Jeffrey C. Minnette
Rolland Strasser
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Berry Global Inc
Original Assignee
Berry Plastics Corp
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Berry Plastics Corp filed Critical Berry Plastics Corp
Priority to US14/211,553 priority Critical patent/US20140262916A1/en
Publication of US20140262916A1 publication Critical patent/US20140262916A1/en
Assigned to BERRY PLASTICS CORPORATION reassignment BERRY PLASTICS CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MINNETTE, JEFFREY C, STRASSER, Rolland
Abandoned legal-status Critical Current

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Classifications

    • 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
    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/40—Details of walls
    • 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
    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/02—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents
    • B65D1/0207—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by material, e.g. composition, physical features
    • B65D1/0215—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by material, e.g. composition, physical features multilayered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/065—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/025—Polyolefin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles

Definitions

  • the present disclosure relates to vessels, and in particular to cup or bottles. More particularly, the present disclosure relates to a cup formed from polymeric materials.
  • a vessel in accordance with the present disclosure is configured to hold a product in an interior region.
  • the vessel is an insulated container such as a drink cup.
  • the vessel is a container such as a shampoo bottle.
  • a container is formed multi-layer tube in a multi-layer co-extrusion blow molding process.
  • the multi-layer tube includes an inner polymeric layer, an outer polymeric spaced apart from the inner polymeric material, and a middle cellular non-aromatic polymeric material located between the inner and outer polymeric layers.
  • the middle cellular non-aromatic polymeric layer has a density in a range of about 0.01 g/cm 3 to about 0.19 g/cm 3 . In illustrative embodiments, the middle cellular non-aromatic polymeric layer has a density in a range of about 0.05 g/cm 3 to about 0.19 g/cm 3 . In illustrative embodiments, the middle cellular non-aromatic polymeric layer has a density in a range of about 0.1 g/cm 3 to about 0.185 g/cm 3 .
  • FIG. 1 is a perspective view of a first embodiment of a container in accordance with the present disclosure showing that the container includes, from top to bottom, a brim, a side wall, and a floor, and suggesting that the container is formed from a multilayer tube according to a container-manufacturing process as suggested in FIGS. 3A-4 ;
  • FIG. 2 is an enlarged sectional view of a portion of a side wall included in the container of FIG. 1 showing that the side wall is made form a multilayer tube that includes, from left to right, an outer polymeric layer, a middle cellular non-aromatic polymeric layer, and an inner polymeric layer;
  • FIGS. 3A-3C are a series of partial perspective view of a first embodiment of a container-manufacturing process in accordance with the present disclosure showing the formation of the container of FIG. 1 ;
  • FIG. 3A is a partial perspective view of a portion of the container-manufacturing process showing that the container-manufacturing process begins with extruding an inner layer, a middle layer, and an outer layer to establish a multi-layer tube that is received between two mold halves for forming as suggested in FIG. 3B ;
  • FIG. 3B is a view similar to FIG. 3A showing the two mold halves in a closed position trapping the multilayer tube therebetween in a mold cavity formed by the two mold have when the two mold have are closed;
  • FIG. 3C is a view similar to FIG. 3B showing the two mold halves in an opened position and a molded vessel being ejected from the mold halves for further processing to establish the container of FIG. 1 as suggested in FIG. 4 ;
  • FIG. 4 is a diagrammatic view of the container-manufacturing process of FIGS. 3A-3C showing that the container-manufacturing process includes the operations extruding the inner layer that provides the inner polymeric layer, extruding the middle layer that provides the middle insulative cellular non-aromatic polymeric layer, extruding the outer layer that provides the outer polymeric layer, establishing a pre-form multilayer tube, extruding the pre-form multilayer tube into an open mold cavity, closing the mold, pumping air into the pre-form multilayer tube in the mold cavity to cause the multi-layer tube to expand and take the shape of the mold cavity, opening the mold, removing the vessel from the mold cavity, cutting a top portion off the vessel to establish a body as suggested in FIG. 5 , and forming the container of FIG. 1 from the body;
  • FIG. 5 is a view similar to FIG. 1 showing the body formed during the container-manufacturing process of FIG. 4 ;
  • FIG. 6 is a perspective view taken from a bottom of the body showing a floor included in the container;
  • FIGS. 7A-7D are a series of partial perspective view of a second embodiment of a container-manufacturing process in accordance with the present disclosure showing the formation a body as suggested in FIG. 9 that processed to form a container;
  • FIG. 7A is a partial perspective view of a portion of the container-manufacturing process showing that the container-manufacturing process begins with extruding an inner layer, a middle layer, and an outer layer to establish a multi-layer tube that is received between two mold halves for forming as suggested in FIG. 7B ;
  • FIG. 7B is a view similar to FIG. 7A showing the two mold halves in a closed position trapping the multilayer tube therebetween in a mold cavity formed by the two mold have when the two mold have are closed;
  • FIG. 7C is a view similar to FIG. 7B showing the two mold halves in an opened position and a molded vessel being ejected from the mold halves for further processing where a cutting operation removes a top and bottom end of the vessel to establish a side wall;
  • FIG. 7D is a view similar to FIG. 7C showing the side wall after the cutting operation has been performed and a floor has been coupled to a bottom end of the side wall to establish a body as suggested in FIG. 9 ;
  • FIG. 8 is a diagrammatic view of the container-manufacturing process of FIGS. 7A-7D showing that the container-manufacturing process includes the operations extruding the inner layer that provides the inner polymeric layer, extruding the middle layer that provides the middle insulative cellular non-aromatic polymeric layer, extruding the outer layer that provides the outer polymeric layer, establishing a pre-form multilayer tube, extruding the pre-form multilayer tube into an open mold cavity, closing the mold, pumping air into the pre-form multilayer tube in the mold cavity to cause the multi-layer tube to expand and take the shape of the mold cavity, opening the mold, removing the vessel from the mold cavity, cutting top and bottom portions off the vessel to establish the side wall, forming the floor, coupling the floor to the side wall to establish the body, and forming the container as suggested in FIG. 9 ;
  • FIG. 9 is a perspective view of a another embodiment of the body formed using the container-manufacturing process of FIGS. 7A-8 with portions broken away to reveal that the container includes the side wall and the floor;
  • FIG. 10 is a perspective view taken from a bottom of the body of FIG. 9 showing the floor coupled to the side wall of the body;
  • FIG. 11 is a perspective view of another embodiment of a container in accordance with the present disclosure suggesting that a container including, from top to bottom, a brim, a side wall including a plurality of ribs, and a floor may be formed using the container-manufacturing processes of the present disclosure;
  • FIG. 12 is a perspective view taken from a bottom of the container of FIG. 11 showing the floor appended to the side wall of the container
  • FIG. 13A is a photograph showing two containers in accordance with another embodiment of the present disclosure.
  • FIG. 13B is a photograph showing one of the containers of FIG. 13A with a portion of a side wall removed for photographing as suggested in FIG. 13C ;
  • FIG. 13C is an enlarged photograph of a portion of the side wall of FIG. 13B showing that the side wall includes, from top bottom, a inner polymeric layer, a middle insulative cellular non-aromatic polymeric layer, an outer polymeric layer;
  • FIG. 13D is an enlarged photograph of a portion of the side wall in section showing that the side wall includes, from top to bottom, an outer polymeric layer (outside skin), a middle insulative cellular non-aromatic polymeric layer (foam core), and an inner polymeric layer (inside skin);
  • FIG. 13E is a photograph showing one of the containers of FIG. 13A coupled to a top-load testing device undergoing top-load testing;
  • FIG. 14A is a photograph showing another embodiment of a container in accordance with the present disclosure being removed from a mold cavity after air has been pumped into a pre-form multilayer tube in a mold cavity to cause the multi-layer tube to expand and take the shape of the mold cavity;
  • FIG. 14B is a photograph showing a series of finished containers formed in accordance with the present disclosure.
  • FIG. 14C is an enlarged photograph showing a section of a side wall included in the containers of FIGS. 14A and 14B showing that the side wall includes, from top bottom, a inner polymeric layer, a middle insulative cellular non-aromatic polymeric layer, and an outer polymeric layer;
  • FIG. 14D is a photograph showing two containers formed in accordance with the present disclosure and two multi-layer tubes used to form the containers.
  • FIG. 14E is a photograph showing two containers formed in accordance with the present disclosure and two multi-layer tubes used to form the containers.
  • FIG. 1 A first embodiment of a container 10 in accordance with the present disclosure is shown in FIG. 1 .
  • Container 10 is made from a multi-layer tube 12 , also called multi-layer parison 12 , as shown in FIGS. 3A-3C and 7 A- 7 C.
  • Multi-layer tube 12 includes an inner polymeric layer 12 I, a middle cellular non-aromatic polymeric layer 12 M, and an outer polymeric layer 12 O as shown in FIG. 2 .
  • Container 10 is formed using a first embodiment of a container-manufacturing process 100 as shown, for example, in FIGS. 3A-4 .
  • Another embodiment of a body 218 in accordance with the present disclosure is shown, for example in FIGS. 9 and 10 .
  • Body 218 is formed during and used in a second embodiment of a container-manufacturing process 300 as shown, for example, in FIGS. 7A-8 .
  • Still yet another embodiment of a container 410 formed using one of the container-manufacturing process of the present disclosure is shown, for example, in FIGS. 11 and 12 .
  • Another embodiment of a container 510 formed using one of the container-manufacturing processes of the present disclosure is shown, for example, in FIGS. 13A and 13E .
  • Another embodiment of a container 610 is formed using one of the container-manufacturing processes of the present disclosure is shown, for example, in FIGS. 14B , 14 D, and 14 E.
  • Container 10 is made during container-manufacturing process 100 from multi-layer tube 12 as shown in FIG. 3A-3C .
  • Multi-layer tube 12 includes inner polymeric layer 12 I, middle cellular non-aromatic polymeric layer 12 M, and outer polymeric layer 12 O as shown in FIG. 2 .
  • inner polymeric layer 12 I, middle insulative cellular non-aromatic polymeric layer 12 M, and outer polymeric layer 12 O are made from the same polymeric material or materials.
  • each of the inner polymeric layer 12 I, middle insulative cellular non-aromatic polymeric layer 12 M, and outer polymeric layer 12 O are made from different materials.
  • inner and outer polymeric layers 12 I, 12 O are made from polypropylene. In another example, inner and outer polymeric layers 12 I, 12 O are made from high density polyethylene. In still yet another example, one of the polymeric layers may include a polymeric material and an oxygen barrier material such as Ethylene Vinyl Alcohol (EVOH). However, inner and outer polymeric layers 12 I, 12 may be made from any suitable polymeric material.
  • EVOH Ethylene Vinyl Alcohol
  • Middle insulative cellular non-aromatic polymeric layer 12 M is configured to provide means for insulating a beverage or food placed in an interior region 14 formed in container 10 , forming a structure having sufficient mechanical characteristics to support the beverage or food, and providing resistance to deformation and puncture.
  • middle insulative cellular non-aromatic polymeric layer 12 M is made from an insulative cellular non-aromatic high density polyethylene material.
  • middle insulative cellular non-aromatic polymeric layer 12 M is made from a predominantly polypropylene material.
  • the middle cellular non-aromatic polymeric layer 12 M has a density in a range of about 0.01 g/cm 3 to about 0.19 g/cm 3 . In illustrative embodiments, the middle cellular non-aromatic polymeric layer has a density in a range of about 0.05 g/cm 3 to about 0.19 g/cm 3 . In illustrative embodiments, the middle cellular non-aromatic polymeric layer has a density in a range of about 0.1 g/cm 3 to about 0.185 g/cm 3 .
  • Outer polymeric layer 12 O and inner polymeric layer 12 I are, for example, made a non-aromatic polymer.
  • Inner polymeric layer 12 I is spaced apart from outer polymeric layer 12 O so as to locate middle insulative cellular non-aromatic polymeric layer 12 M therebetween
  • Inner polymer layer 12 I is located between interior region 14 and middle insulative cellular non-aromatic polymeric layer 12 M as shown, for example, in FIG. 2 .
  • outer and inner polymeric layers 12 O, 12 I are made from polypropylene. While inner and outer polymeric layers 12 O, 12 I may be made from the same material, they may also be made from different materials so as to achieve desired performance characteristics of the container.
  • Container 10 includes, from top to bottom, a brim 16 and a body 18 as shown in FIG. 1 .
  • Brim 16 is appended to a top portion of body 18 and arranged to define a mouth 20 opening into interior region 14 formed in body 18 .
  • container 10 is an insulative drink cup and brim 16 is adapted to mate with a lid which covers and closes mouth 20 .
  • Container 10 is formed using container-manufacturing process 100 as shown, for example in FIGS. 3A-4 .
  • Container-manufacturing process 100 is, for example, a multi-layer co-extruded blow molding operation as suggested in FIGS. 3A and 4 .
  • Container-manufacturing process 100 includes an inner layer extrusion operation 102 , a middle layer extrusion operation 104 , an outer layer extrusion operation 106 , and a tube forming operation 108 as shown in FIGS. 3A and 4
  • Inner layer extrusion operation 102 occurs when a first extruder 131 extrudes an inner layer 142 which provides inner polymeric layer 12 I.
  • Middle layer extrusion operation 104 occurs when a second extruder 132 extrudes a middle layer 142 which provides middle cellular non-aromatic polymeric layer 12 M.
  • Outer layer extrusion operation 106 occurs when a third extruder 133 extrudes an outer layer 143 which provides outer polymeric layer 12 O. All three layers 141 , 142 , 143 are brought together in order during tube forming operation 108 in a die 140 to establish multi-layer tube 12 as shown in FIG. 3A .
  • container-manufacturing process 100 shows the extrusion of three layers, any number of inner layers, middle layers, and outer layers may be extruded by any number of extrudes. These various layers may then be combined in the die to establish a multi-layer tube.
  • Container-manufacturing process 100 further includes an extruding multi-layer tube operation 110 , a mold closing operation 112 , an air pumping operation 114 , a mold opening operation 116 , and a vessel removing operation 118 as shown, for example, in FIGS. 3B-4 .
  • extruders 131 , 132 , 133 continue to extrude associated layers 141 , 142 , 143 so that multi-layer tube 12 is extruded between two mold halves 134 A, 134 B included in a mold 134 as shown in FIG. 3A .
  • mold halves 134 A, 134 B are brought together to establish a mold cavity 134 C formed in mold 134 .
  • air is pumped into a portion of multi-layer tube 12 trapped in mold cavity 134 C to cause multi-layer tube 12 to expand and take on a shape of mold cavity 134 C and establish a vessel 22 including an interior space 24 filled with air.
  • vacuum may be applied to the multi-layer tube 12 in mold cavity 134 to take on the shape of mold cavity 134 .
  • mold halves 134 A, 134 B open and move away from one another as shown in FIG. 3C . Vessel 22 is removed from mold 134 .
  • a continuous extrusion process may be used in combination with a rotary blow molding machine.
  • a continuous multi-layer tube is extruded and a series of molds included in the rotary blow molding machine rotate relative to the multi-layer tube.
  • molds approach the extruders forming the multi-layer tube, they begin to move from an opened arrangement to a closed arrangement trapping a portion of the multi-layer tube in a mold cavity formed in the mold.
  • the molds move away from the extruders forming the multi-layer tube, they move from the closed position to an opened position where a vessel is ejected from the mold cavity.
  • a rotary extrusion blow molding machine is available from Wilmington Machinery of Wilmington, N.C.
  • a continuous extrusion process may be used in combination with a shuttle blow molding machine.
  • a first mold on a track moves to an opened position, slides over to receive the multi-layer tube in the mold cavity, and moves to a closed position.
  • the first mold then slides away from the multi-layer tube where air is pumped into the interior space to cause the multi-layer tube to assume the mold shape.
  • a second mold moves to an opened position, slides over to receive the continuously extruded multi-layer tube in a mold cavity of the second mold, and moves to a closed position.
  • the second mold then slides away from the multi-layer tube where air is pumped into the interior space. While the second mold moves away from the multi-layer tube, the first mold moves to the opened position ejecting the vessel to start the process over again.
  • a shuttle blow molding machine is available from Graham Engineering Corporation of York, Pa.
  • Container-manufacturing process 100 may include an optional step of inserting a label or other item in the mold cavity prior to receiving the multi-layer tube 12 therein.
  • body 18 may be formed with a printed label or other feature coupled to the side wall 28 during molding.
  • container-manufacturing process 100 is capable of an-mold labeling operation.
  • Container-manufacturing process 100 further includes a cutting operation 120 and a forming operation 122 as shown in FIG. 4 .
  • cutting operation 120 a top portion 26 of vessel 22 is cut and separated from vessel 22 to cause body 18 to be established.
  • body 18 includes a side wall 28 and a floor 30 .
  • Floor 30 is appended to a lower portion of side wall 28 and cooperates with side wall 28 to define interior region 14 as shown in FIG. 5 .
  • Body 18 may then be accumulated and transported to forming operation 122 where a brim-forming step and a printing step may be performed.
  • brim 16 is formed on body 18 using a brim-forming machine (not shown) where a top portion of body 18 is rolled downwardly toward side wall 28 .
  • graphics, words, or other indicia may be printed on outwardly facing surface of outer polymeric layer 12 O.
  • Body 18 is shown, for example, in FIGS. 5 and 6 after cutting operation 120 has been performed on vessel 22 .
  • Body 18 includes side wall 28 and floor 30 as shown in FIGS. 5 and 6 .
  • An aperture 32 is formed as a result of cutting operation 120 .
  • Aperture 32 will become mouth 20 after the brim-forming step has occurred.
  • Container-manufacturing process 300 is, for example, a multi-layer co-extruded blow molding operation as suggested in FIGS. 7A-8 .
  • Container-manufacturing operation 300 includes inner layer extrusion operation 102 , middle layer extrusion operation 104 , outer layer extrusion operation 106 , and tube forming operation 108 as shown in FIGS. 3A , 4 , 7 A, and 8
  • Inner layer extrusion operation 102 occurs when first extruder 131 extrudes an inner layer 141 which provides inner polymeric layer 12 I.
  • Middle layer extrusion operation 104 occurs when second extruder 132 extrudes a middle layer 142 which provides middle insulative cellular non-aromatic polymeric layer 12 M.
  • Outer layer extrusion operation 106 occurs when third extruder 133 extrudes an outer layer 143 which provides outer polymeric layer 12 O. All three layers 141 , 142 , 143 are brought together in die 140 during tube forming operation 108 to establish multi-layer tube 12 as shown in FIG. 7A .
  • Container-manufacturing process 300 further includes extruding multi-layer tube operation 110 , mold closing operation 112 , air pumping operation 114 , mold opening operation 116 , and vessel removing operation 118 as shown, for example, in FIGS. 7B-8 .
  • extruding multi-layer tube operation 110 extruders 131 , 132 , 133 continue to extrude associated layers 141 , 142 , 143 so that multi-layer tube 12 is extruded between two mold halves 134 A, 134 B included in mold 134 as shown in FIG. 7A .
  • mold closing operation 112 mold halves 134 A, 134 B are brought together to establish mold cavity 134 C formed in mold 134 .
  • Container-manufacturing process 300 further includes a cutting operation 320 , a floor forming operation 322 , a floor coupling operation 324 , and a body establishing operation 326 as shown in FIG. 8 .
  • cutting operation 320 a top portion 226 of vessel 22 and a bottom portion 227 of vessel 22 is cut and separated from vessel 22 to cause a side wall 228 to be established as suggested in FIGS. 7C and 7D .
  • a floor 230 is formed.
  • Floor 230 may be injection molded, thermoformed, or any other suitable alternative.
  • floor coupling operation 324 floor 230 is coupled to a bottom portion of side wall 228 .
  • Body 218 is established during body establishing operation 326 as shown in FIGS. 7D , 9 , and 10 .
  • Body 218 includes side wall 228 and floor 230 as shown in FIGS. 9 and 10 .
  • Floor 230 is coupled to the lower portion of side wall 228 and cooperates with side wall 228 to define interior region 214 as shown in FIG. 9 .
  • floor 230 is coupled by adhesive to floor 230 .
  • floor 230 is coupled by a heat seal to floor 230 .
  • any suitable means for coupling floor 230 to side wall 228 may be used.
  • Body 218 may then be accumulated and transported to forming operation 328 where a brim-forming step and a printing step may be performed.
  • a brim is formed on body 218 using a brim-forming machine (not shown) where a top portion of body 218 is rolled downwardly toward side wall 228 .
  • graphics, words, or other indicia may be printed on outwardly facing surface of outer polymeric layer 12 O.
  • Container 410 is made using one of the container-manufacturing processes 100 , 300 .
  • Container 410 includes a brim 416 , a side wall 428 , a floor 430 as shown, for example in FIGS. 11 and 12 .
  • Container 410 has relatively vertical side wall 428 as compared to container 10 which has an angled side wall 28 .
  • side wall 428 is formed to include a plurality of ribs 434 as shown in FIGS. 11 and 12 . Ribs 434 may be used to maximize stack strength of container 410 .
  • Container 510 is made from another embodiment of a multi-layer tube that includes an inner polymeric layer 512 I, middle insulative cellular non-aromatic polymeric layer 512 M, and outer polymeric layer 512 O as shown in FIGS. 13C and 13D .
  • Container 510 has, for example, an interior region 514 configured to hold about 750 ml.
  • Container 510 weights about 44 grams.
  • Inner polymeric layer 512 I is made from a polymeric material including high density polyethylene and colorant.
  • Outer polymeric layer 512 O is made from a polymeric material including high density polyethylene.
  • Middle insulative cellular non-aromatic polymeric layer 512 M is made from an insulative cellular non-aromatic polymeric material that includes high density polyethylene and a talc nucleating agent as suggested in FIG. 13D .
  • Container 510 includes, from top to bottom, a brim 516 and a body 518 as shown in FIG. 13A .
  • Brim 516 is appended to a top portion of body 518 and arranged to define a mouth 520 opening into interior region 514 formed in body 518 .
  • container 510 is an insulative drink cup and brim 516 is adapted to mate with a lid which covers and closes mouth 520 .
  • Body 518 includes a side wall 528 and a floor 530 as shown in FIG. 13B .
  • containers 510 were formed from a multi-layer tube.
  • the middle layer used to form middle insulative cellular non-aromatic polymeric material 512 M had a density of about 0.83 grams per cubic centimeter.
  • container 510 After mating the inner layer with the inner and outer layers and forming container 510 , container 510 had a density of about 0.95 grams per cubic centimeter.
  • operation of the second extruder 132 was optimized to minimize density of the middle layer.
  • thicknesses of inner and outer layers were minimized.
  • inner polymeric layer 512 I is about 15% of a total thickness of side wall 528 of container 510 .
  • Outer polymeric layer 512 O is about 15% of the total thickness of side wall 528 of container 510 .
  • Middle insulative cellular non-aromatic polymeric material 512 M is about 70% the total thickness of side wall 528 of container 510 .
  • Container 510 as a result, has a density of about 0.87 grams per cubic centimeter after optimization.
  • Inner polymeric layer 512 I of container 510 has a weight of about 32 grams.
  • Outer polymeric layer 512 O of container 510 has a weight of about 40 grams.
  • Middle insulative cellular non-aromatic polymeric material 512 M has a weight of about 35 grams.
  • the optimized container 510 was tested in an Instron tester to determine top load performance as suggested in FIG. 13E . Containers were tested until they failed or necked in to form an hourglass shape. Table 1 shows the performance of several containers 510 (including middle cellular layer 512 M) tested vs. several high density polyethylene containers (excluding middle cellular layer 512 M).
  • Container 610 is made from another embodiment of a multi-layer tube 612 that includes an inner polymeric layer 612 I, middle insulative cellular non-aromatic polymeric layer 612 M, and outer polymeric layer 612 O as shown in FIG. 14C .
  • Container 610 has, for example, an interior region 614 .
  • Container 610 includes, from top to bottom, a neck 616 and a body 618 as shown in FIG. 14B .
  • Neck 616 is appended to a top portion of body 618 and arranged to define a mouth 620 opening into interior region 614 formed in body 618 .
  • container 610 is a shampoo bottle and neck 616 is adapted to mate with a lid which covers and closes mouth 620 .
  • Body 618 includes a side wall 628 and a floor 630 as shown in FIG. 14B .
  • containers 610 were formed from a multi-layer tube.
  • the middle layer used to form middle insulative cellular non-aromatic polymeric layer 612 M had a density of about 0.62 grams per cubic centimeter.
  • container 610 After mating the inner layer with the inner and outer layers and forming container 610 , container 610 has a density of about 0.88 grams per cubic centimeter as suggested in FIG. 14D .
  • Another embodiment of a container 610 A has a density of about 0.81 grams per cubic centimeter as suggested in FIG. 14E .

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Containers Having Bodies Formed In One Piece (AREA)
  • Laminated Bodies (AREA)
  • Details Of Rigid Or Semi-Rigid Containers (AREA)
  • Packages (AREA)
US14/211,553 2013-03-14 2014-03-14 Container Abandoned US20140262916A1 (en)

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US15/938,352 Active US10246209B2 (en) 2013-03-14 2018-03-28 Container
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US10059037B2 (en) 2014-09-23 2018-08-28 Dart Container Corporation Insulated container and methods of making and assembling
US10351332B2 (en) 2011-06-17 2019-07-16 Berry Plastics Corporation Insulated sleeve for a container
US10428195B2 (en) 2011-08-31 2019-10-01 Berry Plastics Corporation Polymeric material for an insulated container
US10513589B2 (en) 2015-01-23 2019-12-24 Berry Plastics Corporation Polymeric material for an insulated container
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GB2511559B (en) 2013-03-07 2018-11-14 Mondelez Uk R&D Ltd Improved Packaging and Method of Forming Packaging
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US20160107784A1 (en) 2016-04-21
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US9725202B2 (en) 2017-08-08
US10633139B2 (en) 2020-04-28

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