Note: Descriptions are shown in the official language in which they were submitted.
CA 02891524 2015-12-16
MAKING A MULTILAYER ARTICLE, BLANK, AND INSULATING CUP
BACKGROUND
Field
The presently disclosed subject matter relates to a disposable cup for
serving beverages, such as water and coffee, and food items, such as soup or
ice
cream. Particularly, the presently disclosed subject matter is directed to a
blank
having a multilayer structure to provide improved insulating properties, among
other
benefits.
Description of Related Art
Some known types of disposable cups include those made from
polystyrene, expanded polystyrene or paper. Although polystyrene cups can be
aesthetically pleasing, such cups tend to not have an outer surface more
suitable for
printing graphics or logos. Further, polystyrene cups are generally not
biodegradable
or easily recyclable.
Another type of cup, made from expanded polystyrene, or EPS (e.g., a
Styrofoam cup), can have improved thermal insulation properties compared to
other
cups, and thus can maintain the temperature of a drink, either hot or cold,
for a longer
amount of time. Expanded polystyrene cups can be relatively inexpensive, and
can be
comfortable to handle as the exterior of the cup remains relatively close to
ambient
temperature regardless of the temperature of the item inside the cup. However,
expanded polystyrene is also generally not biodegradable or easily recyclable.
Additionally, as expanded polystyrene cups are typically printed after they
have been
folined, and the relatively rough surface of the cup can be incompatible with
high-
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resolution printing, relatively slow and costly processes are typically used
for printing
on expanded polystyrene cups.
Yet another type of disposable cup, made from paper, is generally
recyclable and biodegradable, and thus can be considered environmentally
friendly.
However, paper cups, particularly single-layer paper cups, can have relatively
poor
thermal insulation properties. Furthermore, paper cups constructed with a
single wall
or layer can be susceptible to weakening after exposure to liquids.
Multilayer paper cups can provide improved thermal insulation and
increased strength compared to single-layer paper cups. Although relatively
strong
and thermally efficient, multilayer cups generally are more expensive due to
the
complicated manufacturing processes and excess material typically required.
Some
examples of multilayer cups, including paper cups and paper wrapped expanded
polystyrene cups, that attempt to address these concerns can be found in U.S.
Patent
No. 7,552,841; 6,663,926; 6,598,786; and 6,193,098; U.S. Patent Application
Publication Nos. 2008/0121681 and 2008/0041860; and International Publication
No.
W02011/003569. Other examples of cups include U.S. Patent 3,941,634; U.S.
Patent
4,477,518; U.S. Patent 6,509,384; U.S. Patent 6,749,913; U.S. Patent
6,908,651; U.S.
Patent 7,956,096; U.S. Publication 2007/0228134; U.S. Publication
2009/0321508.
However, there remains an opportunity for improvement for a disposable cup
that is
strong, well-insulated and inexpensive to manufacture.
SUMMARY
The purpose and advantages of the disclosed subject matter will be set
forth in and apparent from the description that follows, as well as will be
learned by
practice of the disclosed subject matter. Additional advantages of the
disclosed
subject matter will be realized and attained by the methods and systems
particularly
pointed out in the written description and claims hereof, as well as from the
appended
drawings.
To achieve these and other advantages and in accordance with the
purpose of the disclosed subject matter, as embodied and broadly described,
the
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disclosed subject matter includes a method of making a multilayer blank,
comprising:
providing a first substrate having an inner surface and an outer surface;
providing a second substrate having an inner surface and an outer surface;
disposing an expandable insulating material on the inner surface of at least
one of the
first substrate and the second substrate, wherein the expandable insulating
material is in a
first condition during disposing and is configured to expand to a second
condition upon
application of energy:
adhering the second substrate to the first substrate with the expandable
insulating
material therebetween to form a blank, wherein an insulating space is defined
in the blank
between the first substrate and the second substrate with the expandable
insulating material
therein, the insulating space having a first volume when the expandable
insulating material is
in the first condition and the insulating space having a second volume when
the expandable
insulating material is in the second condition.
As embodied herein, the disclosed subject matter further includes a multilayer
blank,
comprising:
a first substrate having an inner surface and an outer surface;
a second substrate having an inner surface and an outer surface; and
an expandable insulating material applied to the inner surface of at least one
of the
first substrate and the second substrate, wherein the expandable insulating
material is in a
first condition and is configured to expand to a second condition upon
application of energy,
and
wherein the second substrate is adhered to the first substrate with the
expandable
insulating material therebetween to form a blank, wherein an insulating space
is defined in
the blank between the first substrate and the second substrate with the
expandable insulating
material therein, the insulating space having a first volume when the
expandable insulating
material is in the first condition and the insulating space having a second
volume when the
expandable insulating material is in the second condition.
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As embodied herein, the disclosed subject matter further includes, an
insulating cup,
comprising:
a sidewall defining a compartment with top opening and a bottom portion, the
sidewall including a multilayer blank having:
a first substrate having an inner surface and an outer surface,
a second substrate having an inner surface and an outer surface, and
an expandable insulating material applied to the inner surface of at least one
of the first substrate and the second substrate, wherein the expandable
insulating
material is in a first condition and is configured to expand to a second
condition upon
application of energy, and
wherein the second substrate is adhered to the first substrate with the
expandable insulating material therebetween in the first condition, wherein an
insulating space is defined between the first substrate and the second
substrate with
the expandable insulating material therein, the insulating space has a first
volume
when the expandable insulating material is in the first condition and the
insulating
space has a second volume when the expandable insulating material is in the
second
condition; and
a base coupled to the bottom portion of the sidewall when the expandable
insulating
material is in the first condition,
wherein the expandable insulating material is configured to be expanded from
the
first condition to the second condition with the compartment empty to form a
finished
insulated cup, and
wherein the expandable insulating material is expanded to the second condition
upon
the application of thermal energy between approximately 400 F and
approximately 500 F.
In another embodiment, an insulating cup is provided. The insulating cup,
comprising a
sidewall defining a top opening and a bottom portion. The sidewall includes a
multilayer
article having a first substrate having inner surface and an outer surface and
a second
substrate having an inner surface and an outer surface. An expandable
insulating material is
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applied to the inner surface of at least one of the first substrate and the
second substrate,
wherein the expandable insulating material includes a first condition at
ambient temperature
and a second condition upon
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application of energy. The second substrate is adhered to the first substrate
with the
expandable insulating material therebetween, wherein an insulating space is
defined
between the first substrate and the second substrate with the expandable
insulating
material therein, The cup further includes a base coupled to the bottom
portion of the
siA-wall when the expandable insulating material is in the first condition.
It is to be understood that both the foregoing general description and
the following detailed description arc exemplary and are intended to provide
further
explanation of the disclosed subject matter claimed.
The accompanying drawings, which are incorporated in and constitute
part of this specification, are included to illustrate and provide a further
understanding
of the method and system of the disclosed subject matter. Together with the
description, the drawings serve to explain the principles of the disclosed
subject
matter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a multilayer blank according to a representative
embodiment of the disclosed subject matter, with a printed pattern of
insulating
material featured for purposes of understanding.
FIG. 2 is a cross-sectional view of the multilayer blank of FIG. l along
detail line AA, according to the disclosed subject matter.
FIG, 3A depicts a photograph of the expandable insulating material
printed in a diamond pattern on a first substrate of a multilayer blank,
according to an
embodiment of the disclosed subject matter.
FIG. 3B depicts an enlarged photograph of the expandable insulating
material of FIG. 3A after the application of energy, according to an
embodiment of
the disclosed subject matter.
FIG. 4A depicts a photograph of the expandable insulating material
printed in a dot pattern on a first substrate of a multilayer blank, according
to an
embodiment of the disclosed subject matter.
FIG. 4B depicts an enlarged photograph of the expandable insulating
material of FIG. 4A after the application of energy, according to an
embodiment of
the disclosed subject matter.
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FIG. SA depicts a photograph of the expandable insulating material
printed in a lined pattern on a first substrate of a multilayer blank,
according to an
embodiment of the disclosed subject matter.
FIG. 5B depicts an enlarged photograph of the expandable insulating
material of FIG. 5A after the application of energy, according to an
embodiment of
the disclosed subject matter.
FIG. 6 is a schematic cross-sectional view of the multilayer blank of
FIG. 1 at ambient temperature along detail line A-A, according to an
embodiment of
the disclosed subject matter.
FIG. 7 is a schematic cross-sectional view of the multilayer blank of
FIG. 6 after application of suitable energy, according to an embodiment of the
disclosed subject matter.
FIG. 8 is an exploded view of an insulating cup having a multilayer
blank, according to an embodiment of the disclosed subject matter.
FIG. 9 is the insulating cup of FIG. 8, according to an embodiment of
the disclosed subject matter.
FIG. 10 depicts a flow chart of a method of making a multilayer
article, according to an embodiment of the disclosed subject matter.
FIG. 11A depicts a photograph of an insulating cup Ruined according
to the disclosed subject matter, and FIG. 1113 depicts a photograph of the cup
of FIG.
11A with the outer substrate removed, according to an embodiment of the
disclosed
subject.
FIG. 12 depicts a table of samples and experiment data of the samples,
according to embodiments of the disclosed subject matter.
FIG. 12A depicts an infrared image of the temperature of the sidewall
of a cup measured with a Flir 15 infrared camera, according to embodiments of
the
disclosed subject matter.
FIG. 13 demonstrates the data means for the effects plot for weight of
the samples of FIG. 12, according to embodiments of the disclosed subject
matter.
FIG. 14 demonstrates the data means for the effects plot for hold time
in seconds of the samples of FIG. 12, according to embodiments of the
disclosed
subject matter.
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FIG. 15 demonstrates the data means for the effects plot for the
sidewall of the samples of FIG. 12, according to embodiments of the disclosed
subject
matter.
FIG. 16 demonstrates the data means for the effects plot for the
average gauge of the samples of FIG. 12, according to embodiments of the
disclosed
subject matter.
FIG. 17 demonstrates the data means for the effects plot for the ridge
gauge of the samples of FIG. 12, according to embodiments of the disclosed
subject
matter.
FIG. 18 demonstrates the data means for the effects plot for the
appearance of the samples of FIG. 12, according to embodiments of the
disclosed
subject matter.
FIG. 19 demonstrates the data means for the effects plot for the
strength of the samples of FIG. 12, according to embodiments of the disclosed
subject
matter.
FIG. 20 shows a front view of the blank and corresponding cup,
according to embodiments of the disclosed subject matter.
FIG. 21 shows a back seam side view of the blank and corresponding
cup of FIG. 20, according to embodiments of the disclosed subject matter.
FIG, 22 shows a front view of the blank and corresponding cup,
according to embodiments of the disclosed subject matter.
FIG. 23 shows a back scam side view of the blank and corresponding
cup of FIG. 22, according to embodiments of the disclosed subject matter.
FIG. 24 depicts another embodiment of the disclosed subject matter
showing a blank, according to embodiments of the disclosed subject matter.
FIG. 25 and FIGS. 25A-25C depict another embodiment of the
disclosed subject matter showing a cup made from a blank, according to
embodiments
of the disclosed subject matter.
FIG. 26 demonstrates the insulation characteristics of an article of the
disclosed subject matter, according to embodiments of the disclosed subject
matter.
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DETAILED DESCRIPTION
The products and methods presented herein may be used for serving,
storage and transportation of beverages and food items, and other perishable
and
nonperishable products. The disclosed subject matter is particularly suited
for
serving, storage, and transportation of hot or cold beverages or food items,
wherein
the multi-layer configuration of the cup provides improved insulating
properties to
maintain the temperature of the beverage or food item contained therein during
consumption, storage and/or transportation.
In accordance with the disclosed subject matter herein, the disclosed
subject matter includes a method of making a multilayer article, comprising
providing
a first substrate having an inner surface and an outer surface and providing a
second
substrate having an inner surface and an outer surface. The method further
includes
disposing an expandable insulating material on the inner surface of at least
one of the
first substrate and the second substrate, wherein the expandable insulating
material is
in a first condition during disposing. The second substrate is adhered to the
first
substrate with the expandable insulating material therebetween to form a
blank,
wherein an insulating space is defined between the first substrate and the
second
substrate with the expandable insulating material therein and the insulating
space
includes a first volume. The method further includes forming the blank into
the article
and expanding the expandable insulating material of the article to a second
condition
by application of energy, wherein the expandable insulating material in the
second
condition increases the insulating space to a second volume.
As embodied herein, the disclosed subject matter further includes a
multilayer article, comprising a first substrate having an inner surface and
an outer
surface and a second substrate having an inner surface and an outer surface.
The
article further including an expandable insulating material applied to the
inner surface
of at least one of the first substrate and the second substrate, wherein the
expandable
insulating material includes a first condition at ambient temperature and a
second
condition upon application of energy. The second substrate is adhered to the
first
substrate with the expandable insulating material therebetween to form a
blank. An
insulating space is defined between the first substrate and the second
substrate with
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the expandable insulating material therein. The insulating space has a first
volume
when the expandable insulating material is in the first condition and the
insulating
space has a second volume when the expandable insulating material is in the
second
condition.
In another embodiment, an insulating cup is provided. The insulating
cup, comprising a sidewall defining a top opening and a bottom portion. The
sidewall
includes a multilayer article having a first substrate having inner surface
and an outer
surface and a second substrate having an inner surface and an outer surface.
An
expandable insulating material is applied to the inner surface of at least one
of the first
substrate and the second substrate, wherein the expandable insulating material
includes a first condition at ambient temperature and a second condition upon
application of energy. The second substrate is adhered to the first substrate
with the
expandable insulating material therebetween, wherein an insulating space is
defined
between the first substrate and the second substrate with the expandable
insulating
material therein. The cup further includes a base coupled to the bottom
portion of the
sidewall when the expandable insulating material is in the first condition.
Reference will now be made in detail to the various exemplary
embodiments of the disclosed subject matter, exemplary embodiments of which
are
illustrated in the accompanying drawings. The structure and corresponding
method of
operation of the disclosed subject matter will be described in conjunction
with the
detailed description of the system.
The accompanying figures, where like reference numerals refer to
identical or functionally similar elements throughout the separate views,
serve to
further illustrate various embodiments and to explain various principles and
advantages all in accordance with the disclosed subject matter. For purpose of
explanation and illustration, and not limitation, exemplary embodiments of the
multilayer blank in accordance with the disclosed subject matter are shown in
FIGS.
1-2. The multilayer blank is suitable for the manufacture of articles such as
containers, cups, bowls, and the like. Such articles incorporating the
multilayer blank
can be used with a wide variety of perishable and nonperishable goods.
However, for
purpose of understanding, reference will be made to the use of the multilayer
blank as
an insulating cup disclosed herein with beverages, wherein the insulating cup
can be
used for transporting, serving, storing, preparing and/or re-using such
beverages. As
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described in further detail below, the insulating cup has suitable insulating
properties
to assist in maintaining the temperature of a beverage therein. For purpose of
illustration, and not limitation, reference will made herein to a multilayer
blank and an
insulating cup incorporating a multilayer blank that is intended to contain a
relatively
hot food or beverage, such as hot water or coffer or other similar beverage,
wherein
the insulating cup has a multilayer structure to provide improved insulating
properties,
among other benefits.
The multilayer blank generally includes a first substrate, an expandable
insulating material, and a second substrate. However, the subject matter of
the
application further contemplates a blank having a plurality of substrates and
expandable insulating materials and is not herewith limited to two substrates
and one
insulating material. For example, the multilayer blank could include four
substrates
and three insulating materials.
As shown FIG. 1, a first substrate 110 and an insulating material 200
of a multilayer blank 100 are depicted, according to an embodiment of the
subject
matter. For purpose of illustration, FIG. 1 depicts a pattern of insulating
material 200
that is positioned between the first substrate 110 and the second substrate
120 of the
multilayer blank 100. In the embodiment of FIG. 1, the insulating material is
printed
between the first substrate 110 and the second substrate 120, However, other
application methods of coupling the insulating material to the first substrate
and/or the
second substrate include, but are not limited to, coating, spraying,
laminating, and
extruding, as further discussed herein.
FIG. 2 is a cross-section of a multilayer blank that includes the first
substrate 110 and insulating material 200 of FIG. 1, the cross-section taken
along
lines A-A of FIG. 1. As depicted in FIG. 2, the first substrate 110 has an
outer surface
112 and an inner surface 114. The first substrate 110 defines a thickness T1
between
the outer surface 112 and the inner surface 114. The thickness T1 of the first
substrate
110 can be any suitable dimension, depending on the material used. For
example, in
one embodiment the thickness Ti can range between 0.002 inches and 0.020
inches.
Other embodiments include the first substrate 110 as having a value of the
thickness
T1between approximately 8 to approximately 15 pts and in particular
approximately
10 to approximately 11 pts, where a conventional paperboard is used.
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The multilayer blank 100 further includes a second substrate 120. The
second substrate 120 has an inner surface 122 and an outer surface 124. The
second
substrate 120 defines a thickness T2 between the inner surface 122 and the
outer
surface 124. The thickness T2 of the second substrate 120 can be any suitable
dimension and can be the same or different than the thickness T I of the first
substrate
110. For example, in one embodiment the thickness T2 can range between 0.002
inches and 0.020 inches. As embodied herein in one embodiment, the thickness
of the
second substrate is less than that of the first substrate. In one embodiment,
the second
substrate 120 has a value of the thickness T2 between approximately 3 to 8
pts. In
another embodiment, the second substrate 120 has a value of the thickness T2
of
approximately 6 pts.
As depicted in FIG. 2, the first substrate 110 and the second substrate
120 are coupled together such that the inner surface 122 of the second
substrate 120
faces the inner surface 114 ofthe first substrate 110. As such, in one
embodiment, the
inner surface 122 of the second substrate 120 is coupled to at least a portion
of the
inner surface 114 of the first substrate to form the blank 100. The first
substrate 110
and the second substrate 120 define an insulating space 300 therebetween with
the
expandable insulating material 200 therein, as further discussed herein. The
insulating
space 300 can additionally be filled with a suitable gas, such as air, or can
be filled
with a variety of suitable materials to achieve desired insulating properties.
The
insulating space 300 can further include an adhesive applied randomly or in a
pattern
within the insulating space, as further discussed herein. Furthermore, the
adhesive can
he applied about the entire surface area of each of the first substrate and
second
substrate, if desired.
The first substrate 110 and the second substrate 120 can be coupled
together by a plurality of suitable methods. In one embodiment, the first
substrate 110
and the second substrate 120 are coupled together along the margin 116 with an
adhesive. In another aspect of the disclosed subject matter, the first
substrate 110 and
the second substrate 120 are coupled together along the surface areas of the
first
substrate and the second substrates, respectively, including within the
insulating space
300. A plurality of suitable adhesives can be used including, but not limited
to,
pressure sensitive adhesive, glue, thelinal bond, and the like. When the
adhesive
comprises a glue, certain kinds of glue can be used depending on the level of
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thickness and material of construction of each of the first and second
substrates. For
example, for substrates of a smaller thickness dimension, a glue having low
moisture
content, a non water-based glue, or a glue having a higher solids content can
be better
suited for such application. With any kind of suitable adhesive, the adhesive
can
prevent leaching and be compatible with the insulating material. With respect
to the
embodiment of FIG. 2, the adhesion of the first substrate 110 with the second
substrate 120 about the margin 116 allows for the expandable insulating
material 200
to expand independently within the insulation space 300, as described further
below.
The blank 110 need not be limited to just a single margin about the entire
perimeter of
the blank. In additional embodiments, perimeter margins and interior channel
breaks
are also herein contemplated. The first substrate 110 and the second substrate
120 can
be coupled together prior to the application of energy to the blank 100,
further
discussed herein.
In another embodiment, the first substrate 110 and the second substrate
120 can be adhered together by adhesion in alternate patterns. For example,
the
adhesive can be positioned on the first substrate and/or the second substrate
in
channels alternating with the insulating material adhered thereto. In another
example,
the adhesive can be positioned within the pattern of the insulating material,
such as
for purposes of example, within the diamond pattern of the embodiment of FIG.
1.
Such embodiments can accommodate for a more controlled expansion of the
insulating material. As such, the adhesive can include an adhesive pattern or
can have
an overall application about the surface area of the first substrate and/or
the second
substrate. In another aspect of the disclosed subject matter, the adhesive can
be
applied in a registered application. In registered applications, the adhesive
may bond
the first substrate with the second substrates in areas devoid of or with
limited
expandable insulating material in addition to or alternative to the
application of
adhesive to the margins of the substrates.
The first substrate 110 and the second substrate 120 can have any
suitable shape and dimension for the intended purpose. For example, the first
substrate 110 and the second substrate 120 can have geometric shapes, such as
cylindrical, rectangular, triangular, or any suitable geometrical shape.
Generally,
although not necessarily, the shape and dimension of the first substrate 110
and the
second substrate 120 are substantially similar. In alternative embodiments,
the shape
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and dimension of the first substrate 110 and the second substrate 120 vary
dependent
on the use of the blank. As depicted in FIG. 1 for purposes of illustration,
the first
substrate 110 has a semi-rectangular shape with arcuate edges for use in
making a
cup, such as a wrapped cup. In other embodiments as discussed herein, the
first
substrate and the second substrate each can comprise a web of material that is
later
machined, cut, and processed into suitable shapes and dimensions for articles,
such as
cups and the like as previously disclosed.
The first substrate 110 and the second substrate 120 can also include
any suitable material. Examples of such suitable materials include paperboard,
polymeric sheets, foil or metalized film, foam sheets (e.g., expanded
polystyrene), a
water-soluble (e.g., starch-based) material, a foamed heat-insulating layer or
coating
(e.g., polyethylene, polyolefin, polyvinylehloricle, polystyrene, polyester,
or nylon),
unscored paperboard such as chipboard (plain chip or bending chip),
linerboard,
virgin paperboard, paperboard with recycled content, SBS board, SUS board,
corrugated paper or board, polymeric solid sheets, combinations thereof, or
the like.
The first substrate and the second substrate can further include foil or
metalized film
laminated paperboard, porous sheets, foam sheets (e.g., expanded polystyrene),
combinations thereof, or the like.
Suitable substances and coatings can be applied to the blank as desired.
For example, the outer surface 1.12 of the first substrate 110 can include a
coating
such as a wax or polyethylene that can cooperate with a liquid such as coffee
or a
soup, when the blank is incorporated into a cup. For example, the first
substrate 110
can include approximately between one-half to 1 mil of polyethylene coating to
create
a seal in the interior of the cup. Further, the outer surface 124 of the
second substrate
120 can include a coating to improve printing graphics on the blank or to
improve
gripping of the blank. Alternatively or additionally, the blank can be coated
with a
waterproof coating including, for example, polyethylene. Other suitable
coatings
such as e.g., polyethylene, polyolefin, polyvinylchloride, polystyrene,
polyester, or
nylon, combinations thereof, or the like are furthermore contemplated as known
in the
.. art. The blank can furthermore be coated with ink or graphics, as known in
the art.
Turning back to FIG. I and FIG 2, the blank 100 includes an insulating
material 200 applied between the first substrate 110 and the second substrate
120 in
the insulating space 300. The expandable insulating material 200 is applied on
the
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inner surface of at least one of the inner surface of the 114 of the first
substrate and
the inner surface 122 of the second substrate 120. The expandable insulating
material
200 can be applied to at least one of the inner surface 114 of the first
substrate and the
inner surface 122 of the second substrate 120 in a plurality of suitable ways
and
processes, as further discussed herein. For example, and not by limitation, in
one
embodiment, the expandable insulating material 200 is printed on the inner sin-
face
114 of the first substrate 110 in a pattern. For example, a mesh can be
utilized to print
the expandable insulating material 200 on at least one of the first substrate
110 and
the second substrate 120. In another aspect of the disclosed subject matter,
the
expandable insulating material 200 is applied by at least one of printing,
coating,
spraying, laminating, and extruding, as further discussed herein.
A variety of suitable patterns of the expandable insulating material can
suffice, such as, but not limited to, dots, chevrons, diamonds, lines,
zigzags, spirals,
and the like. The pattern can be an ordered pattern or can be random, such as
a
.. camouflage pattern. If desired, the pattern can define individual cells,
wherein each
individual cell of the pattern can be sufficiently spaced from an adjacent
cell. In an
embodiment, the first substrate can include a pattern on an inner surface area
of the
substrate whereas the second substrate can include a complementary pattern on
the
outer surface area of the second substrate for a complementary fit between the
first
and second substrates. In other embodiments and as depicted herein, the
pattern can
be printed on an inner surface area of the inner surface of the first
substrate while
leaving an outer margin surrounding the expandable insulating material, as
shown in
FIG. I. Other embodiments do not include a margin free of expandable
insulating
material. For purposes of illustration, FIG. 1 depicts a diamond pattern of
the
expandable insulating material 200.
As previously discussed, the adhesive can be applied within the
diamonds on either the first substrate andior the second substrate. The
pattern of the
expandable insulating material can influence the shape of the overall
container after
expansion of the expandable insulating material. The pattern can furthermore
influence the structure of the container such as the rigidity and dimensional
stability.
The pattern can also create an aesthetically pleasing design and decorative
graphic.
The pattern can also provide different areas of insulation that can be
application
specific for the intended use of the container. For example, with embodiments
of the
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container used as a hot coffee cup, the center of the cup can include a dense
pattern of
the insulating material thereabout, whereas the peripheral areas at the top
and bottom
of the cup include a less dense pattern or can be lacking insulating material.
The expandable insulating material 200 of the disclosed subject matter
is formed of expandable beads or microspheres, which expand in size upon the
application of sufficient energy, such as heat. As embodied herein, one such
suitable
expandable insulating material is available from Akzo Nobel, under the
trademark
Expancelg. Such expandable insulating material can be combined with inks,
solution
binders, carrier medium, or other additives to allow for disposing onto a
substrate
surface. The binder can have flexible characteristics and not be a rigid
substance. A
carrier medium of the insulating material can include a variety of suitable
characteristics such as being dry to touch after application, but not cured to
the extent
to lock in any beads of the expandable insulating material and prevent
expansion. The
carrier medium can have a predetermined viscosity and predetermined drying
time
based on the method of disposing the expandable insulating material on the
substrate(s).
The expandable insulating material 200 can have certain expansion
properties upon the application of energy. Thus, the expandable insulating
material
200 can be printed or disposed in a first condition at a first temperature on
the
substrate(s), the first and second substrates can be adhered to each other and
dried to
form a blank and, after forming an article from the blank, can subsequently be
processed with energy, such as but not limited to radio frequency (RF),
infrared,
convection, conduction, laser, heat, microwaves, or the like, such that the
expandable
insulating material 200 includes a second condition. Depending on the desired
article
of manufacture, different energy or heating applications of the expandable
insulating
material have different advantages. For articles having a poly-coated
applications, the
application of the energy to the article need not exceed the melting point of
the poly
coating.
In an example embodiment, at ambient temperature the expandable
insulating material 200, such as an expandable ink with mierospheres, can
include
rnicrospheres having pre-expansion diameters ranging from approximately 6 to
approximately 12 microns, i.e, the first condition. However, another
embodiment
contemplates a bead having a pre-expansion diameter ranging from approximately
10
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to approximately 16 microns, such as for purposes of example, Akzo Nobel,
031WUF40 Expancel bead used in hot cup applications. The expandable insulating
material 200 can be printed or disposed on the substrate in the first
condition with the
thickness dimension of the expandable insulating material 200 based on the
density of
the microspheres. For example, but not limited to, the thickness of the
expandable
insulating material 200 can be printed with a thickness dimension between
approximately 0.001 inches to 0.008 inches. For applications desiring more
stiffness
and less insulation, the thickness dimension of the expandable insulating
material 200
can be printed or disposed with a thickness dimension of approximately 0.0005
inches
in the first condition. For hot cup articles such as hot coffee cups, the
thickness
dimension of the expandable insulating material 200 can be printed or disposed
with a
thickness of approximately 0.0015 inches to approximately 0.003 inches, in the
first
condition.
Upon the application of energy to the microspheres to e.g.,
approximately 100-500 degrees Fahrenheit (hereinafter, " F") and for a
duration
ranging between approximately 5 to approximately 120 seconds, the micro
spheres
permanently expand to increase the original diameter of the microspheres,
i.e., the
second condition. The expansion of the insulating material can be a function
of the
application of energy and the associated duration time. For example, in a hot
cup
application using the Akzo Nobel, 031WUF40 Expancel bead, convective heat can
be
applied at approximately 400 F to approximately 500 F for approximately 30 to
approximately 90 seconds, and in some embodiments for approximately 60
seconds.
Such expansion can be generally uniform across the surface of the substrate so
as to
increase the dimension or distance between the inner surfaces of the
substrates and
thus the volume of the insulation space. For example, the microspheres can
expand up
to 10 times the original diameter and volume. In another example, the printed
microspheres can have a thickness dimension of 0.0005 inches in the first
condition at
ambient temperature and expand to 0.012 inches or greater in the second
condition,
depending at least on the kind and construction of bead.
In an example of the disclosed subject matter, the expandable
insulating material, inclusive of the expandable beads with a carrier
medium/coating,
can be applied using screen printing technology with a mesh ranging from
approximately 60 mesh to approximately 200 mesh size, and in one example,
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approximately 60 mesh to approximately 100 mesh. With screens of greater mesh
dimensions, the lower the amount of insulation material is applied on the
substrate.
Another factor that can affect the thickness of the expanded insulation
material is the
ratio of beads to the carrier medium (i.e., the density of the beads within
the carrier
medium/coating). With a higher density of beads in the carrier medium, the
expansion of the beads can be limited due to the lack of space for the bead to
expand.
However, with a lower density of beads in the carrier medium, there may not be
enough expansion of the beads for the insulation of the article and the
desired use
thereof. Other factors that can affect the expansion of the beads, include but
are not
limited to, the application of the adhesive material and the flexibility and
construction
of the substrates.
The spacing of the pattern of the expandable insulating material can
accommodate the expansion of the microspheres. Similarly, the first and second
substrates are joined or coupled together in a matter to allow for such
expansion.
Furthermore, a pleat or embossment can be provided in one or both substrates
to
allow for such expansion. After the energy is applied, the expandable
insulating
material 200 can be allowed to cure for a suitable time, for example, but not
limited
to, between approximately 20 and approximately 60 hours. However, curing after
the
energy is applied is not necessary. It is noted however that the energy can be
applied
at a suitable time after the insulating material is applied. Long delays
between
application of insulating material and energizing the insulating material can
cause the
carrier medium to lock or become rigid, which can be adverse to the expansion
of the
material. In one embodiment, the blank is allowed to dry up to approximately 2
days,
as further discussed herein
FIGS. 3A-5B depict various examples of the expandable insulating
material 200 printed on at least one of the inner surface 114 of the first
substrate and
the inner surface 122 of the second substrate 120. For purpose of illustration
and
description only, each embodiment depicts the blank with the second substrate
removed and the insulating material expanded prior to forming a corresponding
article
from the blank. FIG. 3A depicts a photograph of the expandable insulating
material
200, embodied as microspheres, in an uniform diamond pattern at ambient
temperature, similar to the embodiment of FIG. 1. FIG. 3B depicts an enlarged
view
of the microspheres of FIG. 3A after the application of energy. As shown in
FIG. 3B,
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upon the application of suitable energy, the microspheres have increased in
diameter
and volume. The expansion of the expandable insulating material 200 further
supplements the insulation properties of the blank, such as by increasing the
dimension or distance between the facing inner surfaces of the first and
second
substrates and thus the volume of the insulating space 300.
FIG. 4A depicts the expandable insulating material 200, embodied as
microspheres, in an ordered dot pattern at ambient temperature. FIG. 4B
depicts an
enlarged view of the microspheres of FIG. 4A at a maximized view after the
application of energy. As shown in FIG. 4B, upon the application of suitable
energy,
the microspheres have increased in diameter and volume.
FIG. 5A depicts the expandable insulating material 200, embodied as
microspheres, in an ordered lined pattern at ambient temperature. FIG. 5B
depicts an
enlarged view of the microspheres of FIG. 5A at a maximized view after the
application of energy. As shown in FIG. 5B, upon the application of suitable
energy,
the microspheres have increased in diameter and volume.
The expandable insulating material 200 can also include suitable
additives to further enhance the properties of the expandable insulating
material. The
additives may include suitable binders and/or adhesive substances that do not
hinder
the subsequent expansion of the expandable insulating material upon the
application
of energy. The additives may include those as known and customary in the art.
The selective expansion of the article can have additional benefits. For
example, the portions of the article with the insulating material can be
disposed at any
suitable location such as in the bottom of a carton to create wells, as
further discussed
herein. The insulating material can furthermore be used to increase rigidity
at select
portions of a container and can facilitate stacking.
For purpose of illustration only, FIG. 6 and FIG. 7 show cross-sections
of a multilayer blank 100 prior to the application of suitable energy and
after the
application of suitable energy, respectively. Again, it is understood that
such
expansion generally, although not necessarily, would be performed after first
forming
the multilayer blank into a corresponding article. FIG. 6 is substantially
similar to
FIG. 2, but reproduced for comparative purposes with FIG. 7.
As depicted in FIG. 6, the blank 100 includes a margin thickness Ts
along the margin 116 at ambient temperature. The margin thickness Ts generally
is
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the sum of the thickness Ti of the first substrate 110, the thickness Ts of
the second
substrate 120, and the thickness of any adhesive and additives between the
first
substrate 110 and the second substrate 120. The margin thickness Ts can be any
suitable dimension such as, but not limited to, for example, 0.002 inches to
0.040
inches.
The blank 100 further includes an original thickness To between the
margins 116 along the inner surface area. The original thickness To is the sum
of the
thickness T1 of the first substrate 110, the thickness Ts of the second
substrate 120,
and the thickness of the expandable insulating material 300 at ambient
temperature.
The thickness of the expandable insulating material 200 generally defines the
dimension or height of the insulating space 300 between the facing inner
surfaces of
the first and second substrates. As depicted in FIG. 6, the dimensional value
of the
insulating space 300 is defined by the original blank thickness To minus the
thickness
T1 of the first substrate 110 and the thickness T2 of the second substrate
120. The
original thickness To can be any suitable dimension such as, but not limited
to, for
example, approximately 0.001 to 0.008 inches, and particularly approximately
0.0015
to 0.003 inches.
FIG. 7 shows a cross-section of a multilayer blank 100 after the
application of suitable energy. As depicted, the margin thickness Ts of the
margins
116 stays substantially the same thickness. In other words, the thickness T1
of the first
substrate 110 and the thickness T2 of the second substrate 120 remains
unchanged and
furthermore the adhesive with any additives that binds the first substrate 110
to the
second substrate 120 at the margins 116, remains substantially nonreaetive to
any
application of energy.
As previously discussed, the expandable insulating material 200
expands upon the application of suitable energy to increase the dimension, and
thus
the volume, of the insulating space 300.
As shown by FIG. 7, the thickness of the blank 100 defined at the inner
surface area, i.e. between margins 116 of FIG. 7, changes with the application
of
suitable energy due to the material characteristics of the expandable
insulating
material 200. Thus, the original thickness To of the blank 100 increases to a
second
thickness TH upon application of suitable energy due to the change in size of
the
expandable insulating material 200 disposed between margins 116. In other
words,
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the second thickness TH of the blank 100 is greater than the original
thickness Ts of
the blank 100 between the margins 116. The second thickness TH can be any
suitable
range, for example, but not limited to, from about 0.007 inches to 0.090
inches. As
depicted in FIG. 6 and FIG. 7 for purposes of illustration, the second
thickness TH of
the blank 100 is two times the size of the original thickness To of the blank
100
whereas the thickness Ts of the margins 116 remains the same before and after
application of suitable energy. Although FIG. 7 depicts the expansion of the
insulating
space 300 outwardly such that the first substrate 110 deforms relative the
second
substrate 120, the application further includes embodiments in which both the
first
substrate 110 and the second substrate 120 deform together and in which the
second
substrate 120 deforms inwardly with respect to the first substrate 110.
In FIG. 7 after the application of suitable energy, the dimension of the
insulating space 300 has increased from its original dimension and is defined
by the
second thickness TH minus the thickness Ti of the first substrate 110 and the
thickness
T7 of the second substrate 120. In one example, an insulating cup including
the blank
110 had an original thickness To of approximately 0.020 inches at the first
condition
and a second thickness TH of approximately 0.080 inches at the second
condition such
that the thickness increased approximately 4 times. Other embodiments
contemplate
increases of approximately 0 to 10 times.
As previously noted, and in accordance with another aspect, the blank
100 of the embodiments discussed above can be used to make a plurality of
suitable
articles, for example, but not limited to, an insulating cup. Particularly,
the multilayer
blank disclosed herein can be formed into a corresponding article using
conventional
manufacture techniques, such as rim rolling and the like, and can expanded by
the
application of energy to form an insulated article. For purpose of
illustration and not
limitation, the insulating cup comprises a sidewall defining a top opening and
a
bottom portion. The sidewall includes a multilayer article having a first
substrate
having inner surface and an outer surface and a second substrate having an
inner
surface and an outer surface. An expandable insulating material is applied to
the inner
surface of at least one of the first substrate and the second substrate,
wherein the
expandable insulating material includes a first condition at ambient
temperature and a
second condition upon application of energy. The second substrate is adhered
to the
first substrate with the expandable insulating material therebetween, wherein
an
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insulating space is defined between the first substrate and the second
substrate with
the expandable insulating material therein. The cup further includes a base
coupled to
the bottom portion of the sidewall when the expandable insulating material is
in the
first condition.
FIG. 8 and FIG. 9 depict an embodiment of the subject matter wherein
a blank 100 of the embodiments discussed herein is used to form a sidewall of
an
insulating cup 400. For purpose of illustration and not limitation, as shown
in FIG. 9,
the insulating cup 400 comprises a sidewall 415 and a base 435. The sidewall
415
includes a multilayer blank 100 that can include any of the characteristics as
previously disclosed. The sidewall 415 is configured, for example, by wrapping
a
multilayer blank 100 about itself prior to the application of energy to expand
the
expandable insulating material, such that the blank 100 forms the sidewall 415
of the
cup in which the first substrate 110 forms an interior of the insulating cup
400 and the
second substrate 120 forms an exterior of the insulating cup 400. Because the
article
is formed prior to expanding the expandable insulating layer, any of a variety
of
known manufacturing techniques or processes can be used for each component of
cup
and. assembly of the cup therefrom.
As shown in FIG. 9, the multilayer blank wraps about itself such that a
longitudinal portion of the first substrate 110 adheres to a longitudinal
portion of the
second substrate 120 to form a seam of the insulating cup 400. The sidewall
415
defines a top opening 420 and bottom portion 430, as embodied herein. The
sidewall
415 can further comprise a rolled top portion to define a rim 417 about the
top
opening 420. The rim 417 can be disposed above a top edge of the second
substrate
120 of the blank which forms the exterior of the insulating cup 400. Although
not
shown in the illustrated embodiments, the insulating cup 400 and the sidewall
415 can
include additional surface features, such as ribs, dimples, corrugations,
scores, pleats,
embossing, or the like and combinations thereof, or the like for aesthetics,
gripping or
other desired characteristics. For example, such characteristics can be formed
by the
pattern of the insulating material after expansion, as shown in FIG. 11A.
The bottom portion 430 of the sidewall 415 can be folded toward the
interior of the cup to form an inwardly folded segment for connection with the
base
435 of the insulating cup. The base 435 is coupled to the bottom portion 430
of the
sidewall. The base 435 can be spaced from a bottom of the cup such that a
bottom
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circumferential periphery of the sidewall supports the cup and the base is
suspended
from the bottom of the cup.
The base can include a substantially flat planar portion with a skirt
depending therefrom to define a surface-engaging edge with the sidewall 415.
The
skirt of the base 435 can cooperate with the inwardly folded segment of the
sidewall
415 for adhering the base to the sidewall 415 to form the insulating cup 400.
The first
substrate 110 together with the flat planar portion of the base 435 define the
inner
volume of the insulating cup 400.
The base 435 can be formed from the blank material or other suitable
material, as known in the art. The base 435 can include any suitable material
and can
be a single substrate or can alternatively include a plurality of substrates.
Examples
of such suitable materials include paperboard, polymeric sheets, foil or
metalized
film, foam sheets (e.g., expanded polystyrene), a water-soluble (e.g., starch-
based)
material, a foamed heat-insulating layer or coating (e.g., polyethylene,
polyolefin,
polyvinylchloride, polystyrene, polyester, or nylon), combinations thereof, or
the like.
The base can further include suitable coatings such as the coatings previously
disclosed in relation to the blank.
Once the insulating cup is assembled, the insulating material can be
expanded by the application of energy as described in detail above to expand
the
insulating space 300 and thus provides a region of insulation between the
contents of
the insulating cup 400 and the air surrounding the sidewall to reduce thermal
flow
therebetween. In one example, an insulating cup of an embodiment of the
disclosed
subject matter containing a hot beverage can insulate the heat such that only
approximately 50-70% of the heat is transferred to the exterior of the
insulating cup.
For example, a person holding an insulating cup of the disclosed subject
matter
containing coffee at 190 F can only feel the insulating cup at approximately
70% to
approximately 80% of the coffee temperature, such as at a range of
approximately
133 F to approximately 152 F, and in particular approximately 140 F to
approximately 145 F, such that approximately 30% to approximately 20% of the
temperature is diffused by the insulating properties of the insulating cup.
For purposes
of example, a person holding a solid paper cup containing coffee at 190 F can
feel
the exterior surface of the paper cup at a temperature of approximately 162
F, such
that only 15% is diffused by the paper cup. In an embodiment of the disclosed
subject
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matter, the multilayer blank includes a total heat flux of approximately 1800
W/m2 to
2000 W/m2. For purposes of example, an 18 pt paper cup will have a total heat
flux
of approximately 6890 W/m2.
As illustrated, the insulating cup 400 can have a generally
frustoconical shape. Alternatively, the cup can have other geometric shapes,
such as
cylindrical, rectangular, triangular, or any suitable geometrical shape. The
insulating
cup can include a suitable stiffness to support a hot substance or a cold
substance. For
example, but not limited to, the stiffness deflection can range from
approximately
0.35 lbs. force of deflection to approximately 1.2 lbs. force of deflection.
In accordance with the disclosed subject matter herein, a method of
making a multilayer article, comprising providing a first substrate having an
inner
surface and an outer surface and providing a second substrate having an inner
surface
and an outer surface. The method further includes disposing an expandable
insulating
material on the inner surface of at least one of the first substrate and the
second
substrate, wherein the expandable insulating material is in a first condition
during
disposing. The second substrate is adhered to the first substrate with the
expandable
insulating material thercbctween to form a blank, wherein an insulating space
is
defined between the first substrate and the second substrate with the
expandable
insulating material therein and the insulating space includes a first volume.
The
method further includes forming the blank into the article and expanding the
expandable insulating material of the article to a second condition by
application of
energy, wherein the expandable insulating material in the second condition
increases
the insulating space to a second volume.
FIG. 10 depicts a flow chart of the method of making a multilayer
article, according to an embodiment of the disclosed subject matter. The first
substrate
is provided, as depicted in step 501. The first substrate can be provided on a
roll or
web of material suitable for intim processing and downstream manufacturing by
an
apparatus.
The method further includes providing a second substrate as depicted
in step 503 of FIG. 10. The second substrate can be provided in a conventional
manner similar to the first substrate, i.e. on a roll or web of material as
known in the
art.
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As depicted in step 505 of FIG. 10, an expandable insulating material
is printed on the inner surface of at least one of the first substrate and the
second
substrate. As previously disclosed, the expandable insulating material in a
first
condition can be printed on the at least portion of the inner surface of at
least one of
the first substrate and the second substrate, as the webs of the first
substrate and the
second substrate are transported downstream. The disposing can be in a pattern
on the
portion of the inner surface of the first substrate, as previously disclosed
above. The
expandable insulating material can be printed on an inner surface area of the
substrates such that an outer margin of the substrates remain free of the
expandable
insulating material.
As depicted in step 507, the second substrate is adhered to the first
substrate. The second substrate can be coupled with the first substrate along
the outer
margin of the inner surface of the first substrate with an adhesive to form
the blank.
However, other embodiments of the disclosed subject matter as further
discussed
herein, contemplate the first substrate coupled with the second substrate
along the
entire surface areas thereof. In such embodiments, the adhesion can be between
any
pattern of expandable insulating material attached thereto. The second
substrate can
be coupled with the first substrate by conventional methods as known in the
art, for
example, pressure sensitive adhesion, glue, thermal bonding, or the like. The
first
substrate and the second substrate define an insulating space therebetween
with the
expandable insulating material therein wherein the insulating space includes a
first
volume when the first substrate and the second substrate arc adhered together.
As
previously discussed, the adhesive can be positioned within the insulating
space.
The method can also include forming the blank into an article, as
depicted in step 509 of FIG. 10. For example, the rnultilayer blank can be
manufactured to a desired shape or dimension as known in the art. Furthermore,
a
method of making an insulating cup including the rnultilayer blank as
disclosed is also
herewith contemplated. Conventional methods of making a cup are known. For
example, the following patents include such conventional methods: U.S. Patent
5,569,143;
U.S. Patent 5,624,367; and U.S. Patent 5,556,364. In one embodiment, the
application
further includes embodiments where a mandrel, heated or otherwise, fits within
the
insulating cup to form the structure of the cup. In other embodiments, the
application
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further includes embodiments where a mandrel, heated or otherwise, fits
exterior to
the insulating cup to form the structure of the cup and further embodiments
include
using a system of mandrels, heated or otherwise, fits within and exterior to
the
insulating cup to form the structure of the cup.
As depicted in step 511 of FIG. 10, the method further includes the
application of energy to expand the expandable insulating material in the
insulating
space to a second condition. The expandable insulating material in the second
condition increases the insulating space to a second volume. The application
of
energy can be applied by any conventional methods as known in the art, for
example
but not limited to, by use of an open/closed oven, hot air application,
microwave, laser
device, heated mandrel, radio frequency (RF), infrared, convection, conduction
or the
like.
The method can further include coating the blank with a substance,
such as a coating material. For instance, the outer surface of the first
substrate can be
coated with coating substance, as previously discussed. The method can also
include
coating the blank with ink or graphics, as known in the art.
Solely for purpose of illustration, FIGS. 11A-B depicts an insulating
cup 400, according to an embodiment of the disclosed subject matter. In this
example,
the insulating cup 400 was formed by wrapping, in lieu of the line processing
described with respect to FIG. 10, to show the different phases and substrates
of an
insulating cup 400 for purposes of illustration. FIG. 11A depicts a final
article of an
insulating cup 400 having a sidewall 415 of the multilayer blank with the
expandable
insulating material 200 in the second condition having the first substrate 110
coupled
to the second substrate 120.
FIG. 11B depicts the insulating cup 400 of FIG. 11A after the
application of suitable energy, with the second substrate removed for purposes
of
illustration. The insulating cup 400 was baked in an oven at approximately 230
F, in
this embodiment. In this FIG. 11B, the expandable insulating material 200 is
in the
second condition. In other embodiments of the disclosed subject matter, the
article is
placed in a convective heat tunnel at approximately 400 F to approximately
500 F
for a duration of approximately 60 seconds.
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EXPERIMENTS
The disclosed subject matter is further described by means of the
examples and experiments, presented below. The use of such examples is
illustrative
only and in no way limits the scope and meaning of the disclosed subject
matter or of
.. any exemplified term. Likewise, the disclosed subject matter is not limited
to any
particular preferred embodiments described herein. Indeed, many modifications
and
variations of the disclosed embodiments will be apparent to those skilled in
the art
upon reading this specification.
Experimentation was conducted to deteimine optimal characteristics of
the article and blanks, specifically for a hot cup application, according to
the
embodiments of the disclosed subject matter. A plurality of variables can
affect the
performance and characteristics of the article and blank, including but not
limited to
dimension of the screen mesh, the content of the beads and carrier medium, the
pattern of the expandable insulating material upon the substrates inclusive of
any
width dimension between stripes of expandable insulating material, the length
of the
drying time of the article or blank prior to the application of energy, the
kind of
energy applied, the intensity of the energy applied including the temperature
of heat
application, the duration of the energy or heat applied, whether the articles
were
loosely stacked during application of energy, whether the articles were
stacked as a
compressed unit during application of energy, the positioning of the adhesive
upon
the substrate(s), the thickness dimension of the adhesive upon the
substrate(s), and the
like.
In an embodiment of the disclosed subject matter, the expandable
insulation material can be disposed on the substrate(s) by using a screen mesh
of at
.. least one of approximately 60 Mesh, approximately 86 Mesh, approximately
110
Mesh, and any Mesh dimension therebetween, wherein the higher the Mesh screen
dimension, the lower the density of the beads within the carrier medium of the
expandable insulating material, as previously discussed. In another
embodiment, the
expandable insulating material includes a bead content of at least one of
approximately 15 percent of the expandable insulating material, approximately
20
percent of the expandable insulating material, approximately 25 percent of the
expandable insulating material, or combinations thereof. In another
embodiment, the
substrate(s) include stripes of expandable insulating material having a width
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dimension of at least one of approximately 0.23 inches, approximately 0.30
inches,
approximately 0.45 inches, or combinations thereof. In another embodiment, the
stripes of the expandable insulating material are spaced at a width dimension
of at
least one of approximately 0.04 inches, approximately 0.07 inches,
approximately
0.09 inches, or combinations thereof In another embodiment, the adhesive(s)
are
applied at a setting range between approximately 3 mil gap to approximately
7.5 mil
gap, and in particular at least one of approximately 4 mil gap, approximately
5 mil
gap, approximately 6 mil gap, or any setting therebetween. As such, a
thickness
dimension of the adhesive can range according to the setting parameter, and in
particular for purposes of example, the adhesive can have a thickness
dimension of
approximately 2.4 mil, approximately 2.9 mil, and approximately 3.5 mil for a
glue
adhesive having approximately 54% solids. In another embodiment of the
disclosed
subject matter, the article or blank is allowed to dry up to approximately 2
days prior
to the application of energy.
In another embodiment, heat energy is applied to the article or blank at
a temperature of at least one of approximately 400 F, approximately 450 F,
approximately 500 F, or anywhere therebetween for a duration of at least one
of
approximately 40 seconds, approximately 60 seconds, approximately 90 seconds
or
anywhere therebetween. In another embodiment, the articles are stacked after
the
application of energy to minimize distortion whereas other embodiments of the
disclosed subject matter contemplate unstacked articles during the application
of
energy.
Based on the plurality of combinations of the embodiments discussed
above, the article and blank can be customized for a variety of articles and
blanks of
varying needs. For example, by combining any of the plurality of combinations
of the
embodiments discussed above, the following characteristics can be customized:
weight of the article or blank, strength of the article or blank, the
thickness dimension
of the glue, the sidewall gauge of the article, the average sidewall
temperature of an
article, the average temperature at the portions of insulating material, the
duration of
time the article can be handled with a substance contained within the article
at 185
F, the appearance of the article or blank such as but not limited to a person
of ordinary
skill in the art judgment regarding aesthetics, wrinkles, distortion, and
delamination.
Based on the plurality of combinations of the embodiments discussed above,
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fractional factorial design experiments were conducted to demonstrate the
customized
characteristics of articles produced, according to aspects of the disclosed
subject
matter.
FIG. 12 provides characteristics of 36 samples of articles of the
disclosed subject matter, in particular cups, and a sampling of data from
experiments
conducted thereto. As evident from FIG. 12, controlling certain variables
provides
certain characteristics, which can be used for article and blank
customization, as
desired. The test protocols include gauge of the sidewall in which an
automated
equipment measures 18 thickness points starting 1 inch from the bottom of the
article
spaced 3/16 of an inch apart The average gauge is an average of all points
along the
sidewall, whereas the ridge gauge is a maximum gauge measured along the
sidewall
of the cup. The strength protocol includes strength wherein the force required
to
deflect a cup 0.25 inch at a location 1/3 of the total cup height from the top
using JS-1
rigidity tester is measured. The sidewall and temperature protocol is measured
with a
Flir 15 infrared camera and water at a temperature of approximately 185 F is
placed in
an un-lidded cup and the sidewall temperature image is taken from a 20 inch
distance
from the cup after a duration of approximately 60 seconds. The average
temperature is
within approximately a 1 inch by 1 inch square (15 pixels by 15 pixels) in a
center of
the cup opposite the seam, as shown in the example of FIG. 12A. The hold time
protocol test includes a cup handled from above the area where the sidewall
temperature measurement was conducted, picked up and held such that the hand
of
the tester did not contact the seam. The cup was held until a tester
determined the cup
was too uncomfortable to hold by a reasonable hand sensitivity of the tester.
The
appearance protocol includes a qualitative evaluation of cup appearance,
wherein the
0 signal is the best and the 3 signal is the worst, such that a good quality
is marked for
the 0 signal, wrinkles appear on the inner and/or outer surface of the cup for
a 1
signal, the cup is distorted for the 2 signal, and the cup experienced
delamination of
glued areas for the 3 signal.
FIG. 13 - FIG. 19 demonstrate various trends of the data gathered
from experimentation of the 36 samples of FIG. 12. FIG. 13 demonstrates the
data
means for the effects plot for weight of the samples, wherein the dimension of
the
screen mesh and the thickness dimension of the glue weight exhibit the
greatest
variable changes. As understood by persons of ordinary skill in the art, the
data means
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referred to herein and in the figures is the mean value of the data collected.
FIG. 14
demonstrates the data means for the effects plot for hold time in seconds of
the
samples containing a substance of 185 F, wherein the temperature of the oven,
the
dimension of the screen mesh and the duration of the articles in the oven
exhibit the
greatest variable changes. FIG. 15 demonstrates the data means for the effects
plot for
the sidewall of the samples containing a substance of 185 F, wherein the
dimension
of the screen mesh, the density of the Expancel beads of the expandable
insulating
material, and the duration of the articles in the oven exhibit the greatest
variable
changes.
FIG, 16 demonstrates the data means for the effects plot for the
average gauge of the samples, wherein the dimension of the screen mesh, the
density
of the Expancel beads of the expandable insulating material, and the duration
of the
articles in the oven exhibit the greatest variable changes. FIG. 17
demonstrates the
data means for the effects plot for the ridge gauge of the samples, wherein
the
dimension of the screen mesh, the density of the Expancel beads of the
expandable
insulating material, and the duration of the articles in the oven exhibit the
greatest
variable changes. FIG. 18 demonstrates the data means for the effects plot for
the
appearance of the samples such as distortion, delamination and the like,
wherein the
dimension of the screen mesh, the density of the Expancel beads of the
expandable
insulating material, and the duration of the articles in the oven exhibit the
greatest
variable changes. FIG. 19 demonstrates the data means for the effects plot for
the
strength of the samples, wherein the thickness dimension of the stripe of
expandable
insulating material, the dimension of the screen mesh, the density of the
Expancel
beads of the expandable insulating material, and the duration of the articles
in the
oven exhibit the greatest variable changes.
As evident from the plots of FIG. 13 - FIG. 19, by controlling certain
variables and varying other variables of the samples, customized articles are
contemplated with the aspects of embodiments of the disclosed subject matter.
FIG. 20 - FIG. 21 depict an embodiment of the disclosed subject matter
showing a blank juxtaposed with a frustroconical cup made from the blank. For
purposes of illustration only, the blank is shown with only a first substrate
and the
second substrate is not shown in the figure. FIG. 20 shows a front view of the
blank
and corresponding cup and FIG. 21 shows a back seam side view of the blank and
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corresponding cup of FIG. 20. As depicted, the expandable insulating material
is
disposed in ridges at an angle of approximately 45 F with respect an axis
perpendicular to the center longitudinal axis of the frustroconical cup. FIG.
21 depicts
the back seam side view of the frustroconical cup and blank of FIG, 20. Due to
the
frustroconical shape of the cup and the positioning of the ridges having no
degrees of
curvature, the angle of the striped expandable insulation material ridges is
approximately 29.3 F on the left side of the cup and 60.7 F on the right
side of the
cup. The parallelograms of expandable insulating material disposed at the
bottom of
the cup can comprise stacking lugs and can facilitate stacking and/or
securement of
cups.
FIG. 22 - FIG. 23 depict another embodiment of the disclosed subject
matter showing a blank juxtaposed with a frustroconical cup made from the
blank. For
purposes of illustration only, the blank is shown with only a first substrate
and the
second substrate is not shown in the figure. FIG. 22 shows a front view of the
blank
and corresponding cup and FIG. 23 shows a back seam side view of the blank and
corresponding cup of FIG. 22. As depicted, the expandable insulating material
is
disposed in ridges at an angle of approximately 45 F with respect the center
longitudinal axis of the frustroconical cup and disposed at a substantially
constant
radius of curvature of approximately 17.13 inches. The substantially constant
curve
line can be generated and manipulated based on an involute curve of the blank.
The
involute curve can in turn be used to design a curve on the top of the teeth
for the
machine gears of the apparatus manufacturing the blank and/or corresponding
article.
For purposes of example, in manufacturing a 16 ounce cup according to an
embodiment of the disclosed subject matter, the expansion cell curve line of
the blank
can have an increment of approximately 0.26 inch in the radius, every time the
angle
turns approximately 0.784 F. However, the increment can have any suitable
range
dimension depending on the blank and article being manufactured, as different
size
articles and blanks can have different angles and shapes which impact the
specifications of the involute curves and any matching substantially constant
curve
lines.
FIG. 23 depicts the back seam side view of the frustroconical cup and
blank of FIG. 22. Due to the frustroconical shape of the cup and the degree of
curvature of the ridges of expandable insulating material, the angle of the
striped
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expandable insulation material ridges at the seam is still approximately 45
F. Such
embodiment can facilitate better aesthetic appearance than the embodiment of
FIG.
20-21 and can increase strength for the cup.
FIG. 24 depicts another embodiment of the disclosed subject matter
showing a blank, similar to the embodiment of FIG. 22-23. The ridges of FIG.
24 are
disposed at a predetermined radius of curvature, as shown.
FIG. 25 and detail FIGS. 25A-25C depict another embodiment of the
disclosed subject matter showing a cup made from a blank. The ridges of FIG.
25 are
disposed at a predetermined radius of curvature, as shown. The cup is depicted
after
the application of energy to the cup such that the expandable insulating
material has
expanded to the second condition. As shown in the details FIGS. 25A-25C and
along
the side of cup of FIGS. 25A and 25B, adhesive has been disposed between the
ridges
of the insulating material such that the first and second substrate are
coupled to each
other at areas lacking the insulating material. According to the embodiment of
FIG.
25, the cup has a rolled rim and there is no insulating material at the top of
the cup, as
apparent in detail A. The insulating ridges create a unique topography about
the
surface area of the sidewalls of the cup.
FIG. 26 demonstrates the insulation characteristics of the article of the
disclosed subject matter of FIGS. 20-21, in comparison with an economy level
cup
and in comparison with an ultra premium cup. An example of an ultra premium
cup
can be found in the disclosure of U.S. Patent No. 7,552,841, entitled
"Reinforced
plastic foam cup, method of and apparatus for manufacturing same".
While the disclosed subject matter is described herein in terms of
certain preferred embodiments, those skilled in the art will recognize that
various
modifications and improvements may be made to the disclosed subject matter
without
departing from the scope thereof. Moreover, although individual features of
one
embodiment of the disclosed subject matter may be discussed herein or shown in
the
drawings of the one embodiment and not in other embodiments, it should be
apparent
that individual features of one embodiment may be combined with one or more
features of another embodiment or features from a plurality of embodiments.
In addition to the specific embodiments claimed below, the disclosed
subject matter is also directed to other embodiments having any other possible
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combination of the dependent features claimed below and those disclosed above.
As
such, the particular features presented in the dependent claims and disclosed
above
can be combined with each other in other mariners within the scope of the
disclosed
subject matter such that the disclosed subject matter should be recognized as
also
.. specifically directed to other embodiments having any other possible
combinations.
Thus, the foregoing description of specific embodiments of the disclosed
subject
matter has been presented for purposes of illustration and description. It is
not
intended to be exhaustive or to limit the disclosed subject matter to those
embodiments disclosed.
It will be apparent to those skilled in the art that various modifications
and variations can be made in the method and system of the disclosed subject
matter
without departing from the scope of the disclosed subject matter. Thus, it is
intended that the disclosed subject matter include modifications and
variations that are
within the scope of the appended claims and their equivalents.
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