CONTAINER WITH BARRIER LAYER

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 63/639,133, filed on Apr. 26, 2024.

INCORPORATION BY REFERENCE

The disclosure of U.S. Provisional Patent Application No. 63/639,133, which was filed on Apr. 26, 2024, is hereby incorporated by reference for all purposes as if presented herein in its entirety.

BACKGROUND OF THE DISCLOSURE

The present disclosure generally relates to containers and to constructs for forming containers and/or other suitable items. M ore specifically, the present disclosure relates to cups or other suitable containers for holding liquids (e.g., beverages, cooking oils, etc.) and/or solids (e.g., food products, etc.), the cups or other containers including a substrate and one or more coatings/laminations/films and having one or more seams.

SUMMARY OF THE DISCLOSURE

In general, one aspect of the disclosure is generally directed to a container for holding one or more products. The container can comprise a sidewall extending at least partially around an interior of the container. The sidewall can comprise at least a support layer and a barrier layer. A seam can comprise a first end margin of the sidewall in an overlapping relationship with a second end margin of the sidewall. The first end margin and the second end margin can be at least partially attached to one another. The barrier layer can comprise polyethylene terephthalate (PET).

In another aspect, the present disclosure is generally directed to a sidewall blank for at least partially forming a container for holding one or more products. The sidewall blank can comprise a support layer and a barrier layer, which can comprise polyethylene terephthalate (PET). A first end margin of the sidewall blank and a second end margin of the sidewall blank are for being at least partially attached to one another in an overlapping relationship to form a seam when the container is formed from the sidewall blank.

In another aspect, the present disclosure is generally directed to a method of forming a container. The method can comprise obtaining a sidewall blank. The sidewall blank can comprise a support layer and a barrier layer, wherein the barrier layer comprises polyethylene terephthalate (PET). The method further can comprise forming the sidewall blank into a sidewall of the container so that the sidewall extends at least partially around an interior of the container and forming a seam of the sidewall comprising attaching a first end margin and a second end margin of the sidewall to one another in an overlapping relationship.

Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

FIG. 1A is a plan view of a sidewall blank for forming a sidewall of a container according to exemplary embodiments of the disclosure.

FIG. 1B is a schematic cross-sectional view of the sidewall blank of FIG. 1A.

FIG. 2A is a plan view of a bottom blank for forming a bottom wall of the container according to the exemplary embodiments of the disclosure.

FIG. 2B is a schematic cross-sectional view of the bottom blank of FIG. 2A.

FIG. 3 is a perspective view of the container formed from the sidewall blank of FIGS. 1A and 1B and the bottom blank of FIGS. 2A and 2B according to the exemplary embodiments of the disclosure.

FIGS. 4A and 4B are schematic cross-sectional views of a seam of the container of FIG. 3 according to the exemplary embodiments of the disclosure.

FIG. 4C is a schematic cross-sectional view of a portion of a bottom of the container of FIG. 3 according to the exemplary embodiments of the disclosure.

FIGS. 5A and 5B are schematic cross-sectional views of a seam of the container of FIG. 3 according to alternative embodiments of the disclosure.

FIG. 5C is a schematic cross-sectional view of a portion of a bottom of the container of FIG. 3 according to alternative embodiments of the disclosure.

Corresponding parts are designated by corresponding reference numbers throughout the drawings.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

The present disclosure relates generally to various aspects of containers, constructs, cups, materials, packages, elements, and articles, and methods of making such containers, constructs, cups, materials, packages, elements, and articles. Although several different aspects, implementations, and embodiments are disclosed, numerous interrelationships between, combinations thereof, and modifications of the various aspects, implementations, and embodiments are contemplated hereby. In exemplary embodiments, the present disclosure relates to a container for holding, heating, cooking, refrigerating, storing, serving, etc. food items, beverage items, and/or various other articles. However, in other embodiments, the container can be used to form other non-food containing articles or may be otherwise used.

In this specification, the terms “inner,” “interior,” “outer,” “exterior,” “lower,” “bottom,” “upper,” and “top” indicate orientations determined in relation to fully erected and upright cartons. As described herein, constructs can be formed with multiple walls, panels, portions, tabs, flaps, and/or other aspects, which may be designated herein in terms relative to one another, e.g., “first,” “second,” “third,” etc., in sequential or nonsequential reference, without departing from the disclosure.

FIG. 1A is a plan view of the interior side 101 of a sidewall blank, generally indicated at 103, and FIG. 2A is a plan view of the interior side 105 of a bottom blank, generally indicated at 107, wherein the sidewall blank 103 and the bottom blank 107 are used in cooperation to form a container 109 (FIG. 3) according to an exemplary embodiment of the disclosure. In the illustrated embodiments, the container 109 is a cup for holding one or more food items and/or beverages and/or other products. Alternatively, the container 109 could be any suitable container (e.g., containers formed from two blanks such as a sidewall blank and a bottom blank and/or containers with a bottom wall that is offset from the lowermost support feature of the container and/or any suitable container having a sidewall seam or other suitable seam) for holding food and/or beverage items or other suitable liquid and/or solid materials. For example, the container 109 can be configured for holding beverages, soups, and/or other suitable products with high water content (e.g., products that are mostly water). Further, the container 109 can be configured to hold food items and/or other suitable products with lower water contents (e.g., products that may reach higher temperatures during heating/cooking). For example, products with high water content (e.g., soups, beverages, etc.) may be limited to the boiling temperature of water with respect to the temperature of the product that is in contact with the interior surface of the container 109. However, products with lower water content (e.g., solid foods, oils, etc.) can reach higher temperatures where the products contact the inner surface of the container 109, such as when heating/cooking the products, serving the products, etc. The container 109 could be alternatively shaped and/or could be alternatively formed without departing from the scope of this disclosure.

In the illustrated embodiments, the sidewall blank 103 has a longitudinal axis L1 and a lateral axis L2. In the illustrated embodiments, the sidewall blank 103 comprises a top edge 113, a bottom edge 115, a first end edge 117, and a second end edge 119 extending from the respective ends of the top and bottom edges 113, 115. In embodiments, the top edge 113 can comprise a convex curve (e.g., having a radius of curvature extending away from the bottom edge 115), and the bottom edge 115 can comprise a concave curve (e.g., having a radius of curvature extending toward the top edge 113) so that the sidewall blank 103 forms a generally cylindrical sidewall that is at least partially tapered (e.g., the diameter at the top of the sidewall is greater than the diameter at the bottom of the sidewall) as shown by way of example in FIG. 3. Further, as shown in FIG. 1A, the end edges 117, 119 can be oblique, extending at an acute angle with respect to the lateral direction L2. As shown in FIG. 2A, the bottom blank 107 can have a generally circular perimeter (e.g., can be in the shape of a disc). The sidewall blank 103 and/or the bottom blank 107 could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure. For example, one or more of the edges 113, 115, 117, 119 could be orthogonal (e.g., generally orthogonal) and/or straight (e.g., generally straight) and can, for example, form a cylindrical sidewall that is not tapered (e.g., that has a generally constant diameter) without departing from the disclosure.

As shown in the schematic cross-sectional view of FIG. 1B, the sidewall blank 103 can include a sidewall substrate or support layer 121 extending along an exterior surface 123 of the sidewall blank 103 and a side coating or barrier layer 125 extending along the interior side 101 (e.g., product-contacting side 101) of the sidewall blank 103. Similarly, as shown in the schematic cross-sectional view of FIG. 2B, the bottom blank 107 can include a bottom substrate or support layer 127 extending along an exterior (or bottom) surface 129 of the bottom blank 107 and a bottom coating or barrier layer 131 extending along the interior side 105 (e.g., product-contacting side 105) of the bottom blank 107. In embodiments, each of the substrates 121, 127 can be formed from one or more layers of a paper-based material (e.g., paperboard, cardboard, etc.) and/or could be formed of any other suitable material. In exemplary embodiments, the barrier layers 125, 131 can be liquid and/or gas barrier layers that can help reduce fluids from being absorbed and/or passing through the substrate at least for as long as the container 109 is intended to hold one or more products.

In embodiments, the barrier layers 127, 129 can comprise polyethylene terephthalate (PET) or another suitable material. In exemplary embodiments, the PET barrier layers can be applied to the substrates 121, 127 by extrusion and/or other suitable coating methods (e.g., flood coating, application with nozzles and/or rollers, etc.). In exemplary embodiments, the barrier material (e.g., PET) extending along the interior 142 of the container 109 can have softening and/or melting temperature that is higher (e.g., significantly higher) than the boiling point of water. For example, PET materials can have a melting point of up to about 500 degrees Fahrenheit (F) or higher (about 260 degrees Celsius (C) or higher), such as between about 225 degrees C. and about 255 degrees C. (about 437 degrees F. to about 491 degrees F.). In exemplary embodiments, the barrier material can have a melting point of above 200 degrees C. (about 392 degrees F.) for withstanding contact with products that may reach temperatures that are significantly higher than the boiling temperature of water. Accordingly, the container 109 can hold products (e.g., food items, beverages, etc.) that can reach temperatures (e.g., surface temperatures) of more than the boiling point of water during cooking/heating while avoiding degradation and/or compromising of the barrier properties of the barrier layers and/or avoiding adulterating of the products by the barrier material such as due to softening and/or melting of the barrier material. For example, the container 109 can hold products with high temperatures while avoiding a reduction in the ability of the barrier layers 125, 131 to prevent liquids in the interior 142 from being absorbed into the substrates 121, 127 (e.g., paperboard layers) of the container 109 and/or in the ability of the barrier layers 125, 131 to prevent gas such as oxygen from moving through the sidewall or bottom of the container 109. In exemplary embodiments, most foods can be heated in the container 109 with the PET barrier layers in a microwave or conventional oven.

As shown in FIG. 1A, an end margin 135 extends along the end edge 117 of the sidewall blank 103 and a bottom margin 137 extends along the bottom edge 115 of the sidewall blank 103. In the illustrated embodiments, a second end margin 139 can extend along the end edge 119 of the sidewall blank 103, opposite to the first end margin 135, and a top margin 141 can extend along the top edge 113 of the sidewall blank 103, opposite to the bottom margin 137.

In embodiments, the barrier layer 125 can include a heat seal primer or other suitable material(s) that can facilitate the bonding of the PET barrier layer 125 at the end margins 135, 139 and/or at the bottom margin 137 and the bottom blank 107. In exemplary embodiments, forming the seam(s) of the container as described below can be more challenging with the PET barrier layer 125 than other materials (e.g., PE) that could be used as a barrier layer on a container since PET has a higher melting temperature than such other materials. A heat seal primer can be added to the PET to help seal the barrier layer 125 extending along the first end margin 135 to the substrate 121 extending along the second end margin 139, for example. For example, the heat seal primer could be MICA MC634 (available from Mica Corporation in Shelton, CT), MICA R-1509-C (available from Mica Corporation in Shelton, CT), and/or any other suitable primer and/or other suitable material for facilitating the formation of a seam of a container with a high melting point polymer barrier layer. In embodiments, the heat seal primer can be applied to the barrier layer 125 such as by printing (e.g., with flexographic, gravure, and/or other suitable printing processes) and/or by another suitable process. For example, the heat seal primer can be printed onto the barrier layer 125 along the first end margin 135 and/or along the bottom margin 137, such as in the area along the margins 135, 137 schematically shown by the broken line 140 in FIG. 1A. In alternative embodiments, the heat seal primer or other suitable material could be included in at least a portion of the barrier material (e.g., PET) forming the barrier layer 125 or could be otherwise added to the barrier layer 125.

In the illustrated embodiments, the sidewall blank 103 and the bottom blank 107 can be formed into the container 109 having an interior 142 as shown in FIG. 3. For example, the sidewall blank 103 can be bent and curved (e.g., around a mandrel, not shown) to form a sidewall 143 of the carton 109. As shown in FIG. 3, the end margins 135, 139 of the sidewall blank 103 adjacent the respective end edges 117, 119 overlap one another to form a side seam 145 of the sidewall 143. As shown in the schematic cross-sectional views of FIGS. 4A and 4B, the seam 145 includes the portion of the side barrier layer 125 extending along the first end margin 135 and positioned between the portions of the substrate 121 that extend along the first end margin 135 and the second end margin 139. The portion of the side barrier layer 125 that extends along the second end margin 139 faces toward the interior 142 of the container 109. In embodiments, the side barrier layer 125 can at least partially form a seal (e.g., a heat seal) along the seam 145, wherein heat and/or pressure can be applied along the seam 145 so that at least the side barrier layer 125 fuses the end margins 135, 139 together and forms a seal (e.g., a liquid-proof and/or liquid resistant seal). In embodiments, the heat seal primer printed on or otherwise added to at least the portion of the side barrier layer 125 along the first end margin 135 can facilitate the fusing of the side barrier layer 125 along the first end margin 135 to the substrate 121 along the second end margin 139, forming the sealed seam 145. The sidewall 143 and/or the seam 145 could be otherwise formed without departing from the disclosure. For example, an adhesive and/or a heat seal material can be applied between the end margins 135, 139 to at least partially form the seal along the seam 145. In another example, the seam 145 could be at least partially formed by ultrasonic welding and/or other suitable processes.

As shown in FIGS. 3 and 4C, the bottom blank 107 can be secured to the interior surface 101 of the sidewall 143 to form a bottom wall 147 of the container 109. In the illustrated embodiments, the bottom wall 147 and the sidewall 143 can extend at least partially around and can at least partially form the interior 142 of the container 109. In embodiments, a marginal portion 149 of the bottom wall 147 can be folded with respect to the central portion of the bottom wall and can be attached in face-to-face contact with the bottom margin 137 of the sidewall 143 to form a bottom seam 151 (FIG. 4C). In the illustrated embodiments, the marginal portion 149 of the bottom wall 147 and the bottom margin 137 of the sidewall 143 can be secured (e.g., heat sealed) together, such as by applying heat and/or pressure so that the side barrier layer 125 along the bottom margin 137 cooperates with the bottom barrier layer 131 of the marginal portion 149 to fuse the marginal portion 149 and the bottom margin 137 together and form a seal (e.g., a liquid-proof and/or liquid resistant seal) along the bottom seam 151. In embodiments, the heat seal primer can be included along the bottom margin 137 to facilitate the fusing of the barrier layers 125, 131 along the bottom seam 151. In another example, a heat seal primer can be included along at least a portion of the bottom wall 147 instead of or in addition to the bottom margin 137. Alternatively, the heat seal primer could be omitted from the bottom margin 137 and the bottom wall 147. The bottom wall 147 could be otherwise formed and/or could be otherwise sealed to the sidewall 143 without departing from the disclosure. For example, an adhesive and/or a heat seal material can be applied between the bottom margin 137 and the marginal portion 149 to at least partially form the seal along the bottom seam 151. In another example, the bottom seam 151 could be at least partially formed by ultrasonic welding and/or other suitable processes.

In embodiments, a rolled rim 155 can be formed at a top end of the container 109. For example, the top edge 113 can be rolled outwardly and downwardly along the top margin 141 to form the rolled rim 155. The rolled rim 155 could be omitted or could be otherwise formed without departing from the disclosure.

The formed container 109 is shown in FIG. 3 by way of example. In the illustrated embodiments, the marginal portions 137, 149 forming the bottom seam 151 can extend downwardly from the portion of the bottom wall 147 extending along the interior 142 of the container 109 to a support edge 153 of the container 109 (FIGS. 3 and 4C). In embodiments, the container 109 can be a cup with a bottom wall 147 that is supported above the lowermost support element (e.g., support edge 153) so that the bottom wall 147 is offset from/spaced upwardly from a supporting surface on which the container 109 is placed (e.g., with the support edge 153 in contact with the supporting surface).

In an alternative embodiment shown in FIGS. 5A-5C, a secondary layer 133 can be included along at least a portion of the side seam 145′ and/or along at least a portion of the bottom seam 151′ for forming the seal or for helping to form the seal at the seams 145′, 151′. For example, the secondary layer 133 can extend along the interior side 101 of the sidewall blank 103 along at least a portion of the end margin 135 and the bottom margin 137 and/or along the interior side 105 of the bottom blank 107 along at least a portion of its marginal portion 149. Alternatively, or in addition, the secondary material 133 could be applied on the exterior side of the sidewall blank 103 along at least a portion of the end margin 139. In embodiments, the secondary layer 133 can include one or more layers of the material that makes up the barrier layers 125, 131 (e.g., PET) and/or another suitable material for facilitating the formation of the seal along the seams 145′, 151′ (e.g., adhesive, heat seal material, etc.). For example, the secondary layer 133 could be the barrier material of the side barrier layer 125 (e.g., PET) including the heat seal material, and the secondary layer 133 can be applied (e.g., printed) onto the barrier layer 125 of the sidewall blank 103 (e.g., in the areas of the margins 135, 137 schematically shown by the dashed line 140 in FIG. 1A). The secondary layer 133 could be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.

In embodiments, the container 109 (e.g., a cup formed from two blanks, such as the sidewall blank 103 and the bottom blank 107, a cup formed with a bottom wall that is supported above the bottom support edge of the container 109, and/or any other suitable container with one or more suitable seams) can have barrier layers 125, 131 comprising PET, which can have improved barrier properties over other materials used in cups, and/or can be used to heat products to higher temperatures. For example, other containers (e.g., cups) can have barrier layers including polyethylene (PE), which can have melting points between 210 degrees F. and 230 degrees F. (between 99 degrees C. and 110 degrees C.) and can be suitable for heating products to temperatures below these melting points (e.g., water-based products). In contrast, grades of PET can have melting points of up to about 500 degrees F. or more and, accordingly, can be in contact with products heated to higher surface temperatures than PE materials can without degradation and/or compromising of the barrier properties of the PET barrier layers and/or without adulteration of the product by the product-contacting layers. Stated another way, the barrier properties of a PE food-contacting layer may be compromised when containing food products that can have surface temperatures above the boiling temperature of water, while a PET food-contacting layer would not be compromised by such food products. Accordingly, PET barrier layers can be used to heat foods that may need to be heated to sufficient temperatures so that the inner-most parts of the products are heated to safe temperatures (e.g., to destroy potential pathogens), which may lead to the surface temperatures of the product (which may be in contact with the barrier layers) to reach higher temperatures. Further, PET materials can form an improved barrier to water and oxygen, for example, so that a broader range of products can be stored in the container 109 (e.g., foods that are more sensitive to oxygen).

In addition, the container 109 (e.g., having the paperboard substrates 121, 127 and PET barrier layers 125, 131) can have advantages over polypropylene (PP) cups used to store and/or heat products. For example, the container 109 can have an 80% to 90% reduction in the amount of plastic used in the packaging when compared to PP cups.

Any of the dimensions and/or other parameters noted above or otherwise included in this disclosure are approximate and could be larger or smaller than noted or could be inside or outside the listed ranges without departing form the scope of the disclosure. All of the dimensional information presented herein is intended to be illustrative of certain aspects of the disclosure and is not intended to limit the scope of the disclosure, as various other embodiments of the disclosure could include dimensions that are greater than or less than the dimensions included herein.

The blanks according to the present invention can be, for example, formed from coated paperboard and similar materials. For example, the interior and/or exterior sides of the blanks can be coated with a clay coating. The clay coating may then be printed over with product, advertising, price coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on either or both sides of the blanks.

In accordance with the exemplary embodiments, the blanks and/or other constructs may be constructed of paperboard of a caliper such that it is heavier and more rigid than ordinary paper. The blanks can also be constructed of other materials, such as cardboard, hard paper, or any other material having properties suitable for enabling the carton package to function at least generally as described above.

The foregoing description illustrates and describes various embodiments of the present disclosure. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, and alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments, but various other combinations, modifications, and environments are contemplated and are within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non-illustrated embodiments without departing from the scope of the disclosure.