Source: https://patents.google.com/patent/US9648969B2/en
Timestamp: 2018-12-16 02:57:32
Document Index: 528873539

Matched Legal Cases: ['§119', 'art.\n6', 'Application No. 1', 'application No. 07754092', 'Application No. 10', 'application No. 2007245165', 'application No. 571637', 'application No. 593231', 'application No. 2008141055', 'application No. 200807307', 'Application No. 2009', 'Application No. 2009', 'Application No. 593231', 'application No. 200780018298', 'application No. 200780018298', 'application No. 201380044374', 'Application No. 201410708435', 'application No. 1', 'Application No. 2010001881', 'application No. 96111303', 'application No. 201109426']

US9648969B2 - Insulating packaging - Google Patents
Insulating packaging Download PDF
US9648969B2
US9648969B2 US12490121 US49012109A US9648969B2 US 9648969 B2 US9648969 B2 US 9648969B2 US 12490121 US12490121 US 12490121 US 49012109 A US49012109 A US 49012109A US 9648969 B2 US9648969 B2 US 9648969B2
US12490121
US20090321508A1 (en )
B31B2201/622—
B31B2201/628—
B31B50/753—Coating; Impregnating; Waterproofing; Decoating by spraying
B31B50/756—Coating; Impregnating; Waterproofing; Decoating by spraying only the interior of the boxes
A package or container includes a side wall, the side wall having an inner surface and an outer surface. At least one of the inner surface or the outer surface of the side wall may be at least partially coated by a layer of a insulating material. The material may be adapted to be expanded to provide thermal insulation.
The present patent application is a continuation-in-part of application Ser. No. 11/728,973 filed Mar. 27, 2007 and which claims the benefit of the filing date under 35 U.S.C. §119(e) of Provisional U.S. Patent Application Ser. No. 60/789,297, filed Apr. 3, 2006. All of the foregoing applications are hereby incorporated by reference.
Consumers frequently purchase ready-made products, such as food and beverages, in containers. Thermally insulated containers may be designed for hot or cold liquids or foods, such as hot coffee, iced-tea, or pizza. These containers may maintain the temperature of the liquid or food contents by reducing heat or cold transfer from the contents to the consumer's hand.
A package, container, or container sleeve includes a side wall, the side wall having an inner surface and an outer surface. At least one of the inner surface or the outer surface of the side wall may include a layer of an insulating material.
FIG. 19 is an example graph showing a thermal conductivity of example containers.
FIG. 20 is an example graph showing thermal insulation of example containers.
FIG. 21 is an example graph showing thermal insulation of example containers.
A package, container, or container sleeve may be constructed of, and/or insulated with a insulating material. The insulating material may be fixed to a container or it may be applied to a removable sleeve. Insulating material, such as thermally-expandable and/or void containing material may be applied to the container or an outer wall or both. Insulating materials that are not expandable, or that are expanded in ways other than by temperature may also be used, for example, pressure sensitive materials, light sensitive materials, microwave sensitive materials and others. The insulating material may be expanded before reaching an end user, such as when the container and/or container sleeve are manufactured, and/or the insulating material may be expanded only on end use and only in response to, for example, temperature or pressure. The insulating material may be used to aid with insulating capabilities of the container and/or container sleeve, and/or to add rigidity to the container and/or the container sleeve, such as to reduce a thickness of the material components of container and/or container sleeve.
The insulating material 216 may be expandable when wet or dry. The insulating material 216 may include any synthetic or natural material including aqueous based, solvent based, high solids, or 100% solid materials. The amount of solid content is typically 30% to 80% of the material, and more preferably 40% to 70%. Additional ingredients may be added to the binder and/or insulating material 216, including but not limited to, pigments or dyes, fillers/extenders, surfactants for dispersion, thickeners or solvents to control viscosity for optimized application, foaming agents, defoaming agents, additives like waxes or slip aids, etc. Alternatively, the binder and/or insulating material 216 may be an adhesive. The insulating material 216 may have several properties, including but not limited to thermal insulation to keep container contents hot or cold, absorption of condensation and/or liquid, and/or it may expand on contact with hot material (such as, over 150° F.), and preferably remains inactive before a determined designed activation temperature, such as at about room temperatures. The insulating material 216 may be repulpable, recyclable, and/or biodegradable.
Alternatively or additionally, the insulating material 216 may be a coating or adhesive that is combined with a blowing agent or foaming agent. The blowing or foaming agent may generate a gas upon heating which may activate the insulating material 216 to assume, for example, air voids, a cellular structure, or otherwise. Alternatively, the blowing or foaming agent may be a material that decomposes to release a gas under certain conditions such as temperature or pressure. Heating may occur during filling of the container with contents 206, such as hot food or beverage. Alternatively, heating may occur from an external source—such as a microwave or water bath.
FIG. 5 illustrates a cross section of an outer wall 104, such as a sleeve, assembled with the container 100. This figure is meant to be illustrative and not limiting. The cup may be replaced with any container, for example, a press-formed tray, a soup tub, or a bulk beverage container. The outer wall 104 may have an inner face 506 and an outer face 504. An insulating material 216 may be applied to the inner face 506, the outer face 504, and/or to a surface 502 between the inner face 506 and the outer face 504, such as to an inner wall of the sleeve. The inner face 506 and outer face 504 do not necessarily contain a space therebetween.
The insulating material 216 may be activated and thereby expanded by, for example, adding contents 206, such as hot liquid, beverage or food into the container 100. Alternatively or additionally, the container 100 may be prefilled with contents 206, such as beverage or food and the insulating material 216 may be activated upon heating such as by microwave or water bath. Activation may occur only at the consumption stage and not at the processing stage of the outer wall 104, such that the outer wall 104 may be shipped to the consumer with a substantially inactivated insulating material 216. For example, the activation point of the insulating material 216 may be about 120° F. or higher and/or less than 60° F., such that the insulating material 216 may be activated only by the temperature of hot (or cold) liquids, beverages, or food and not activated by ambient or body temperature. The activation may cause the expandable material to expand and “push back” the outer wall 104 from the container 100 creating an increased air gap. The air gap may create a thermal barrier between the hot beverage container 100 and the hand of the consumer. The activation may also enhance the stiffness and/or rigidity of the container, which may allow for a reduction in the material or thickness of the container wall. As described in more detail below, the insulating material 216 may also be activated, or at least partially activated, before reaching the consumer. Consequently, this ability of the insulating material 216 to respond to target temperature can make the container or sleeve “smart” in the sense that it can increase its insulation as the packaged content 206 gets hotter.
Q T[Cal./second]=Q 1 +Q 2 +Q 3 +Q 4
Where QT is the total heat loss. Q1 1504 may be the heat loss due to water evaporation. Q2, Q3, and Q4, represented by 1502, 1506, and 1508, respectively, may represent the convectional and conductional heat loss.
FIG. 19 provides a graphical representation of how the insulating material 216 may alter thermal conductivity. The temperature on the inside of a cup may be represented by Ti. The temperature on the outside of the cup may be represented by To. The top line, X, may represent a container without the coated outer wall 104. The second line, Y, may represent a container assembled with a coated outer wall 104. This example may illustrate that, in a container without an outer wall 104 coated with the insulating material 216, the difference in the temperature inside versus the outside of the container may be very small. In a container with a outer wall 104 coated with the insulating material 216, the difference in the temperature between inside and outside may be small when the hot food or beverage is added to the container. However, the food or beverage may activate the material, A, on contact, causing the material to expand. When the material expands, the difference in temperature Ti−To, may increase.
Example 2 illustrates temperature sensory comparison of various outer wall 104 materials coated with the insulating material 216 compared to without the insulating material 216. The following experiment is for illustration only and is not limiting, other experimental results might be obtained.
An insulating material 216, such as a thermally, or other, expandable material may be applied to outer wall 104 blanks made of various materials, such as but not limited to paper, paperboard, and fluted corrugated paper. Each outer wall 104 blank may be wrapped around a container, such as a cup. The cup may be filled with hot water. The cups may then be handled with bare hands and a comparison made between the sensory responses to the two conditions. In each test, the cups with coated outer wall 104 were less “hot” to the touch than those with uncoated outer wall 104. Expansion occurred within a few minutes of pouring hot water into the cup.
Coatings of insulating material 216 may be applied to a single face medium. The coating may be expanded when wet using a MASTER-MITE 120 V, 475 W heat gun at 600 degrees F.
Coatings of insulating material 216 may be applied to the outside of a 12 Oz cup and allowed to air-dry overnight. The next day, 190 degree F. hot water may be poured into the cup. Noticeable expansion may be observed shortly after filing the 190 degree F. hot water into the cup. Lids may be placed on the cup, and after 7 minutes more expansion may be observed, but still partial expansion. A benefit of post-heat activation may be that the hotter the liquid the more the coating expands.
A coating of an insulating material 216 was applies to a cup. A 250 W IR heater manufactured by Fisher Scientific model no. 11-504-50 may be used to heat the insulating material 216. Expansion may be slow when the lamp is six inches away from the insulating material 216 and immediate when one inch away from the insulating material 216.
Coatings of insulating material 216 may be applied to paper, which may them be wrapped around a paper cup after the coating is allowed to air dry. Heat from a heat gun may be used to heat the part of the insulating material 216 coating indirectly through the paper shell for one minute. The coating expanded. Another part of the unheated insulating material 216 coating may be heated under an IR lamp through the paper. The insulating material 216 coating expanded.
An insulating material 216, such as a heat expandable coating, may be applied within the walls of a double wall sleeve or container, such as a cup. During manufacture, the insulating material 216 may be adequately dried but not expanded, or not fully expanded. When the sleeve or container is exposed to high temperature, such as the temperature of coffee or soup, the insulating material 216 may expand pushing the walls of the double wall sleeve or container away from each other. This expansion through activation may “smartly” increase the air voids in the insulating material 216 as well as the insulation and rigidity of the package. The following details an experiment illustrating how use of the insulating material 216 decreases a weight of a material used in the manufacture of a container or container sleeve. Although the experiment employs a limited set of materials, they demonstrate the feasibility and benefits of the insulating material 216.
Two samples were compared. The reference container was a 16 ounce disposable cup with a 16 pt outer wrap. The experimental container was a 16 ounce disposable cup with a pattern of insulating material 216, in this case a foam coating, and a 12 pt outer wrap. Both cups were filled with 190 F water. The insulating material 216 of the experimental container expanded upon addition of the 190 F water. The outer surface temperature of each cup was measured and plotted in FIG. 20. The experimental cup displayed improved insulating properties during the first few minutes of the experiment.
A second trial illustrated the use of container sleeves. The reference container sleeve was an N-flute single face sleeve. The experimental container sleeve was an N-flute single face sleeve with an inside layer of insulating material 216, in this case, foam coating. A layer of kraft paper was laminated over the layer of insulating material 216 and the material was dried, but not expanded. The insulating material 216 was applied in two patterns: full coverage and lines running from the top to the bottom of the sleeve. To summarize, there were five formats of container sleeves tested:
N-flute single face sleeve with inner layer of kraft paper
N-flute single face sleeve with inner layer of dried non-expanded heat activatable aqueous coating (“AP”) and an inner layer of kraft paper
N-flute single face sleeve with inner layer of expanded heat activatable aqueous coating and no layer of kraft paper
N-flute single face sleeve with inner layer of expanded heat activatable aqueous coating arranged in vertical lines and inner layer of kraft paper
N-flute single face sleeve with a full coverage inner layer of expanded heat activatable aqueous coating and inner layer of kraft paper
The sleeves were applied to a 16 oz disposable cup which was filled with 190 F water. After filling, the temperature of the outside of the cup was tested at one minute intervals for 5 minutes. The results are charted in FIG. 21.
The cups and sleeves containing the foam coatings also had higher rigidity, even at a reduced paper stock. The patterned foamed coating prevented even the 12 pt outer wrap from collapsing into the inner wall during handling. This may allow the use of lower basis weight and caliper paper board while maintaining good insulation.
an outer wall attached to the inner wall;
a single layer of expanded insulation arranged in a plurality of bands between and in contact with both the inner wall and the outer wall to create a plurality of air channels between the inner wall and the outer wall, the expanded insulation being formed from an insulating material including expandable microspheres having an activation temperature not exceeding 190° F., the plurality of bands of expanded insulation include expanded, non-ruptured microspheres.
2. The double-wall container of claim 1 where the expanded insulation comprises a synthetic or natural material.
3. The double-wall container of claim 1 where the expanded insulation accommodates a reduction in a weight of a paper stock used to form the inner wall and the outer wall.
4. The double-wall container of claim 1 where the expanded insulation is applied in a striped pattern that is continuous or intermittent.
5. The double-wall container of claim 4, wherein the stripes are positioned a variable distance apart.
6. The double-wall container of claim 1, wherein the expanded insulation prevents the outer wall from collapsing onto the inner wall under holding pressure.
7. The double-wall container of claim 1, further comprising openings near a top of the outer wall, exposing at least some of the air channels and configured to provide air flow along the at least some of the air channels.
8. The double-wall container of claim 7 further comprising openings near a bottom of the outer wall, exposing the at least some of the air channels.
9. The double-wall container of claim 1, wherein the air channels extend between the inner wall and the outer wall from a bottom edge of the container to a top edge of the container.
10. The double-wall container of claim 1, wherein the air channels direct heat convection upward.
11. The double-wall container of claim 1, wherein the air channels reduce horizontal heat transfer.
12. The double-wall container of claim 1 where the plurality of bands are horizontal or spiral bands.
13. The double-wall container of claim 1 where the inner and outer walls are of a paper stock material.
14. The double-wall container of claim 13 where the paper stock material is provided in roll or web form.
15. The double-wall container of claim 14 where the paper stock material is flexible to be provided in roll or web form.
16. The double-wall container of claim 13 where the paper stock material of the inner wall is different from the paper stock material of the outer wall.
17. A double-wall container, comprising:
a single layer of expanded insulation arranged between the inner wall and the outer wall to create air gaps between the inner wall and the outer wall, the single layer of expanded insulation engaging both the inner wall and the outer wall, the single layer of expanded insulation being formed from an insulating material including expandable microspheres having an activation temperature not exceeding 190° F. such that the single layer of expanded insulation includes expanded, non-ruptured microspheres between the inner wall and the outer wall.
18. The double-wall container of claim 17, wherein the microspheres have an activation temperature greater than 150° F.
19. The double-wall container of claim 17, further comprising:
an adhesive material different than the expanded insulation, the adhesive material arranged between the inner wall and the outer wall and bonded thereto.
20. The double-wall container of claim 19, wherein the adhesive material is a hot melt adhesive.
21. The double-wall container of claim 19, wherein the adhesive material is a cold melt adhesive.
22. The double-wall container of claim 17, wherein the inner wall and the outer wall form a wall assembly, and wherein the wall assembly includes at least a portion thereof formed of a coated stock material.
23. The double-wall container of claim 17, wherein the expanded insulation further comprises a synthetic binder material, wherein the synthetic binder material is a thermoplastic binder, and wherein the microspheres are disposed in the thermoplastic binder.
24. The double-wall container of claim 17, wherein the expanded insulation further comprises a natural binder material, wherein the natural binder material is a starch-based material, and wherein the microspheres are disposed in the starch-based material.
25. The double-wall container of claim 17 where the inner and outer walls are of a paper stock material.
26. The double-wall container of claim 25 where the paper stock material is provided in roll or web form.
27. The double-wall container of claim 26 where the paper stock material is flexible to be provided in roll or web form.
28. The double-wall container of claim 25 where the paper stock material of the inner wall is different from the paper stock material of the outer wall.
29. A double-wall container, comprising:
a single layer of expanded insulation engaging both the inner wall and the outer wall to create air gaps between the inner wall and the outer wall, the single layer of expanded insulation being formed from an insulating material including expandable microspheres having an activation temperature not exceeding 190° F.; and
an adhesive that is different than the expanded insulation and that adheres the inner wall and the outer wall together with the single layer of expanded insulation including expanded, non-ruptured microspheres therebetween.
30. The double-wall container of claim 29, wherein the single layer of expanded insulation has a thickness in an expanded state that is approximately 100-400% greater than a thickness in an unexpanded state.
31. The double-wall container of claim 29, wherein the single layer of expanded insulation is formed from an insulating material having a thickness of approximately 1/64th of an inch in an unexpanded state.
32. The double-wall container of claim 29, wherein the single layer of expanded insulation has a thickness of approximately 1/32nd of an inch.
33. The double-wall container of claim 29, wherein the single layer of insulating material has a thickness of approximately 1/16th of an inch.
34. The double-wall container of claim 29 where the inner and outer walls are of paper stock material.
35. The double-wall container of claim 34 where the paper stock material is provided in roll or web form.
36. The double-wall container of claim 35 where the paper stock material is flexible to be provided in roll or web form.
37. The double-wall container of claim 36 where the paper stock material of the inner wall is different from the paper stock material of the outer wall.
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US78929706 true 2006-04-03 2006-04-03
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CA2766553C (en) 2015-03-17 grant
US20090321508A1 (en) 2009-12-31 application
CN106081372B (en) 2018-10-02 grant
US9591937B2 (en) 2017-03-14 grant
RU2011152262A (en) 2013-07-27 application
EP2445651B1 (en) 2016-10-05 grant
CN102802808B (en) 2016-06-01 grant
WO2010151456A1 (en) 2010-12-29 application
US20140103103A1 (en) 2014-04-17 application
KR101882294B1 (en) 2018-07-27 grant
KR20180085832A (en) 2018-07-27 application
CN102802808A (en) 2012-11-28 application
CN106081372A (en) 2016-11-09 application
CA2766553A1 (en) 2010-12-29 application
JP2012531363A (en) 2012-12-10 application
JP2016210513A (en) 2016-12-15 application
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EP2445651A1 (en) 2012-05-02 application
KR20130023188A (en) 2013-03-07 application
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