Patent ID: 8444902

Claim:
A method for forming a container having an injection-molded feature, comprising: obtaining a blank; obtaining a tool, the tool comprising a cavity having at least one sidewall for forming at least one sidewall of the container, a core operatively connected to the cavity, an injection cavity for receiving liquid resin and directing liquid resin around at least a portion of the perimeter of the cavity to form the injection molded feature of the container, the injection cavity having an advanced-flow section and a delayed-flow section, the advanced-flow section having a greater cross-sectional area than the delayed-flow section, and the advanced-flow section being located adjacent the at least one sidewall of the cavity; placing the blank in the tool; then closing the tool while the blank is in the tool, the closing the tool comprises the core entering the cavity so that the blank is formed into a three-dimensional article that is in the closed tool, the three dimensional article having at least one sidewall and a flange that extends from the sidewall, the three dimensional article being positioned in the tool such that the injection cavity extends around the outer edge of the flange; then forming the injection-molded feature on the article while the article is in the closed tool, the forming comprises injecting resin into the injection cavity so that resin flows along the underside of the flange and around the perimeter of the article, the injecting resin comprises forming a flow front comprising resin in the advanced-flow section flowing at a higher flow rate than resin in the delayed-flow section, the resin injected in the advanced-flow section being in contact with the at least one sidewall and the underside of the flange and extending around the perimeter of the article; and then removing the article with the injection-molded feature from the tool.