Blank for container

Abstract

A blank made of a polymeric material is provided and used to form at least a portion of a container. The blank is folded to establish a base and a side wall included in the container.

Claims

1. A blank for a container comprising a base including at least a first edge, a second edge spaced apart from the first edge, a third edge, and a fourth edge spaced apart from the third edge, a first side wall coupled to the base along the first edge, a second side wall coupled to the base along the second edge, a front wall coupled to the base along the third edge, and a back wall coupled to the base along the fourth edge, wherein the blank is made from a sheet of insulative cellular non-aromatic polymeric material, wherein the insulative cellular non-aromatic polymeric material includes a cell forming agent and a base resin having a high melt strength polypropylene, wherein each of the first side wall, the second side wall, the front wall, and the back wall all have a first thickness and the blank further comprises a flap at an outboard edge of the first side wall, the flap being separated from the first side wall by an area having a second thickness, and the second thickness being less than the first thickness, wherein each area having the second thickness is plastically deformed, and wherein the second wall thickness is plastically deformed without fracturing the insulative cellular non-aromatic polymeric material so that a predetermined insulative characteristic is maintained in the blank.

2. The blank of claim 1, wherein each of the first side wall, the second side wall, the front wall, and the back wall all have a first thickness and separated from the base by a respective region that has a second thickness that is less than the first thickness.

3. The blank of claim 2, further comprising first and second flaps positioned at side edges of the front wall, the first flap being separated from the front wall by an area having the second thickness, and the second flap being separated from the front wall by an area having the second thickness.

4. The blank of claim 2, further comprising a flap at an outboard edge of the first side wall, the flap being separated from the first side wall by an area having the second thickness.

5. The blank of claim 2, further comprising a flap at an outboard edge of the second side wall, the flap being separated from the first side wall by an area having the second thickness.

6. The blank of claim 2, further comprising first and second flaps positioned at side edges of the back wall, the first flap being separated from the back wall by an area having the second thickness, and the second flap being separated from the back wall by an area having the second thickness.

7. The blank of claim 2, wherein each of the first side wall, the second side wall, the front wall, and the back wall all have a first thickness and the blank further comprises a cover coupled to the back wall at an outboard edge of the cover, the cover separated from the back wall by an area having a second thickness, and the second thickness is less than the first thickness.

8. The blank of claim 1, wherein each of the first side wall, the second side wall, the front wall, and the back wall all have a first thickness and the blank further comprises first and second flaps positioned at side edges of the front wall, the first flap being separated from the front wall by an area having the second thickness and the second flap being separated from the front wall by an area having the second thickness.

9. The blank of claim 8, further comprising a flap at an outboard edge of the first side wall, the flap being separated from the first side wall by an area having the second thickness.

10. The blank of claim 8, further comprising a flap at an outboard edge of the second side wall, the flap being separated from the first side wall by an area having the second thickness.

11. The blank of claim 8, further comprising first and second flaps positioned at side edges of the back wall, the first flap being separated from the back wall by an area having the second thickness and the second flap being separated from the back wall by an area having the second thickness.

12. The blank of claim 8, further comprising a cover coupled to the back wall at an outboard edge of the cover, the cover separated from the back wall by an area having the second thickness.

13. The blank of claim 1, further comprising a flap at an outboard edge of the second side wall, the flap being separated from the first side wall by an area having the second thickness.

14. The blank of claim 1, further comprising first and second flaps positioned at side edges of the back wall, the first flap being separated from the back wall by an area the second thickness and the second flap being separated from the back wall by an area having the second thickness.

15. The blank of claim 1, further comprising a cover coupled to the back wall at an outboard edge of the cover, the cover having the first thickness, and the cover being separated from the back wall by an area having the second thickness.

16. The blank of claim 1, further comprising a cover coupled to the back wall at an outboard edge of the cover, the cover separated from the back wall by an area having the second thickness.

17. The blank of claim 16, wherein each area having the second thickness is reduced to about 50% of the generally uniform first thickness.

18. The blank of claim 17, wherein each area having the second thickness is deformed to take a permanent set.

19. The blank of claim 17, wherein each area having the second thickness comprises a localized area of higher density.

20. The blank of claim 17, wherein cells of the insulative cellular non-aromatic polymeric material remain unbroken in the areas having the second thickness.

21. The blank of claim 1, wherein the high melt strength polypropylene is a copolymer.

22. The blank of claim 21, wherein the base resin comprises broadly distributed molecular weight polypropylene.

23. The blank of claim 22, wherein the broadly distributed molecular weight polypropylene is characterized by a molecular weight distribution that is unimodal.

24. The blank of claim 1 wherein the cell-forming agent includes a blowing agent selected from a group consisting of: carbon dioxide, nitrogen, helium, argon, and mixtures thereof.

Description

BRIEF DESCRIPTIONS OF THE DRAWINGS

(1) The detailed description particularly refers to the accompanying figures in which:

(2) FIG. 1 is perspective view of an insulative container in accordance with the present disclosure made from a blank as suggested in FIGS. 2 and 3 and showing that the insulative container includes a floor, a cover spaced apart above the floor, a front wall, an opposite back wall, and two interconnecting side walls;

(3) FIG. 2 is plan view of the blank used to form the insulative container of FIG. 1; and

(4) FIG. 3 is a plan view showing an opposite side of the blank of FIG. 1 and showing that the blank includes graphics which may be displayed on the insulative container after the blank is folded to form the insulative container as shown in FIG. 1.

DETAILED DESCRIPTION

(5) Localized plastic deformation is provided in accordance with the present disclosure in, for example, a region 820 included in a blank 800 about which a front wall 836 is folded relative to a base 838 comprising an insulative cellular non-aromatic polymeric material as suggested in FIGS. 1-3. A material has been plastically deformed, for example, when it has changed shape to take on a permanent set in response to exposure to an external compression load and remains in that new shape after the load has been removed.

(6) Blank 800 for container 810 is formed from a sheet including insulative cellular non-aromatic polymeric material as suggested in FIGS. 1-3. Container 810 is formed when blank 800 is folded and glued as shown in FIG. 1. Blank 800 includes regions 812, 814, 816, 818, 820, 822, 824, 826, 830, 832, 834 (also called connecting webs 812, 814, 816, 818, 820, 822, 824, 826, 830, 832, 834) of localized plastic deformation that correspond to fold lines.

(7) Blank 800 includes a first side 840 that corresponds to the inner surfaces of container 810 as suggested in FIG. 2. Blank 800 may be formed in a blank forming process as described in U.S. patent application Ser. No. 13/526,444, incorporated herein by reference. Blank 800 is cut to include the perimeter shown in FIGS. 2 and 3 and a pressing operation may reduce the regions 812, 814, 816, 818, 820, 822, 824, 826, 830, 832, 834 to define base 838 (also called floor 838) and two side walls 842, 844 coupled to base 838. Two respective flaps 846 and 848 are coupled to side walls 842 and 844. A front wall 836 is coupled to base 838 with two flaps 850 and 852 coupled to front wall 836. A back wall 854 is coupled to base 838. Two flaps 856 and 858 are coupled to back wall 854 and are positioned to engage respective side walls 842 and 844 when blank 800 is folded to form container 810. A cover 860 is also coupled to back wall 854 and a flap 862 is coupled to cover 860 as shown in FIGS. 2 and 3.

(8) When assembled, flaps 850 and 852 are secured to respective side walls 842 and 844; flaps 842 and 844 are each secured to cover 860; flap 862 is secured to front wall 836 and flaps 856 and 858 are secured to side walls 842, 844. Flaps 846, 848, 850, 852, 856, 858, and 862 are secured through gluing. In some embodiments, heat may be applied to flaps 846, 848, 850, 852, 856, 858, and 862 such that flaps 846, 848, 850, 852, 856, 858, and 862 are secured to walls 836, 842, 844 by a heat seal. In other embodiments, an adhesive may be applied to flaps 846, 848, 850, 852, 856, 858, and 862 such that flaps 846, 848, 850, 852, 856, 858, and 862 are secured to the walls 836, 842, 844 by the adhesive.

(9) As shown in FIGS. 1 and 3, a second side 864 of blank 800 corresponds to an outer surface of container 810 when container 810 is assembled. Relief provided by regions 812, 814, 816, 818, 820, 822, 824, 826, 830, 832, and 834 minimizes creasing or buckling on the second side 864 when container 810 is assembled.

(10) Blank 800 is formed from a sheet including insulative cellular non-aromatic polymeric material as disclosed herein. In accordance with the present disclosure, the insulative cellular non-aromatic polymeric material is configured (by application of pressure-with or without application of heat) to provide means for enabling localized plastic deformation in at least one selected region (for example, region 820) of blank 800 to provide a plastically deformed first material segment having a first density located in a first portion of the selected region of blank 800 and a second material segment (based 838) having a second density lower than the first density located in an adjacent second portion of the selected region blank 800 without fracturing the insulative cellular non-aromatic polymeric material so that a predetermined insulative characteristic is maintained in container 810.

(11) Blank 800 is formed from a sheet including insulative cellular non-aromatic polymeric material and a skin coupled to one side of the insulative cellular non-aromatic polymeric material. In one embodiment of the present disclosure, text and artwork or both can be printed on a film included in the skin. The skin may further comprise an ink layer applied to the film to locate the ink layer between the film and the insulative cellular non-aromatic polymeric material. In another example, the skin and the ink layer are laminated to the insulative cellular non-aromatic polymeric material by an adhesive layer arranged to lie between the ink layer and the insulative cellular non-aromatic polymer material. As an example, the skin may be biaxially oriented polypropylene.

(12) Insulative cellular non-aromatic polymeric material comprises, for example, a polypropylene based resin having a high melt strength, one or both of a polypropylene copolymer and homopolymer resin, and one or more cell-forming agents. As an example, cell-forming agents may include a primary nucleation agent, a secondary nucleation agent, and a blowing agent defined by gas means for expanding the resins and to reduce density. In one example, the gas means comprises carbon dioxide. In another example, the base resin comprises broadly distributed molecular weight polypropylene characterized by a distribution that is unimodal and not bimodal. Further details of a suitable material for use as insulative cellular non-aromatic polymeric material is disclosed in U.S. patent application Ser. No. 13/491,327, previously incorporated herein by reference.

(13) Portions (850, 852, 836, 846, 842, 838, 844, 848, 856, 854, 858, 862, 860) of blank 800 have a generally uniform first thickness (also called nominal thickness) while regions (812, 814, 816, 818, 820, 822, 824, 826, 830, 832, 834) each have a second thickness. The second thickness, through plastic deformation, is about 50% of the generally uniform first thickness. In one illustrative example, front wall 836 is folded about connecting web 820 relative to base 838 during an illustrative container-forming process.

(14) Blanks may be used to form other containers in accordance with the present disclosure. Disclosure of other containers formed using blanks may be found in U.S. patent application Ser. No. 13/491,007 and is incorporated by reference in its entirety herein. One suitable container-manufacturing process that makes blanks and containers is disclosed in U.S. patent application Ser. No. 13/526,444 and is incorporated by reference in its entirety herein. Another process for forming blanks is disclosed in U.S. patent application No. 61/737,222 which is incorporated by reference in its entirety.