Container with Barrier Layer

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

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.

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.

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.

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

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.

is a plan view of the interior sideof a sidewall blank, generally indicated at, andis a plan view of the interior sideof a bottom blank, generally indicated at, wherein the sidewall blankand the bottom blankare used in cooperation to form a container() according to an exemplary embodiment of the disclosure. In the illustrated embodiments, the containeris a cup for holding one or more food items and/or beverages and/or other products. Alternatively, the containercould 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 containercan be configured for holding beverages, soups, and/or other suitable products with high water content (e.g., products that are mostly water). Further, the containercan 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. 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, such as when heating/cooking the products, serving the products, etc. The containercould be alternatively shaped and/or could be alternatively formed without departing from the scope of this disclosure.

In the illustrated embodiments, the sidewall blankhas a longitudinal axis Land a lateral axis L. In the illustrated embodiments, the sidewall blankcomprises a top edge, a bottom edge, a first end edge, and a second end edgeextending from the respective ends of the top and bottom edges,. In embodiments, the top edgecan comprise a convex curve (e.g., having a radius of curvature extending away from the bottom edge), and the bottom edgecan comprise a concave curve (e.g., having a radius of curvature extending toward the top edge) so that the sidewall blankforms 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. Further, as shown in, the end edges,can be oblique, extending at an acute angle with respect to the lateral direction L. As shown in, the bottom blankcan have a generally circular perimeter (e.g., can be in the shape of a disc). The sidewall blankand/or the bottom blankcould be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure. For example, one or more of the edges,,,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, the sidewall blankcan include a sidewall substrate or support layerextending along an exterior surfaceof the sidewall blankand a side coating or barrier layerextending along the interior side(e.g., product-contacting side) of the sidewall blank. Similarly, as shown in the schematic cross-sectional view of, the bottom blankcan include a bottom substrate or support layerextending along an exterior (or bottom) surfaceof the bottom blankand a bottom coating or barrier layerextending along the interior side(e.g., product-contacting side) of the bottom blank. In embodiments, each of the substrates,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,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 containeris intended to hold one or more products.

In embodiments, the barrier layers,can comprise polyethylene terephthalate (PET) or another suitable material. In exemplary embodiments, the PET barrier layers can be applied to the substrates,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 interiorof the containercan 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 containercan 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 containercan hold products with high temperatures while avoiding a reduction in the ability of the barrier layers,to prevent liquids in the interiorfrom being absorbed into the substrates,(e.g., paperboard layers) of the containerand/or in the ability of the barrier layers,to prevent gas such as oxygen from moving through the sidewall or bottom of the container. In exemplary embodiments, most foods can be heated in the containerwith the PET barrier layers in a microwave or conventional oven.

As shown in, an end marginextends along the end edgeof the sidewall blankand a bottom marginextends along the bottom edgeof the sidewall blank. In the illustrated embodiments, a second end margincan extend along the end edgeof the sidewall blank, opposite to the first end margin, and a top margincan extend along the top edgeof the sidewall blank, opposite to the bottom margin.

In embodiments, the barrier layercan include a heat seal primer or other suitable material(s) that can facilitate the bonding of the PET barrier layerat the end margins,and/or at the bottom marginand the bottom blank. In exemplary embodiments, forming the seam(s) of the container as described below can be more challenging with the PET barrier layerthan 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 layerextending along the first end marginto the substrateextending along the second end margin, 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 layersuch 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 layeralong the first end marginand/or along the bottom margin, such as in the area along the margins,schematically shown by the broken linein. 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 layeror could be otherwise added to the barrier layer.

In the illustrated embodiments, the sidewall blankand the bottom blankcan be formed into the containerhaving an interioras shown in. For example, the sidewall blankcan be bent and curved (e.g., around a mandrel, not shown) to form a sidewallof the carton. As shown in, the end margins,of the sidewall blankadjacent the respective end edges,overlap one another to form a side seamof the sidewall. As shown in the schematic cross-sectional views of, the seamincludes the portion of the side barrier layerextending along the first end marginand positioned between the portions of the substratethat extend along the first end marginand the second end margin. The portion of the side barrier layerthat extends along the second end marginfaces toward the interiorof the container. In embodiments, the side barrier layercan at least partially form a seal (e.g., a heat seal) along the seam, wherein heat and/or pressure can be applied along the seamso that at least the side barrier layerfuses the end margins,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 layeralong the first end margincan facilitate the fusing of the side barrier layeralong the first end marginto the substratealong the second end margin, forming the sealed seam. The sidewalland/or the seamcould 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,to at least partially form the seal along the seam. In another example, the seamcould be at least partially formed by ultrasonic welding and/or other suitable processes.

As shown in, the bottom blankcan be secured to the interior surfaceof the sidewallto form a bottom wallof the container. In the illustrated embodiments, the bottom walland the sidewallcan extend at least partially around and can at least partially form the interiorof the container. In embodiments, a marginal portionof the bottom wallcan be folded with respect to the central portion of the bottom wall and can be attached in face-to-face contact with the bottom marginof the sidewallto form a bottom seam(). In the illustrated embodiments, the marginal portionof the bottom walland the bottom marginof the sidewallcan be secured (e.g., heat sealed) together, such as by applying heat and/or pressure so that the side barrier layeralong the bottom margincooperates with the bottom barrier layerof the marginal portionto fuse the marginal portionand the bottom margintogether and form a seal (e.g., a liquid-proof and/or liquid resistant seal) along the bottom seam. In embodiments, the heat seal primer can be included along the bottom marginto facilitate the fusing of the barrier layers,along the bottom seam. In another example, a heat seal primer can be included along at least a portion of the bottom wallinstead of or in addition to the bottom margin. Alternatively, the heat seal primer could be omitted from the bottom marginand the bottom wall. The bottom wallcould be otherwise formed and/or could be otherwise sealed to the sidewallwithout departing from the disclosure. For example, an adhesive and/or a heat seal material can be applied between the bottom marginand the marginal portionto at least partially form the seal along the bottom seam. In another example, the bottom seamcould be at least partially formed by ultrasonic welding and/or other suitable processes.

In embodiments, a rolled rimcan be formed at a top end of the container. For example, the top edgecan be rolled outwardly and downwardly along the top marginto form the rolled rim. The rolled rimcould be omitted or could be otherwise formed without departing from the disclosure.

The formed containeris shown inby way of example. In the illustrated embodiments, the marginal portions,forming the bottom seamcan extend downwardly from the portion of the bottom wallextending along the interiorof the containerto a support edgeof the container(). In embodiments, the containercan be a cup with a bottom wallthat is supported above the lowermost support element (e.g., support edge) so that the bottom wallis offset from/spaced upwardly from a supporting surface on which the containeris placed (e.g., with the support edgein contact with the supporting surface).

In an alternative embodiment shown in, a secondary layercan be included along at least a portion of the side seam′ and/or along at least a portion of the bottom seam′ for forming the seal or for helping to form the seal at the seams′,′. For example, the secondary layercan extend along the interior sideof the sidewall blankalong at least a portion of the end marginand the bottom marginand/or along the interior sideof the bottom blankalong at least a portion of its marginal portion. Alternatively, or in addition, the secondary materialcould be applied on the exterior side of the sidewall blankalong at least a portion of the end margin. In embodiments, the secondary layercan include one or more layers of the material that makes up the barrier layers,(e.g., PET) and/or another suitable material for facilitating the formation of the seal along the seams′,′ (e.g., adhesive, heat seal material, etc.). For example, the secondary layercould be the barrier material of the side barrier layer(e.g., PET) including the heat seal material, and the secondary layercan be applied (e.g., printed) onto the barrier layerof the sidewall blank(e.g., in the areas of the margins,schematically shown by the dashed linein). The secondary layercould be otherwise shaped, arranged, positioned, and/or configured without departing from the disclosure.

In embodiments, the container(e.g., a cup formed from two blanks, such as the sidewall blankand the bottom blank, a cup formed with a bottom wall that is supported above the bottom support edge of the container, and/or any other suitable container with one or more suitable seams) can have barrier layers,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(e.g., foods that are more sensitive to oxygen).

In addition, the container(e.g., having the paperboard substrates,and PET barrier layers,) can have advantages over polypropylene (PP) cups used to store and/or heat products. For example, the containercan 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.