WO2010006272A1

WO2010006272A1 - Thermally insulated sidewall, a container made therewith and a method of making the container

Info

Publication number: WO2010006272A1
Application number: PCT/US2009/050271
Authority: WO
Inventors: Donald B. Campbell; Walter Malakhow
Original assignee: Dixie Consumer Products Llc
Priority date: 2008-07-11
Filing date: 2009-07-10
Publication date: 2010-01-14

Abstract

Thermally insulated sidewalls, containers having thermally insulated sidewalls, and methods for making thermally insulted sidewalls are provided. The thermally insulated sidewall can include a base- sheet having a fold score (15) formed therein, the fold score separating the base sheet into a first section (10) and a second section (12). Each section can include a first end adjacent the fold score and a second end opposite the fold score. A distance between the first end and the second end of the second section is greater than a distance between the first end and the second end of the first section. And the sections are adapted to fold about the fold score to provide a seal area between at least a portion of the second ends of each section. Preferably, the seal area has a seal width of about 9.0 mm or more.

Description

THERMALLY INSULATED SIDEWALL , A CONTAINER MADE THEREWITH AND A METHOD OF MAKING THE CONTAINER

BACKGROUND OF THE INVENTION Field of the Invention [0001] Embodiments of the present invention generally relate to disposable cups and containers. More particularly, embodiments of the present invention relate to thermally insulated sidewalls, containers having thermally insulated sidewalls, and methods for making containers having thermally insulted sidewalls.

Description of the Related Art [0002] Containers are often made from materials, such as paper, that are poor thermal insulators and have low sidewall rigidity. Poor thermal insulation and low sidewall rigidity cause the containers to exhibit undesirable characteristics. For example, a hot beverage within a container having low thermal insulation can make the outside of the container too hot to touch. Additionally, a cold beverage stored in a container can cause condensation on the outside of the container, which makes the container difficult to hold. Furthermore, a container having low sidewall rigidity often has a rim geometry that is not concentric, which results in a container that is incompatible with concentric lids.

[0003] A need, therefore, exists for containers having increased thermal insulation and side wall rigidity and methods of making containers that have increased thermal insulation and sidewall rigidity.

SUMMARY OF THE INVENTION

[0004] Thermally insulated sidewalls, containers having thermally insulated sidewalls, and methods for making thermally insulted sidewalls are provided. The thermally insulated sidewall can include a base sheet having a fold score formed therein, the fold score separating the base sheet into a first section and a second section. Each section can include a first end adjacent the fold score and a second end opposite the fold score. A distance between the first end and the second end of the second section is greater than a distance between the first end and the second end of the first section. And the sections are adapted to fold about the fold score to provide a seal area between at least a portion of the second ends of each section. Preferably, the seal area has a seal width of about 9.0 mm or more. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.

[0006] Figure 1 depicts an elevational view of an illustrative cup having a thermally insulated sidewall with a wider seam, according to one or more embodiments described.

[0007] Figure 2A depicts a plan view of an embodiment of an illustrative sidewall blank used to make the thermally insulated sidewall of the cup depicted in Figure 1 , according to one or more embodiments described.

[0008] Figure 2B depicts a plan view of the sidewall blank depicted in Figure 2A in a three- layer arrangement, according to one or more embodiments described.

[0009] Figure 3 A depicts a cross-sectional view of the three-layer arrangement depicted in Figure 2B being formed into the thermally insulated sidewall of the cup depicted in Figure 1 , according to one or more embodiments described.

[0010] Figure 3B depicts a cross-sectional view of the three-layer arrangement depicted in Figure 3 A after being formed into the thermally insulated sidewall of the cup depicted in Figure 1 , according to one or more embodiments described.

[0011] Figure 3 C depicts a cross-sectional elevational view of the cup depicted in Figure 1, according to one or more embodiments described.

[0012] Figure 4 A depicts an elevational view of another illustrative cup and an insulating outer wrapper with a wider seam, according to one or more embodiments described.

[0013] Figure 4B depicts a cross-sectional view of the cup depicted in Figure 4A with the insulating outer wrapper disposed thereon, according to one or more embodiments described. [0014] Figure 5 depicts an enlarged cross-sectional top view of the seam area of the cup and an adjacent part of the insulating outer wrapper depicted in Figure 4 A, according to one or more embodiments described.

DETAILED DESCRIPTION [0015] A detailed description will now be provided. Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims. Each of the inventions will now be described in greater detail below, including specific embodiments, versions and examples, but the inventions are not limited to these embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the inventions, when the information in this disclosure is combined with available information and technology.

[0016] Figure 1 depicts an elevational view of an illustrative cup 5 having a thermally insulated sidewall with a wider seam, according to one or more embodiments. Figure 2A depicts a plan view of an embodiment of an illustrative sidewall blank 12B used to make the thermally insulated sidewall of the cup 5, according to one or more embodiments. Referring to Figures 1 and 2A, the thermally insulated sidewall of the cup 5 can include a first portion or section 10 and a second portion or section 12. The sections 10, 12 can be divided, separated, or otherwise partitioned by a fold score 15. The fold score 15 can be located any where along the length of the blank 12B. Accordingly, the length of the sections 10, 12 can be the same or different. Preferably, one of the sections 10, 12 is longer than the other, meaning the fold score 15 is not located in the middle of the length of the blank 12B.

[0017] The sections 10, 12 can be manufactured from a single sheet or each section 10, 12 can be manufactured individually and joined together at the fold score 15. When folded about the fold score 15, as depicted in Figure 2B, the first section 10 can form an inner layer of the sidewall of the cup 5, and the second section 12 can form an outer layer of the sidewall of the cup 5. [0018] The cup 5 can further have an upper portion 1OR. The upper portion 1OR can be formed into a rim by rolling a portion thereof. For example, the upper portion 1OR can be formed into a rim by rolling a portion thereof radially outward or inward. The upper portion 1OR can be formed into a round, elliptical, or semi-circular rim. The upper portion 1OR can be concentric with the interior of the cup 5.

[0019] The cup 5 can further have a bottom blank 1OB. The bottom blank 1OB can have a concentric geometry. The bottom blank 1OB can be formed by one or more pieces of sheet material, such as paper, or other suitable sheet material. The bottom blank 1OB can be attached to the first section 10 by folding a portion of the first section 10 inward and heat sealing the bottom blank 1OB to the first section 10. A portion of the bottom blank 1OB can be coated with a waterproof material. For example, at least an inner portion or surface of the bottom blank 1OB can be coated with a waterproof material.

[0020] The waterproof material can be polyethylene (low, medium or high density), polypropylene, polyester, or other types of waterproof coatings. Polyethylene can be used as both a waterproof coating and an adhesive. Other types of waterproof coatings can include biodegradable and/or recyclable waterproof and heat sealable coatings. The waterproof coating can have a thickness of about 0.013 millimeters ("mm") to about 0.038 mm. For example, the waterproof coating can have a thickness of about 0.019 mm. The waterproof coating can have either a matte or a gloss finish. Various methods of applying the waterproof coating are well known in the art.

[0021] The first section 10 can be made from any paperboard material. The first section 10 can have a waterproof coating at least partially disposed on either side thereof. The waterproof coating can be any one of the waterproof coatings described above. Preferably, the waterproof coating is the same material as placed on the bottom blank 1OB. The first section 10 can support the upper portion 1OR and the bottom blank 1OB.

[0022] The second sections 10 can be made from any paperboard material. The second section 12 can have a waterproof coating at least partially disposed on either side thereof. The waterproof coating can be any one of the waterproof coatings described above. Preferably, the waterproof coating is the same material as placed on the bottom blank 1OB. [0023] In at least one specific embodiment, such as depicted in Figure 2 A, the second section 12 can be integral with the first section 10 and can form the thermally insulated sidewall of the cup 5. The sidewall blank 12B can have one or more fold scores 15 formed therein. The fold score 15 can separate or form the sections 10, 12. One or more bond areas 21 can be adjacent the fold score 15. The sections 10, 12 can have front surfaces 1OF, 12F and back surfaces 10Bk, 12Bk, respectively. One or more adhesive areas 20 can be located on at least one of the front surfaces 1OF, 12F. One or more insulating sheets 14 can be secured to a portion of one of the sections 10, 12 by an adhesive applied to the adhesive area 20.

[0024] The sidewall blank 12B can be cut from a larger sheet or a roll of paper (not shown) or other suitable sheet material and used to make the sections 10, 12. The thickness of the sidewall blank 12B can have a range of from about 0.2 mm to about 0.6 mm. For example, the sidewall blank 12B can have a thickness of about 0.33 mm. The sidewall blank 12B can be similar to the blanks described in U.S. Patent No. 6,085,970.

[0025] The first section 10 can have an arcuate shape. The first section 10 can form an inner layer of the sidewall of the cup 5 when folded about the fold score 15. The first section 10 can have a side or distal edge 10S, an "upper" or first edge 1OU, and a "lower" or second edge 1OL.

The first edge 1OU can be spaced from the second edge 1OL. The distance between the first edge

1OU and the second edge 1OL can be any distance required to provide a cup 5 of a predetermined size. The distal edge 1OS can be spaced a predetermined distance from the fold score 15. The first section 10 can form the inner surface of the sidewall of the cup 5. A waterproof coating can be applied to both surfaces 1OF, 10Bk of the first section 10. In one or more embodiments, the waterproof coating can be applied to the back surface 10Bk and not to the front surface 1OF.

[0026] The second section 12 can also have an acruate shape. The second section 12 can have a side or distal edge 12S, an "upper" or first edge 12U, and a "lower" or second edge 12L. The first edge 12U and the second edge 12L can be spaced a distance apart. The distance between the first edge 12U and the second edge 12L of the second section 12 can be less than the distance between the first edge 1OU and the second edge 1OL of the first section 10. The distal edge 12S can be a distance away from the fold score 15. The distance between the distal edge 12S of the second section 12 and the fold score 15 can be greater than the distance between the distal edge 1OS of the first section 10 and the fold score 15. The second section 12 can have a waterproof coating disposed on both surfaces 12Bk, 12F. In one or more embodiments, the waterproof coating can be disposed on the back surface 12Bk of the second section 12 and not on the front surface 12F of the second section 12. The second section 12 can include one or more tabs 16. The tabs 16 can extend from the lower edge 12L to the upper edge 12U. The tabs 16 can be configured to provide a seal when the sidewall of the cup 5 is formed.

[0027] The fold score 15 defines the two sections 10, 12 of the sidewall blank 12B, and traverses a width of the sidewall blank 12B. As such, the first section 10 is located on a first side of the fold score 15, and the second section 12 is located on a second side of the fold score 15. The fold score 15 can be cut into the sidewall blank 12B when the sidewall blank 12B is cut from a single sheet or roll of sheet material. In one or more embodiments, the fold score 15 can be formed into the sidewall blank 12B after the sidewall blank 12B is cut and prior to folding. The fold score 15 can be cut into the sidewall blank 12B by a die operation or by milling. The fold score 15 can assist in the folding of the sidewall blank 12B. For example, one of the sections 10, 12 can be folded over the fold score 15, and the fold score 15 can ensure that the folded section 10, 12 is folded about a precise line.

[0028] The bond area 21 can be adjacent the fold score 15. An adhesive, such as a cold adhesive or hot form adhesive, can be applied to the bond area 21 prior to the folding of one of the sections 10, 12 about the fold score 15. The adhesive in the bond area 21 can at least partially secure a portion of the sections 10, 12 together after one of the sections 10, 12 is folded about the fold score 15.

[0029] One or more insulation materials can be disposed on the sidewall blanks 12B to form an insulation layer 14 thereon. The insulation layer 14 can be die cut from a larger sheet or roll of paper (not shown) or other suitable sheet material. The insulation layer 14 can have a thickness of from about 0.25 mm to about 1 mm. For example, the thickness of the insulation layer 14 can be about 0.4 mm. The insulation layer 14 can be made from recycled chipboard (plain chip or bending chip), recycled liner board, virgin paperboard, partially recycled paperboard, or similar sheet material. For example, the insulation layer 14 can be made from solid bleach sulfite paperboard or solid unbleached sulfite paperboard. The insulating layer 14 can be any insulating sheet or material. Illustrative insulation layers 14 are described in more detail in U.S. Patent No. 6,085,970.

[0030] The insulation layer 14 can have a "top" or first edge 14T, a "bottom" or second edge 14B, a "left" or first distal edge 14L, and a "right" or second distal edge 14R. The insulation layer 14 can include spaced grooves or scores 19. The spaced scores 19 can be formed into the surface by die cutting, milling, or otherwise. The scores 19 can be formed into the insulation layer 14 concurrently with cutting the insulation layer 14 from a larger starting sheet, prior to cutting the insulation layer 14 from the larger starting sheet, or subsequent to cutting the insulation layer 14 from the larger starting sheet. The scores 19 can run from the first edge 14T to the second edge 14B, from the first distal edge 14L to the second distal edge 14R, or a combination thereof. The scores 19 can be spaced from each other by a distance of about 3 mm to about 13 mm, more preferably 3 mm to 10 mm or 5 mm to 10 mm. The scores 19 can have a depth of about 0.10 mm to about 0.80 mm, more preferably 0.10 mm to about 0.75 mm, or 0.20 mm to about 0.70 mm. In one or more embodiments, the scores 19 can be or include perforations, corrugations, embossed dimples, other types of integral deformities, or any combination thereof.

[0031] The insulation layer 14 can be secured to the sidewall blank 12B using an adhesive or other fastening mechanism or technique. Preferably, the insulation layer 14 is located on the longer section 12, as depicted in Figure 2A. But the insulation layer 14 can be equally effective if disposed on the first section 10. In a least one specific embodiment, the insulation layer 14 can be placed in a substantially centered position on the front surface 12F of the second section 12 and can be held in place by an adhesive applied an adhesive area 20. The adhesive can be a cold adhesive, a hot-melt adhesive, a pre-applied layer of thermoplastic material, starch-based adhesive, a starch-based paste, or any other adhesive. The adhesive disposed within the adhesive area 20 can secure the insulation layer 14 to the front surface 12F.

[0032] The edges of the insulation layer 14 can be configured to have a length less than the distance between the distal edge 10S, 12S and the fold score 15. When located on the second section 12, the edges 14L, 14R do not contact or extend to the fold score 15 and the distal edge 12S when secured to the second section 12. For example, there can be a gap or margin of at least about 6 mm between the first distal edge 14L and the distal edge 12S and between the second distal edge 14R and the fold score 15. A gap or margin of about 6 mm can also be located between the first edge 14T of the insulation layer 14 and the first edge 12U of the second section 12 and the second edge 14B of the insulation layer 14 and the second edge 12L of the second section 12. The same configuration can apply if the insulation layer 14 is disposed on the first section 10.

[0033] In one or more embodiments, a placing machine can be used to secure the insulation layer 14 to the second section 12 and a folder-gluer can be used to fold one of the sections 10, 12 about the fold score 15 and apply adhesive to the bond area 21. For example, the sidewall blank 12B can be loaded into the feeding station of the folder-gluer and the insulation layer 14 can be loaded into the feeding station of the placing machine. The sidewall blank 12B can be moved into position under an adhesive applicator (not shown) where adhesive is applied at adhesive area 20. The sidewall blank 12B can be moved into position under the placing machine after adhesive is applied to the adhesive area 20. The insulation layer 14 can be placed onto the front surface 12F of the second section 12 when the sidewall blank 12B is positioned under the placing machine.

[0034] Figure 2B depicts a plan view of the sidewall blank 12B in a folded configuration, according to one or more embodiments. Referring to Figures 2A and 2B, a fold edge 22 is formed when the first and section sections 10, 12 are folded about the fold score 15. An adhesive in the bond area 21 can be used to bond a portion of the sections 10, 12 adjacent the fold score 15.

[0035] In one or more embodiments, the folder gluer can be used to form and secure the three- layer arrangement after securing the insulation layer 14 to the second section 12. For example, the sidewall blank 12B can be moved into position under another adhesive applicator where adhesive is applied at bond area 21 after the insulation layer 14 is disposed on the second section 12. The second section 12 can be folded over the first section 10 after the adhesive is applied to the bond area 21, and the adhesive in the bond area 21 can bond or secure the sections 12, 10 together. The three-layered arrangement is secured in the flat arrangement when the sections 12, 10 are bonded together. The bonding of the sections 10, 12, enables higher production speeds on standard machinery. Accordingly, the cup 5 is less expensive to manufacture.

[0036] Figure 3A depicts a cross-sectional view of the folded sidewall blank 12B depicted in Figure 2B being formed into a thermally insulated sidewall, according to one or more embodiments. The three-layer arrangement can be shaped into a sidewall for the cup 5 (depicted in Figure 1) by wrapping or bending the three-layer arrangement around a tapered mandrel (not shown). The sidewall of the cup 5 can have an inner layer 24, a middle layer 25, and an outer layer 26. The inner layer 24 can be or include the first section 10. The middle layer 25 can be or include the insulation layer 14. The outer layer 26 can be or include the second section 12.

[0037] The fold edge 22 can lie flat and substantially parallel to the other edges, as the three- layer arrangement is wrapped around the mandrel. The three-layer arrangement can be wrapped around the mandrel by a folder or a similar machine. The outer layer 26 has a larger circumference than inner layer 24 and middle layers 25. Accordingly, the second section 12 travels a greater distance relative to first section 10 as the flat three-layered arrangement is wrapped about the mandrel. The second section 12 can compensate for the greater distance of travel by moving or sliding about the first section 10, such that the distance between distal edges 1OS and 12S shortens as the flat three-layered arrangement is wrapped about the mandrel. The relative movement between the second section 12 and the first section 10 can be facilitated by gluing or otherwise fastening the first section 10 to the second section 12 at the bond area 21 and from fold edge 22 to an opposing edge 33. For example, the sections 10, 12 can be bonded to each other at inside surfaces 31, 32. The relative movement between the sections 10, 12 ensures that the fold edge 22 lies flat and substantially parallel to the other edges of the sidewall blank 12B as the three-layer arrangement is wrapped about the mandrel. The insulating layer 14 is fixed to the second section 12. Accordingly, the distance between the distal edges 14R and the fold edge 22 and between the distal edges 14L, 12S can remain constant as the flat three-layer arrangement is wrapped about the mandrel.

[0038] Figure 3B depicts a cross-sectional view of the three-layer arrangement after being formed into thermally insulated sidewall of the cup 5, according to one or more embodiments. A side seam 22S can be formed in a seal area 23 after the three-layer arrangement is wrapped about the mandrel.

[0039] The side seam 22S can include overlapping distal edges 12S, 1OS, a portion of the second layer 26 adjacent the fold edge 22, and a portion of the first layer 24. The side seam 22S can be formed by bonding the distal edges 12S, 1OS together and a portion of the second layer 26 and the first layer 27 together. The seal area 23 can be located between a top 41 of the bond area 21 and a bottom 42 of the first section 10 adjacent the distal edge 10S. The seal area 23 has a minimum seal width 21L from fold edge 22 towards the distal edge 12S. The minimum seal width 2 IL can be about 9.0 mm to about 10.0 mm. Preferably, the minimum seal width 21L is greater than about 9.0 mm, 9.5 mm, 10 mm, 11 mm, or 12 mm. The distal edges 10S, 12S of the first layer 24 can be bonded or otherwise secured to a portion of the second layer 26 adjacent the fold edge 22. The side seam 22S can bond the layers 24, 26 to each other at a seal area 23

[0040] In operation, the sidewall blank 12B can be wrapped about the mandrel such that the fold edge 22 is adjacent an inner portion of the sidewall blank 12B, and the fold edge 22 can become part of the inner layer 24. A portion of the second section 12 adjacent the distal edge 12S can overlap the distal edge 1OS and a marginal portion of the second layer 26 adjacent the folded edge 22. The overlapping distal edges 12S, 1OS and a portion of the second layer 26 can be bonded together to provide the side seam 22S. For example, the overlapping distal edges 10S, 12S can have a previously applied layer of polyethylene or other heat sealable waterproof coating, and the overlapping distal edges 10S, 12S can be heat sealed together, and a portion of the distal edge of the first layer 24 can be sealed or bonded to the portion of the second layer 26 adjacent the fold edge 22 to form the side seam 22S having the seal area 23. The seal seam 22S can be formed using a seam clamp that is about 9.5 mm wide.

[0041] Consumer feedback, coupled with in-house testing, has revealed that a cup having the minimum seal width 2 IL at the seal area 23 of about 5.9 mm from the fold edge 22 is more prone to leaks than cups having the minimum distance 21L of about 9.0 mm, more preferably 9.5 mm. The additional seal width of about 3.0 mm can be accomplished by better utilization of the current paper width without consuming any additional paper. The wider seal width 2 IL increases the sealing area of the cup 5. The increased sealing area of the cup 5 decreases side seam leakage. The wider seal width 2 IL also increases the surface area at the bond area 21. The increased surface area at the bond area 21 decreases the out of roundness in the rim area. The wider seal width 2 IL can improve the overall rim geometry providing an overall rim geometry that is concentric. Accordingly, the wider seal width 2 IL improves the overall cup rigidity, cup production, and ease of fitting a concentric lid on the more concentric rim. In addition, the wider seal width 2 IL decreases paper waste because the blank materials that were wasted due to a smaller seal width are now used for the wider seal width 2 IL. Below are Tables 1 and 2 having experimental results of the cups with and without the wider seal width.

[0042] The edges 14L, 14R of the insulation layer 14 are not part of the side seam 22S because the insulation layer 14 is shorter than the sections 10, 12. The exclusion of the edges 14L, 14R from the side seam 22S provides the advantage of saving paper. The exclusion of the edges 14L,

14R from the side seam 22S also reduces the thickness of the side seam 22S (by two layers). A gap or margin can be formed between the edges 14U, 14L of the insulation layer 14.

Accordingly, the insulation layer 14 does not cover the entire vertical length of the cup sidewall 12, as depicted in Figure 1.

[0043] A suction cup with vacuum, in combination with a PTFE-coated lower clamp pad, can be used on the cup machine at the blank wrapping station in order to hold a central portion of section 1OL (which extends past section 12L) stationary as the flat three-layer arrangement is wrapped around the mandrel. This allows the second section 12, which forms the outer layer 26, to slide along the PTFE lower clamp pad, relative to stationary inner layer 24, which is held in place by the vacuum cup when the sidewall of the cup 5 is formed.

[0044] Figure 3C depicts a cross-sectional elevational view of the cup 5, according to one or more embodiments. The cup 5 can include the inner layer 24, the middle layer 25, and the outer layer 26. The inner layer 24 can have an inner surface 27. The middle layer 25 can include the insulation sheet 14. The outer layer 26 can have an outer surface 28. A rim 51 can be formed on the upper portion of the cup 5. A bottom blank 1OB can be secured or bonded to the lower edge 1OL of the first section 10.

[0045] The upper edge 1OU of the first section 10, which forms the inner layer 24, can extend past the upper edge 12U of the second section 12. A portion of the upper edge 1OU can be radially rolled outward to form the rim 51. The lower edge 1OL can extend past the lower edge 12L, and the bottom blank 1OB can be attached to the lower edge 1OL. For example, the lower edge 1OL can be folded inward, and the bottom blank 1OB can be heat sealed to the lower edge 1OL. The tabs 16 (depicted in Figure 2A) can prevent leaking of liquid in the cup 5. For example, the tabs 16 can extend from the side seam 22S (shown in Figure 2B) into the seal between the bottom blank 1OB and inner layer 24.

[0046] The inner surface 27, the fold edge 22, and the outer surface 28 can have a waterproof coating disposed thereon. The waterproof coating can be disposed on the inner surface 27, the fold edge 22, and the outer surface 28 by applying the waterproof coating to at least one surface of the sections 10, 12. This saves costs because coating both sides of blank 12B is not necessary to waterproof both the surfaces 28, 27.

[0047] Figure 4A depicts an elevational view of another illustrative cup 405 and an insulating outer wrapper 420 with a wider seam, according to one or more embodiments. The cup 405 can have a sidewall 410, an upper rim 410R, and a bottom 410B. The cup 405 can be made of a single wall of plastic or plastic-coated paper. The cup 405 can be any cup or container. Illustrative cups and containers are discussed in more detail in U.S. Pat. Pub. No.: 2006/0144915. The cup 405 includes an insulating outer wrapper 420 that insulates the cup 405. The insulating outer wrapper 420 can include a base sheet or layer 412 and an insulation sheet or layer 414.

[0048] The base sheet 412 can be cut from a larger sheet or roll (not shown) of paper or other suitable sheet material. The base sheet 412 can have a rectangular shape or another shape. The base sheet 412 can be secured to the insulation layer 414. The insulation layer 414 can have a rectangular or shape similar to the base sheet 412. For example, the base sheet 412 and the insulation layer 414 can be rectangular with four bounding edges. The insulation layer 414 can have corrugations or other multiple distortions. The corrugations or other distortions can provide thickness to the material of the insulating layer 414. Increasing the thickness of the material of the insulation layer 414 can increase the insulating properties of the insulation layer 414. Illustrative insulating outer wrappers 420 are described in more detail in U.S. Pat. Pub. No.: 2006/0144915. An adhesive can be applied to a portion of the insulation layer 414, the base sheet 412, or both, and can secure the insulation layer 414 to the base sheet 412. [0049] Figure 4B depicts a cross-sectional view of the cup 405 with the insulating outer wrapper disposed thereon, according to one or more embodiments. The edges of the base sheet 412 can overlap when the base sheet 412 is disposed about the cup 405. The overlapping edges of the base sheet 412 can be bonded or secured together. The overlapping edges of the base sheet 412 can be bonded together using cold paste adhesive, hot melt adhesive, a layer of heat- activated adhesive, or other adhesives. For example, a layer of polyethylene can be pre-applied to a portion of the edges of the base sheet 412. The layer of polyethylene can be heat activated to seal the edges of the base sheet 412 when the edges of the base sheet 412 are overlapped and pressed together.

[0050] Figure 5 depicts an enlarged cross-sectional top view of the seal area 421 of the cup 405 and the adjacent part of the insulating outer wrapper 420, according to one or more embodiments. Referring to Figures 4A and 5, a layer or bead of glue 414G can be applied to the cup 405 or a portion of the insulation layer 414. A seam glue 412SG can be applied adjacent one or more distal ends of the base sheet 412. A seal area 421 can be formed when the distal edges of the base sheet 412 are overlapping.

[0051] In operation, the insulation layer 414 can be secured to the cup 405 by the layer of glue 414G. The edges of the base sheet 412 can be overlapped and the seam glue 412SG can bond the overlapping edges together forming the seal area 421. The seal area 421 can have a minimum seal width 42 IL of approximately 9.5 mm between side edges of base sheet 412. The minimum seal width 42 IL can improve certain characteristics of the cup. For example, the minimum seal width 42 IL at the seal area 421 can decrease the out of roundness in the rim area. The minimum seal width 42 IL can improve the overall rim geometry, improve the overall cup rigidity, cup production, and ease of fitting a concentric lid on the more concentric rim.

[0052] The insulating outer wrapper 420 can be adhered to the cup side wall 410 along the seal area 421. The insulating outer wrapper 420 can be bonded to the cup side wall 410 by applying paste adhesive, hot melt adhesive, or a pre-applied heat-activated polyethylene layer to the inner surface of the seal area 421. In one or more embodiments, an adhesive can be applied to a vertical strip (not shown) on the cup 405 and the seal area 421 can be disposed on the vertical strip, which can secure the insulating outer wrapper 420 to the cup 405. In one or more embodiments, the seam glue 412SG can be used to attach the insulating outer wrapper 420 to the cup 405. The attached overlapping edge areas of the base sheet 412 are attached together at the seal area 421, but a portion of the base sheet 412 adjacent the seal area 421 is separated from the cup 405. The space between the cup 405 and the portion of the base sheet 412 adjacent the seal area 421 can be filled with air. The air can provide insulation between the cup 405 and the portion of the base sheet 412 adjacent the bond area 412. In one or more embodiments, the space between the cup 405 and the portion of the base sheet 412 adjacent the seal area 421 can be filled with a foaming adhesive (not shown). The foaming adhesive can be used to attach the portion of the base sheet 412 adjacent the seal area 421 to the cup 405. The foaming adhesive can fill the gap between the portion of the base sheet 412 adjacent the seal area 421 and the cup 405.

Table 1 Seam Width, Dimensions and Rigidity Measurements

16oz Cups with .5.92 mm seam

Note: Sample size of 10 ten Cups

White no-print 16oz Cups with .9.53 mm wide seam

Note: Sample size of 10 ten cups 16oz Cup Specifications

[0053] Table 1 provides measurements of various characteristics for 16oz cups with 5.92 mm seam width and 16oz cups with 9.53 mm inch seam width. Table 1 includes measurements for fiber tear width of outside seam, fiber tear width of inside seam 2 IL, brim outside diameter (BOD) average, BOD at the seam, brim thickness, brim thickness at the seam, height of the cups, spacing from the bottom of the cups to the top of the bottom of the cups, and sidewall rigidity.

[0054] The measurements are taken from ten 16oz cups with 5.92 mm seam width and ten 16oz cups with 9.53 mm seam width. The aggregated data related to the above-mentioned measurements are expressed in average, standard deviation, maximum, minimum, and range. The target or goal at the time of the measurements was to design and produce cups with a BOD average of 89.79 mm having maximum value of 90.04 mm and a minimum value of 89.54 mm; a brim thickness average of 3.30 mm having maximum value of 3.56 mm and a minimum value of 3.05; a height average of 135.00 mm having a maximum value of 135.38 mm and a minimum value of 134.62 mm; and spacing average of 15.94 mm having a maximum value of 16.19 mm and minimum value of 15.68 mm.

Table 2 Out of Roundness Measurement

16oz Cups with 5.92 mm seam

9 90.60 89.36 88.72 89.36 90.45 0.81 90.60 88.72 1.88

10 88.98 88.19 89.18 90.60 88.54 0.94 90.60 88.19 2.41

Note: All BOD measurements in inches 1.85

Overall Range

White no-print 16oz Cups with 9.53 mm wide seam

Overall Range

[0055] Table 2 provides out of roundness measurements for 16oz cups with 5.92 mm seam width and 16oz cups with 9.53 mm seam width. Table 2 includes BOD measurements from A, B, C, D, and E positions at the brim of the cups. The measurements are taken from ten 16oz cups with 5.92 mm seam width and ten 16oz cups with 9.53 mm seam width. The aggregated data related to the BOD measurements are expressed in standard deviation, maximum, minimum, and range.

[0056] Embodiments of the present invention further include the following paragraphs 1 to 20, either alone or in any combination of two or more paragraphs:

[0057] 1. A thermally insulated sidewall, comprising a base sheet having a fold score formed therein, the fold score separating the base sheet into a first section and a second section, wherein: each section comprises a first end adjacent the fold score and a second end opposite the fold score; a distance between the first end and the second end of the second section is greater than a distance between the first end and the second end of the first section; and the sections are adapted to fold about the fold score to provide a seal area between at least a portion of the second ends of each section, the seal area having a seal width of about 9.0 mm or more. [0058] 2. The thermally insulated sidewall according to paragraph 1, wherein the first and second sections have an arcuate shape.

[0059] 3. The thermally insulated sidewall according to paragraph 1 or 2, wherein the first and second sections each have a thickness of about 0.2 mm to about 0.6 mm.

[0060] 4. The thermally insulated sidewall according to any paragraph 1 to 3, wherein the seal width is about 9.5 mm or more.

[0061] 5. The thermally insulated sidewall according to any paragraph 1 to 4, wherein the fold score traverses a width of the base sheet.

[0062] 6. The thermally insulated sidewall according to any paragraph 1 to 5, wherein the first and second sections at least partially overlap when folded about the fold score.

[0063] 7. The thermally insulated sidewall according to any paragraph 1 to 6, further comprising an insulating layer at least partially disposed on either the first section or second section.

[0064] 8. The thermally insulated sidewall according to paragraph 7, wherein the insulating layer comprises a plurality of scores oriented vertically, horizontally, or both and spaced about 3.0 mm to about 13 mm apart.

[0065] 9. The thermally insulated sidewall according to paragraph 8, wherein the scores have a depth of about 0.10 mm to about 0.80 mm.

[0066] 10. The thermally insulated sidewall according to any paragraph 1 to 9, further comprising a waterproof coating at least partially disposed on the base sheet.

[0067] 11. The thermally insulated sidewall according to any paragraph 1 to 10, wherein the first and second sections are made of a single material sheet.

[0068] 12. The thermally insulated sidewall according to any paragraph 1 to 10, wherein the first section and the second section are each made of single sheet materials and joined together at the fold score to form the base sheet. [0069] 13. A container constructed of the thermally insulated sidewall according to any paragraph 1 to 12.

[0070] 14. The container according to paragraph 13, wherein an upper portion of the first section is rolled to form a rim.

[0071] 15. The container according to paragraph 13 or 14, further comprising a bottom blank attached to the first section by folding a portion of the first section and securing the bottom blank to the first section.

[0072] 16. The container according to paragraph 15, wherein a portion of the bottom blank is at least partially coated with a waterproof material.

[0073] 17. A method for making the container according to claim 13, comprising: scoring the base sheet to form the first section and the second section therein, wherein the score is located so that a distance between a distal edge of the second section and the score is greater than a distance between a distal edge of the first section and the score; securing an insulation layer to at least one of the sections; folding at least one of the sections about the score forming a three-layered arrangement having a fold edge; securing the three-layered arrangement adjacent the fold edge; rounding the three-layered arrangement about a mandrel; and attaching at least a portion of the distal edge of the first layer to at least a portion of the second layer adjacent the fold edge to form the seal area.

[0074] 18. The method according to paragraph 17, further comprising applying a waterproof coating on at least a portion of the first section or the second section or both, wherein the waterproof coating comprises polyethylene, polypropylene, or polyester.

[0075] 19. The method according to paragraph 17 or 18, further comprising rolling an upper portion of the first layer to form a rim on the thermally insulated sidewall.

[0076] 20. The method according to any paragraph 17 to 19, wherein securing the insulation layer to one of the sections comprises placing an adhesive on the second section, and centrally locating the insulation layer on the second section. [0077] Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges from any lower limit to any upper limit are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are "about" or "approximately" the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.

[0078] Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.

[0079] While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims

What is claimed is: 1. A thermally insulated sidewall, comprising a base sheet having a fold score formed therein, the fold score separating the base sheet into a first section and a second section, wherein: each section comprises a first end adjacent the fold score and a second end opposite the fold score; a distance between the first end and the second end of the second section is greater than a distance between the first end and the second end of the first section; and the sections are adapted to fold about the fold score to provide a seal area between at least a portion of the second ends of each section, the seal area having a seal width of about 9.0 mm or more.

2. The thermally insulated sidewall according to claim 1, wherein the first and second sections have an arcuate shape.

3. The thermally insulated sidewall according to claim 1 or 2, wherein the first and second sections each have a thickness of about 0.2 mm to about 0.6 mm.

4. The thermally insulated sidewall according to any claim 1 to 3, wherein the seal width is about 9.5 mm or more.

5. The thermally insulated sidewall according to any claim 1 to 4, wherein the fold score traverses a width of the base sheet.

6. The thermally insulated sidewall according to any claim 1 to 5, wherein the first and second sections at least partially overlap when folded about the fold score.

7. The thermally insulated sidewall according to any claim 1 to 6, further comprising an insulating layer at least partially disposed on either the first section or second section.

8. The thermally insulated sidewall according to claim 7, wherein the insulating layer comprises a plurality of scores oriented vertically, horizontally, or both and spaced about 3.0 mm to about 13 mm apart.

9. The thermally insulated sidewall according to claim 8, wherein the scores have a depth of about 0.10 mm to about 0.80 mm.

10. The thermally insulated sidewall according to any claim 1 to 9, further comprising a waterproof coating at least partially disposed on the base sheet.

11. The thermally insulated sidewall according to any claim 1 to 10, wherein the first and second sections are made of a single material sheet.

12. The thermally insulated sidewall according to any claim 1 to 10, wherein the first section and the second section are each made of single sheet materials and joined together at the fold score to form the base sheet.

13. A container constructed of the thermally insulated sidewall according to any claim 1 to 12.

14. The container according to claim 13, wherein an upper portion of the first section is rolled to form a rim.

15. The container according to claim 13 or 14, further comprising a bottom blank attached to the first section by folding a portion of the first section and securing the bottom blank to the first section.

16. The container according to claim 15, wherein a portion of the bottom blank is at least partially coated with a waterproof material.

17. A method for making the container according to claim 13, comprising: scoring the base sheet to form the first section and the second section therein, wherein the score is located so that a distance between a distal edge of the second section and the score is greater than a distance between a distal edge of the first section and the score; securing an insulation layer to at least one of the sections; folding at least one of the sections about the score forming a three-layered arrangement having a fold edge; securing the three-layered arrangement adjacent the fold edge; rounding the three-layered arrangement about a mandrel; and attaching at least a portion of the distal edge of the first layer to at least a portion of the second layer adjacent the fold edge to form the seal area.

18. The method according to claim 17, further comprising applying a waterproof coating on at least a portion of the first section or the second section or both, wherein the waterproof coating comprises polyethylene, polypropylene, or polyester.

19. The method according to claims 17 or 18, further comprising rolling an upper portion of the first layer to form a rim on the thermally insulated sidewall.

20. The method according to any claim 17 to 19, wherein securing the insulation layer to one of the sections comprises placing an adhesive on the second section, and centrally locating the insulation layer on the second section.