Insulated container and methods of making and assembling
AssigneeDart Container Corporation
InventorsChengtao Li, Gary R. Wilkes, Wayne J. Myer, Peter Matysiak
Life of this patent
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Abstract
A multi-layer sheet for forming an expanded foam container, the multi-layer sheet including a first layer of an expanded foam material including a first polyolefin-based material including at least one polypropylene-based polymer and a second layer of an unexpected material including a second polyolefin-based material including at least one polypropylene-based polymer that is co-extruded, extrusion coated, or laminated on a first side of the first layer.
Claims59
A co-extruded sheet comprising an extrusion having at least a first layer of an expanded foam material comprising a blend of a first high melt strength homopolymer or copolymer of polypropylene including long chain branching and having a melt strength of at least 20 cN and a second high melt strength homopolymer or copolymer of polypropylene, and a second layer of an unexpanded material comprising a third high melt strength homopolymer or copolymer of polypropylene having a melt strength of at least 20 cN,
- wherein the co-extruded sheet has a density of less than about 12.5 lb/ft3.
An expanded foam container comprising:
- a peripheral wall having an interior surface defining an interior cavity, an upper end defining an upper opening to the interior cavity and a lower end, opposite the upper end, defining a lower opening to the interior cavity;
- and
- a bottom wall closing the lower opening, the bottom wall comprising a floor having an upper surface defining a bottom of the interior cavity and a lower surface;
- wherein at least the sleeve comprises a co-extruded sheet having at least a first layer of an expanded foam material comprising a blend of a first high melt strength homopolymer or copolymer of polypropylene including long chain branching and having a melt strength of at least 20 cN and a second high melt strength homopolymer or copolymer of polypropylene, and a second layer of an unexpanded material comprising a third high melt strength homopolymer or copolymer of polypropylene having a melt strength of at least 20 cN;
- wherein the co-extruded sheet has a density of less than about 12.5 lb/ft3.
A co-extruded sheet comprising:
- a first extrudate layer of an expanded foam material comprising a blend of a first high melt strength homopolymer or copolymer of polypropylene including long chain branching and having a melt strength of at least 20 cN and a second high melt strength homopolymer or copolymer of polypropylene;
- and
- a second extrudate layer of an unexpanded material comprising a third high melt strength homopolymer or copolymer of polypropylene having a melt strength of at least 20 cN;
- wherein the first and second extrudate layers are in overlying relationship and wherein the co-extruded sheet has a density of less than about 12.5 lb/ft3.
Dependencies are inferred from the claim text.