Insulated multi-layer sheet and method of making the same

A multi-layer sheet comprising:

• a film layer arranged to form a first exterior surface,
• an insulative cellular non-aromatic polymeric material arranged to form a second exterior surface and is located opposite of the first exterior surface formed by the film layer, and
• a polymeric-lamination layer extending between and interconnecting the film layer and the insulative cellular non-aromatic polymeric material, wherein the polymeric-lamination layer is substantially free of an adhesive,
• wherein the film layer is a biaxially oriented polypropylene film,
• wherein the first exterior surface forms an outer surface,
• wherein the second exterior surface forms an inner surface,
• wherein the polymeric-lamination layer comprises i) a polypropylene, ii) regrind, and optionally iii) a colorant,
• wherein the multi-layer sheet comprises an ink layer printed on the film layer,
• wherein the insulative cellular non-aromatic polymeric material comprises about 40% to about 99.5% by weight of a base resin blend, and up to about 50% by weight of regrind, the base resin blend comprising a first polypropylene and a second polypropylene, and
• wherein the regrind comprises ink and regrind of the multi-layer sheet.

A method of producing a multi-layer sheet, comprising,

• extruding an insulative cellular non-aromatic polymeric material, and
• coupling a film layer to the insulative cellular non-aromatic polymeric material to form the multi-layer sheet,
• wherein the step of coupling comprises extruding a polymeric-lamination layer between the insulative cellular non-aromatic polymeric material and the film layer, and
• wherein the polymeric-lamination layer extends between and interconnects the insulative cellular non-aromatic polymeric material and the film layer, wherein the polymeric-lamination layer is substantially free of an adhesive,
• wherein the film layer is a biaxially oriented polypropylene film,
• wherein the polymeric-lamination layer comprises a polypropylene and regrind,
• wherein the regrind is about 0.05% to about 99.5% by weight of the polymeric-lamination layer,
• wherein the multi-layer sheet comprises an ink layer printed on the film layer,
• wherein the insulative cellular non-aromatic polymeric material comprises about 40% to about 99.5% by weight of a base resin blend, and up to about 50% by weight of regrind, the base resin blend comprising a first polypropylene and a second polypropylene, and
• wherein the regrind comprises ink and regrind of the multi-layer sheet.