# US 11,897,683 B2 · Insulated multi-layer sheet and method of making the same

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- Number: US 11,897,683 B2
- Document ID: US11897683B2
- Status: Granted
- Kind: B2
- Application number: 17/528,650
- Filed: 2021-11-17
- Published: 2022-03-10
- Granted: 2024-02-13
- Earliest claimed: 2017-08-08
- Assignees: Berry Global, Inc.
- Applicants: Berry Global, Inc.
- Inventors: John B. Euler; Anvit Gupta; Gerald S. Sutton; Chris Bolek
- Web page: https://patentgrep.com/patent/US11897683B2

## CPC

- B65D 81/3874: {formed of different materials, e.g. laminated or foam filling between walls}
- A47G 19/2288: {with means for keeping liquid cool or hot}
- B32B 1/00: Layered products having a non-planar shape
- B32B 3/02: characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)}
- B32B 5/18: characterised by features of a layer {of} foamed material
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/065: {of foam}
- B32B 27/08: of synthetic resin
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 37/153: {at least one layer is extruded and immediately laminated while in semi-molten state}
- B65D 1/265: {Drinking cups (B65D81/3865 takes precedence, holders for plastic cups A47G23/0208)}
- B65D 1/28: formed of laminated material
- B65D 81/3865: {drinking cups or like containers}
- B65D 81/3867: {formed of foam material}
- B32B 2250/03: 3 layers
- B32B 2266/025: Polyolefin
- B32B 2272/00: Resin or rubber layer comprising scrap, waste or recycling material
- B32B 2307/304: Insulating
- B32B 2307/4023: on the layer surface, e.g. ink
- B32B 2307/50: having particular mechanical properties
- B32B 2307/518: bi-axially
- B32B 2307/558: Impact strength, toughness
- B32B 2307/5825: Tear resistant
- B32B 2307/72: Density
- B32B 2439/00: Containers; Receptacles
- B32B 2439/02: Open containers
- B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- A47G: HOUSEHOLD OR TABLE EQUIPMENT (book-ends A47B5/00; knives B26B)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

A multi-layer sheet includes an insulative cellular non-aromatic polymeric material, a film, and a polymeric-lamination layer. The insulative cellular non-aromatic polymeric material may be formed from a polymeric formulation comprising a base resin blend and a physical nucleating agent.

## Claims

### Claim 1

A multi-layer sheet comprising:
a film layer arranged to form an outer surface,
an insulative cellular non-aromatic polymeric material arranged to form an inner surface, 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 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.

### Claim 2 (depends on 1)

The multi-layer sheet of claim 1, wherein the polymeric-lamination layer comprises a colorant.

### Claim 3 (depends on 1)

The multi-layer sheet of claim 1, wherein the polymeric-lamination layer comprises at least 40% by weight of polypropylene.

### Claim 4 (depends on 1)

The multi-layer sheet of claim 1, wherein the regrind is about 0.05% to about 50% by weight of the insulative cellular non-aromatic polymeric material.

### Claim 5 (depends on 1)

The multi-layer sheet of claim 1, wherein the regrind is substantially free of an adhesive.

### Claim 6 (depends on 1)

The multi-layer sheet of claim 1, wherein the first polypropylene is a first high melt-strength polypropylene and the second polypropylene is a second high melt-strength polypropylene.

### Claim 7 (depends on 1)

The multi-layer sheet of claim 1, wherein the multi-layer sheet has a tear resistance in a machine direction of at least about 75 gf according to ASTM D1922-93.

### Claim 8 (depends on 7)

The multi-layer sheet of claim 7, wherein the multi-layer sheet has a puncture resistance of at least about 6,000 gf.

### Claim 9 (depends on 1)

The multi-layer sheet of claim 1, wherein the multi-layer sheet has a density of about 0.01 g/cm 3 to about 0.2 g/cm 3.

### Claim 10 (depends on 9)

The multi-layer sheet of claim 9, wherein the multi-layer sheet has a thermal conductivity at 93° C. less than about 0.065 W/m-K.

### Claim 11 (depends on 1)

The multi-layer sheet of claim 1, wherein the multi-layer sheet lacks creases.

### Claim 12 (depends on 1)

The multi-layer sheet of claim 1, wherein the film layer is formed of a first polymeric formulation and the polymeric-lamination layer is formed of a second formulation that is different than the first polymer formulation.

### Claim 13 (depends on 1)

The multi-layer sheet of claim 1, wherein the regrind has an average load at break of less than about 0.1 N.

### Claim 14

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.

### Claim 15

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.