# US 8,784,959 B2 · Injection-molded composite construct

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- Number: US 8,784,959 B2
- Document ID: US8784959B2
- Status: Granted
- Kind: B2
- Application number: 13/357,295
- Filed: 2012-01-24
- Published: 2012-05-17
- Granted: 2014-07-22
- Earliest claimed: 2006-03-10
- Assignees: Graphic Packaging International, Inc.
- Applicants: Brian R. O'Hagan; Peter W. Blaas; Scott W. Middleton; Kevin J. Hjort; Bruce Barnard
- Inventors: Brian R. O'Hagan; Peter W. Blaas; Scott W. Middleton; Kevin J. Hjort; Bruce Barnard
- Web page: https://patentgrep.com/patent/US8784959B2

## CPC

- B29C 45/14475: {Joining juxtaposed parts of a single article, e.g. edges of a folded container blank}
- B65D 1/26: Thin-walled containers, e.g. formed by deep-drawing operations {(B65D1/165 takes precedence)}
- B23P 19/00: Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation {(connecting metal parts or objects by metal-working procedures B21J, B23K)}; Tools or devices therefor so far as not provided for in other classes (hand tools in general B25)
- B29C 45/14: incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles {(B29C45/1671 takes precedence)}
- B29C 51/082: {by shaping between complementary mould parts}
- B29C 51/162: {of deep containers or boxes}
- B65D 1/40: Details of walls (other container details B65D23/00, B65D25/00)
- B65D 5/209: {the adjacent edges of folded-up portions being joined by moulding seams in situ}
- B65D 81/3453: {Rigid containers, e.g. trays, bottles, boxes, cups}
- B29C 51/10: Forming by pressure difference, e.g. vacuum
- B29C 51/22: rotatable about an axis
- B29C 51/46: Measuring, controlling or regulating
- B29C 65/48: using adhesives {, i.e. using supplementary joining material; solvent bonding}
- B29C 65/482: {Drying adhesives, e.g. solvent based adhesives}
- B29C 65/4825: {Pressure sensitive adhesives}
- B29C 65/76: Making non-permanent or releasable joints
- B29C 66/4326: {for making hollow articles or hollow-preforms, e.g. half-shells}
- B29C 2791/001: Shaping in several steps
- B29C 2791/006: Using vacuum
- B29K 2001/00: Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
- B29K 2067/00: Use of polyesters {or derivatives thereof}, as moulding material
- B29L 2031/712: {Containers; Packaging elements or accessories, Packages (closures therefor B29L2031/56; ink or toner cartridges B29L2031/7678; squeeze tubes B29L2023/20; suitcases B29L2031/7418)}
- B31B 50/592: {using punches or dies}
- B31B 2105/00: Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs
- B31B 2105/0024: {Making boxes having all side walls attached to the bottom}
- B31B 2120/406: {the lining material being a plunger, a web, a sheet or a bag to be forced into the box, e.g. by using heat}
- B31B 2120/407: {involving forming of the liner before inserting}
- B65D 2581/344: Geometry or shape factors influencing the microwave heating properties
- B65D 2581/3472: Aluminium or compounds thereof
- B65D 2581/3477: Iron or compounds thereof
- B65D 2581/3479: Other metallic compounds, e.g. silver, gold, copper, nickel
- B65D 2581/3493: attached to the base surface
- B65D 2581/3498: attached to the base surface
- Y10T 29/49822: by applying force
- Y10T 428/1303: Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
- Y10T 428/1352: Polymer or resin containing [i.e., natural or synthetic]
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- 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
- B23P: METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS (arrangements for copying or controlling B23Q)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B31B: MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER (making wound articles, e.g. wound tubes, B31C; combined making and filling B65B)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A frame is injection molded onto a group of panels to form a container. The panels extend at least partially around, and at least partially define, a cavity of the container.

## Claims

### Claim 1

A container, comprising:
a plurality of panels extending partially around an interior cavity of the container, wherein the plurality of panels includes first and second panels that together partially define an upright elongate corner of the container, an upright elongate gap is defined between at least a portion of an upright edge of the first panel and at least a portion of an upright edge of the second panel, and for each of the first and second panels
the panel includes a curved portion proximate to the gap,
an outward surface of the curved portion of the panel defines an outwardly projecting protrusion of the panel,
the outwardly projecting protrusion of the panel is elongate, proximate to the gap, and extends upwardly along both the gap and the corner, and
an inward surface of the curved portion of the panel defines a recess that is elongate and extends upwardly along both the gap and the corner; and
an injection-molded strip extending upwardly along and partially defining the corner of the container, wherein
the injection-molded strip covers the gap,
the injection-molded strip includes an upwardly extending inner face that partially defines the cavity of the container, the inner face being smoothly curved from the first panel to the second panel, wherein the inner face being smoothly curved from the first panel to the second panel comprises both
the inner face extending concavely from the first panel to the second panel, and
the inner face extending smoothly from the first panel to the second panel,
the injection-molded strip further includes an outwardly projecting first protrusion that is elongate, extends upwardly along both the corner and the gap, and extends outwardly into the recess of the curved portion of the first panel,
the injection-molded strip further includes an outwardly projecting second protrusion that is elongate, extends upwardly along both the corner and the gap, and extends outwardly into the recess of the curved portion of the second panel,
the injection-molded strip further includes a bead that extends into the gap and is positioned between the first and second protrusions of the injection-molded strip, and
for each of the first and second protrusions, the protrusion extends outwardly from the smoothly curved inner face of the injection-molded strip, so that the protrusion is thicker than an adjacent portion of the injection-molded strip.

### Claim 2 (depends on 1)

The container according to claim 1, wherein:
the plurality of panels includes a curved portion,
an outward surface of the curved portion of the plurality of panels defines an outwardly projecting protrusion of the plurality of panels,
an inward surface of the curved portion of the plurality of panels defines a recess, and
the injection-molded strip further includes an outwardly projecting third protrusion that extends into the recess of the curved portion of the plurality of panels.

### Claim 3 (depends on 2)

The container according to claim 2, wherein:
the outwardly projecting protrusion of the plurality of panels is an outwardly bulbous portion of the plurality of panels;
the recess of the plurality of panels is a substantially bowl-shaped recess;
the third protrusion of the injection-molded strip is an outwardly bulbous portion of the injection-molded strip that extends into the substantially bowl-shaped recess; and
the outwardly bulbous portion of the plurality of panels and the outwardly bulbous portion of the injection-molded strip are positioned at a lower end of the corner.

### Claim 4 (depends on 3)

The container according to claim 3, wherein the gap extends into the outwardly bulbous portion of the plurality of panels.

### Claim 5 (depends on 3)

The container according to claim 3, wherein:
at least one panel of the plurality of panels comprises microwave energy interactive material, paperboard and polymer film,
the microwave energy interactive material is positioned between the paperboard and the polymer film, and
at least a portion of the injection-molded strip is adhered to the polymer film.

### Claim 6 (depends on 1)

The container according to claim 1, wherein a bulbous portion is proximate an end of the corner.

### Claim 7 (depends on 1)

The container according to claim 1, wherein:
at least one panel of the plurality of panels comprises microwave energy interactive material, paperboard and polymer film,
the microwave energy interactive material is positioned between the paperboard and the polymer film, and
at least a portion of the injection-molded strip is adhered to the polymer film.

### Claim 8 (depends on 1)

The container according to claim 1, wherein the injection-molded strip is injection-molded onto both the first panel and the second panel.

### Claim 9 (depends on 1)

The container according to claim 1, wherein:
the plurality of panels includes a curved portion;
an outward surface of the curved portion of the plurality of panels defines an outwardly bulbous portion of the plurality of panels;
an inward surface of the curved portion of the plurality of panels defines a substantially bowl-shaped recess;
the injection-molded strip further includes an outwardly bulbous portion that extends into the substantially bowl-shaped recess;
the outwardly bulbous portion of the plurality of panels and the outwardly bulbous portion of the injection-molded strip are positioned at a lower end of the corner; and
the protrusion of the first panel and the first protrusion of the injection-molded strip respectively extend upwardly from the outwardly bulbous portion of the plurality of panels and the outwardly bulbous portion of the injection-molded strip.

### Claim 10 (depends on 1)

The container according to claim 1, wherein:
the protrusion of the first panel is convex;
the first protrusion of the injection-molded strip is convex; and
the recess of the first panel is concave.

### Claim 11 (depends on 1)

The container according to claim 1, wherein the curved portion of the first panel is not pleated.

### Claim 12 (depends on 1)

The container according to claim 1, wherein:
the corner includes an elongate centerline that extends along the corners' length; and
the centerline is spaced apart from each of
the protrusion of the first panel,
the first protrusion of the injection-molded strip, and
the recess of the first panel.

### Claim 13 (depends on 1)

The container according to claim 1, wherein:
the outwardly projecting protrusion of the first panel is press-formed by the outwardly projecting first protrusion of the injection-molded strip, and
the outwardly projecting protrusion of the second panel is press-formed by the outwardly projecting second protrusion of the injection-molded strip.

### Claim 14

A container, comprising:
a plurality of panels that partially defines an interior cavity of the container, wherein the plurality of panels includes a first panel and a second panel that is proximate to the first panel and together with the first panel partially defines an upright corner of the container, and for each of the first and second panels
the panel includes a curved portion,
an outward surface of the curved portion of the panel defines an outwardly projecting protrusion of the panel,
the outwardly projecting protrusion of the panel is elongate and extends upwardly along the corner, and
an inward surface of the curved portion of the panel defines a recess that is elongate and extends upwardly along the corner; and
an injection-molded strip extending upwardly along and partially defining the corner of the container, wherein
the injection-molded strip includes an upwardly extending inner face that partially defines the cavity of the container, the inner face being smoothly curved from the first panel to the second panel, wherein the inner face being smoothly curved from the first panel to the second panel comprises both
the inner face extending concavely from the first panel to the second panel, and
the inner face extending smoothly from the first panel to the second panel,
the injection-molded strip further includes an outwardly projecting first protrusion that is elongate, extends upwardly along the corner, and extends outwardly into the recess of the curved portion of the first panel,
the injection-molded strip further includes an outwardly projecting second protrusion that is elongate, extends upwardly along the corner, and extends outwardly into the recess defined by the curved portion of the second panel, and
the corner includes an elongate centerline that extends along the corners' length, and the centerline is spaced apart from each of
the protrusion of the first panel,
the first protrusion of the injection-molded strip, and
the recess of the first panel, and
for each of the first and second protrusions, the protrusion extends outwardly from the smoothly curved inner face of the injection-molded strip, so that the protrusion is thicker than an adjacent portion of the injection-molded strip.

### Claim 15 (depends on 14)

The container according to claim 14, wherein:
a gap is defined between at least a portion of an edge of the first panel and at least a portion of an edge of the second panel;
the injection-molded strip includes an outwardly projecting third protrusion that is elongate, extends along the corner, and extends into the gap; and
the third protrusion of the injection-molded strip is positioned between the first and second protrusions of the injection-molded strip.

### Claim 16 (depends on 14)

The container according to claim 14, wherein:
the outwardly projecting protrusion of the first panel is press-formed by the outwardly projecting first protrusion of the injection-molded strip, and
the outwardly projecting protrusion of the second panel is press-formed by the outwardly projecting second protrusion of the injection-molded strip.

### Claim 17 (depends on 14)

The container according to claim 14, wherein:
the protrusion of the first panel is convex;
the first protrusion of the injection-molded strip is convex; and
the recess of the first panel is concave.