Injection-molded composite construct

• US 20070262487A1
• Filed: 03/08/2007
• Published: 11/15/2007
• Est. Priority Date: 03/10/2006
• Status: Active Grant

• Current Assignee: Graphic Packaging International Incorporated
• Original Assignee: Graphic Packaging International Incorporated
• Inventors: Barnard, Bruce, Middleton, Scott, Blaas, Peter, O'Hagan, Brian, Hjort, Kevin
• Granted Patent: US 8,124,201 B2
• Time in Patent Office: Days
• US Class Current: 264/241
• CPC Class Codes: 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
• CPC Class Codes: B29C 2791/001 Shaping in several steps
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 45/14 incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles B29C45/1671 takes precedence
• CPC Class Codes: B29C 45/14475 Joining juxtaposed parts of a single article, e.g. edges of a folded container blank
• CPC Class Codes: B29C 51/082 by shaping between complementary mould parts
• CPC Class Codes: B29C 51/10 Forming by pressure difference, e.g. vacuum
• CPC Class Codes: B29C 51/162 of deep containers or boxes
• CPC Class Codes: B29C 51/22 rotatable about an axis
• CPC Class Codes: B29C 51/46 Measuring, controlling or regulating
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 65/482 Drying adhesives, e.g. solvent based adhesives
• CPC Class Codes: B29C 65/4825 Pressure sensitive adhesives
• CPC Class Codes: B29C 65/76 Making non-permanent or releasable joints
• CPC Class Codes: B29C 66/4326 for making hollow articles or hollow-preforms, e.g. half-shells
• CPC Class Codes: B29K 2001/00 Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
• CPC Class Codes: B29K 2067/00 Use of polyesters or derivatives thereof, as moulding material
• CPC Class Codes: 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
• CPC Class Codes: B31B 2105/00 Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs
• CPC Class Codes: B31B 2105/0024 Making boxes having all side walls attached to the bottom
• CPC Class Codes: 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
• CPC Class Codes: B31B 2120/407 : involving forming of the liner before inserting
• CPC Class Codes: B31B 50/592 : using punches or dies
• CPC Class Codes: B65D 1/26 : Thin-walled containers, e.g. formed by deep-drawing operations B65D1/165 takes precedence
• CPC Class Codes: B65D 1/40 : Details of walls other container details B65D23/00, B65D25/00
• CPC Class Codes: B65D 2581/344 : Geometry or shape factors influencing the microwave heating properties
• CPC Class Codes: B65D 2581/3472 : Aluminium or compounds thereof
• CPC Class Codes: B65D 2581/3477 : Iron or compounds thereof
• CPC Class Codes: B65D 2581/3479 : Other metallic compounds, e.g. silver, gold, copper, nickel
• CPC Class Codes: B65D 2581/3493 : attached to the base surface
• CPC Class Codes: B65D 2581/3498 : attached to the base surface
• CPC Class Codes: B65D 5/209 : the adjacent edges of folded-up portions being joined by moulding seams in situ
• CPC Class Codes: B65D 81/3453 : Rigid containers, e.g. trays, bottles, boxes, cups
• CPC Class Codes: Y10T 29/49822 : by applying force
• CPC Class Codes: Y10T 428/1303 : Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
• CPC Class Codes: Y10T 428/1352 : Polymer or resin containing [i.e., natural or synthetic]

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

1. A container, comprising:

a plurality of panels that extends at least partially around and at least partially defines a cavity of the container, wherein

the plurality of panels includes a base panel, a first side panel extending upwardly from the base panel, and a second side panel extending upwardly from the base panel,

the first side panel includes an edge,

the second side panel includes an edge that is proximate the edge of the first side panel,

at least a first portion of the edge of the first side panel extends along an elongate corner of the container,

at least a first portion of the edge of the second side panel extends along the elongate corner of the container,

a gap is defined between the first portion of the edge of the first side panel and the first portion of the edge of the second panel, and

an overlap exists between a second portion of the edge of the first side panel and a portion of the second side panel; and

an injection-molded structure extends along and at least partially defines the corner of the container, wherein the injection-molded structure obstructs the gap and at least partially covers the overlap.

2. The container according to claim 1, wherein at least one panel of the plurality of panels comprises microwave energy interactive material.

3. The container according to claim 2, wherein:

the at least one panel comprises 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 structure is adhered to the polymer film.

4. The container according to claim 1, wherein:

the first side panel includes an upright portion and a flange that extends outwardly from an upper edge of the upright portion;

the second side panel includes an upright portion and a flange that extends outwardly from an upper edge of the upright portion; and

the flange of the first side panel at least partially overlaps the flange of the second side panel.

5. The container according to claim 4, wherein the injection-molded structure includes:

a band that is injection-molded onto at least the flange of the first side panel and the flange of the second side panel, and

a strip that is injection-molded into the corner of the container.

6. The container according to claim 5, wherein the strip includes a concave face that at least partially defines the cavity of the container.

7. The container according to claim 5, wherein the strip is injection-molded onto at least the first and second side panels.

8. The container according to claim 5, wherein the strip includes an outwardly projecting protrusion that is elongate, extends along the corner, and extends into the gap.

9. The container according to claim 8, wherein the protrusion comprises a bead that fills the gap.

10. A container, comprising:

a base panel;

a plurality of side panels that extends upwardly from the base panel and extends at least partially around and at least partially defines a cavity of the container;

a plurality of multi-part flanges, wherein multi-part flanges of the plurality of multi-part flanges respectively extend outwardly from upper edges of side panels of the plurality of side panels, and wherein at least one of the multi-part flanges includes a lower flange that extends outwardly from the upper edge of the respective side panel, an upright panel that extends upwardly from an outer edge of the lower flange, and an upper flange that extends outwardly from an upper edge of the upright panel; and

a band that is injection-molded onto both

an upper surface of the upper flange, and

an upper surface of the lower flange.

11. The container according to claim 10, wherein:

at least one panel, which is selected from the group consisting of the base panel and the side panels, comprises microwave energy interactive material, paperboard and polymer film,

the microwave energy interactive material is positioned between the paperboard and the polymer film,

the band is part of an injection-molded structure, and

at least a portion of the injection-molded structure is adhered to the polymer film.

12. The container according to claim 10, wherein:

the band includes a flat upper surface,

the upper surface of the upper flange is beneath the flat upper surface of the band, and

the upper surface of the lower flange is beneath the flat upper surface of the band.

13. The container according to claim 10, further comprising a polymeric cover, wherein the polymeric cover is heat sealed to the upper surface of the band so that the polymeric cover closes an opening to the container.

14. A container, comprising:

a plurality of panels that extends at least partially around and at least partially defines a cavity of the container, wherein

the plurality of panels includes a panel that at least partially defines an elongate corner of the container,

the panel includes a curved portion,

an outward surface of the curved portion of the panel defines an outwardly projecting protrusion of the panel,

an inward surface of the curved portion of the panel defines a recess; and

an injection-molded strip that extends along and at least partially defines the corner of the container, wherein the strip includes an outwardly projecting protrusion that extends into the recess of the curved portion of the panel.

15. The container according to claim 14, 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.

16. The container according to claim 14, wherein a bulbous portion is proximate an end of the corner and comprises:

the outwardly projecting protrusion of the curved portion of the panel, and

the outwardly projecting protrusion of the strip, which extends into the recess of the curved portion of the panel.

17. The container according to claim 14, wherein:

the outwardly projecting protrusion of the panel is elongate and extends along the corner,

the recess of the curved portion of the panel is elongate and extends along the corner, and

the outwardly projecting protrusion of the strip is elongate and extends along the corner.

18. The container according to claim 17, wherein an elongate rib comprises:

the outwardly projecting protrusion of the curved portion of the panel, and

the outwardly projecting protrusion of the strip, which extends into the recess of the curved portion of the panel.

19. The container according to claim 17, wherein the strip is injection-molded onto the panel.

20. The container according to claim 17, wherein:

the curved portion is a first curved portion;

the plurality of panels includes a second curved portion;

an outward surface of the second curved portion defines an outwardly bulbous portion of the panels;

an inward surface of the second curved portion defines a substantially bowl-shaped recess;

the strip includes an outwardly bulbous portion that extends into the substantially bowl-shaped recess;

the outwardly bulbous portion of the panels and the outwardly bulbous portion of the strip are positioned at a lower end of the corner; and

the protrusion of the panel and the protrusion of the strip respectively extend upwardly from the outwardly bulbous portion of the panels and the outwardly bulbous portion of the strip.

21. The container according to claim 17, wherein:

the protrusion of the panel is convex;

the protrusion of the strip is convex; and

the recess is concave.

22. The container according to claim 17, wherein the curved portion of the panel is not pleated.

23. The container according to claim 17, wherein the strip includes a concave face that at least partially defines the cavity of the container.

24. The container according to claim 17, 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 panel,

the protrusion of the strip, and

the recess.

25. The container according to claim 24, wherein:

the protrusion of the strip is a first protrusion of the strip;

the panel is a first panel;

the plurality of panels further includes a second panel that is proximate to the first panel and together with the first panel at least partially defines the corner of the container;

the second panel includes a curved portion,

an outward surface of the curved portion of the second panel defines an outwardly projecting protrusion of the second panel,

the outwardly projecting protrusion of the second panel is elongate and extends along the corner,

an inward surface of the curved portion of the second panel defines a recess that is elongate and extends along the corner; and

the strip includes an outwardly projecting second protrusion that is elongate, extends along the corner, and extends into the recess defined by the curved portion of the second panel.

26. The container according to claim 25, 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 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 strip is positioned between the first and second protrusions, of the strip.

27. A container, comprising:

a plurality of panels that extends at least partially around and at least partially defines a cavity of the container, wherein

the container includes an elongate corner,

panels of the plurality of panels include a curved portion,

an outward surface of the curved portion defines an outwardly bulbous portion of the panels,

an inward surface of the curved portion defines a substantially bowl-shaped recess; and

an injection-molded strip that extends along and at least partially defines the corner of the container, wherein

the strip includes an outwardly bulbous portion that extends into the substantially bowl-shaped recess, and

the outwardly bulbous portion of the panels and the outwardly bulbous portion of the strip are positioned at a lower end of the corner.

28. The container according to claim 27, 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 strip is adhered to the polymer film.

29. The container according to claim 27, wherein:

the plurality of panels includes a first panel and a second panel that together at least partially define the corner;

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 gap extends into the outwardly bulbous portion of the panels; and

the strip covers the gap.

30. A blank, comprising:

a base panel;

a plurality flaps respectively connected to and extending outwardly from the base panel, wherein

the plurality of flaps includes a first flap and a second flap that is adjacent to the first flap;

a gap is defined between the first and second flaps,

at least an inner portion of the gap becomes wider farther from the base panel,

the first flap has a feature that has a reducing effect on how width of the gap changes as a function of increased distance outwardly from the base panel.

31. The blank according to claim 30, wherein:

at least a portion of the blank comprises microwave energy interactive material, paperboard and polymer film, and

the microwave energy interactive material is positioned between the paperboard and the polymer film.

32. The blank according to claim 30, wherein:

the feature is a protruding portion of the first flap,

the second flap has a protruding portion that has a reducing effect on how width of the gap changes as a function of increased distance outwardly from the base panel, and

the protruding portion of the second flap extends farther into the gap than does the protruding portion of the first flap.

33. The blank according to claim 30, wherein the feature is a protruding portion of the first flap, and wherein the protruding portion of the first flap and the second flap are configured so that the protruding portion of the first flap and a portion of the second flap are in an overlapping relationship with respect to one another when the blank is erected into a construct in which the gap is at least partially maintained.

34. A construct erected from the blank of claim 33 and including an injection-molded frame, wherein:

the blank has been erected so that the gap has been at least partially maintained, and the protruding portion of the first flap and the portion of the second flap are in an overlapping relationship with respect to one another; and

a portion of the frame covers the gap.

35. The construct according to claim 34, wherein the gap is filled by a protruding portion of the frame.

36. The blank according to claim 30, wherein:

the first flap includes an outwardly extending edge;

the second flap includes an outwardly extending edge that is proximate to the edge of the first flap;

at least portions of the edges of the first and second flaps are spaced apart from one another so that the gap is defined between the edge of the first flap and the edge of the second flap;

an outer portion of the gap is farther from the base panel than the inner portion of the gap,

an inner portion of the edge of the first flap partially defines the inner portion of the gap,

an outer portion of the edge of the first flap at least partially defines both the outer portion of the gap and the feature, which has the reducing effect on how the width of the gap changes as a function of increased distance outwardly from the base panel,

an angle is defined between the inner and outer portions of the edge of the first flap, and

the angle is less than 180 degrees so that that the angle at least partially provides the reducing effect on how width of the gap changes as a function of distance outwardly from the base panel.

37. The blank according to claim 36, wherein the angle, which is defined between the inner and outer portions of the edge of the first flap, is an obtuse angle.

38. The blank according to claim 36, wherein width of the inner portion of the gap changes at a greater rate, as a function of distance outwardly from the base panel, than width of the outer portion of the gap.

39. The blank according to claim 36, wherein with respect to extending outwardly from the base panel, the outer portion of the edge of the first flap extends convergently with respect to a centerline of the gap.

40. The blank according to claim 36, wherein with respect to extending outwardly from the base panel, the outer portion of the edge of the first flap extends divergently with respect to a centerline of the gap.

41. The blank according to claim 40, wherein:

an inner portion of the edge of the second flap partially defines the inner portion of the gap,

an outer portion of the edge of the second flap partially defines the outer portion of the gap, and

an angle of less than 180 degrees is defined between the inner and outer portions of the edge of the second flap, and

with respect to extending outwardly from the base panel, the outer portion of the edge of the second flap extends convergently with respect to the centerline of the gap.

42. A construct, comprising:

a laminate including a releasable adhesive positioned between and at least indirectly joining together a substrate and a polymer film; and

at least one injection-molded feature that is at least indirectly joined to the polymer film.

43. The construct according to claim 42, wherein:

the laminate further includes microwave energy interactive material, and

the microwave energy interactive material is positioned between the substrate and the polymer film.

44. The construct according to claim 42, wherein the substrate comprises cellulosic material.

45. The construct according to claim 42, wherein the construct comprises a container and the injection-molded feature comprises a band.

46. The construct according to claim 42, wherein:

the releasable adhesive provides an adhesive bond between the substrate and the polymer film;

the adhesive bond between the substrate and the polymer film has a peel strength;

there is an adhesive bond between the injection-molded feature and the polymer film;

the adhesive bond between the injection-molded feature and the polymer film has a peel strength;

the peel strength of the adhesive bond between the substrate and the polymer film is less than the peel strength of the adhesive bond between the injection-molded feature and the polymer film.

47. A method of at least partially dismantling the construct of claim 42, with the method comprising:

separating the construct into separate parts, wherein the separating of the construct comprises separating the substrate and the polymer film from one another so that the injection-molded feature remains at least indirectly joined to the polymer film.

48. The method according to claim 47, further comprising recycling at least one of the parts.

49. The method according to claim 47, wherein the separating of the substrate and the polymer film from one another comprises:

manually separating the substrate and the polymer film from one another.

50. An apparatus for use in at least partially forming a container, the apparatus comprising:

a mold that includes a cavity having an elongate interior corner that extends into the cavity, wherein

the interior corner includes

(a) an elongate central region that projects into the cavity and extends along the interior corner and partially defines the cavity and the interior corner,

(b) an elongate first recess that extends along the interior corner and partially defines the cavity and the interior corner, and

(c) an elongate second recess that extends along the interior corner and partially defines the cavity and the interior corner, and

the central region is positioned between the first recess and the second recess.

51. The apparatus according to claim 50, wherein:

the mold includes a base of the cavity and an opening to the cavity,

the opening to the cavity is distant from and diametrically opposite from the base, and

the central region and the first and second recesses extend from proximate the base toward the opening.

52. The apparatus according to claim 51, wherein:

the mold includes a substantially bowl-shaped recess that partially defines the cavity and the interior corner,

the substantially bowl-shaped recess is proximate the base, and

the central region and the first and second recesses extend from the substantially bowl-shaped recess toward the opening.

53. The apparatus according to claim 50, wherein:

the mold is a female mold,

the apparatus further comprises a male mold for being inserted into the cavity of the female mold,

the male mold includes a outer mold and a inner mold that is movably mounted to the outer mold for moving between an extended configuration and a retracted configuration,

the outer mold includes a plurality of corners,

the plurality of corners of the outer mold extend at least partially around the inner mold while the inner mold is in the retracted configuration, and

the plurality of corners of the outer mold are for being respectively positioned in the interior corners of the female mold when the male mold is inserted into the cavity of the female mold, so that the plurality of corners of the outer mold are respectively positioned between the interior corners of the female mold and the inner mold while the male mold is inserted into the cavity of the female mold.

54. An apparatus for use in at least partially forming a container, the apparatus comprising:

a female mold that includes a cavity having a plurality of elongate interior corners that extend into the cavity; and

a male mold for being inserted into the cavity of the female mold, wherein

the male mold includes an outer mold and an inner mold that is movably mounted to the outer mold for moving between an extended configuration and a retracted configuration,

the outer mold includes a plurality of corners,

the plurality of corners of the outer mold extend at least partially around the inner mold while the inner mold is in the retracted configuration, and

the plurality of corners of the outer mold are for being respectively positioned in the interior corners of the female mold when the male mold is inserted into the cavity of the female mold, so that the plurality of corners of the outer mold are respectively positioned between the interior corners of the female mold and the inner mold while the male mold is inserted into the cavity of the female mold.

55. The apparatus according to claim 54, wherein for each corner of the plurality of corners of the outer mold, the corner includes a projection which lengthens the corner.

56. The apparatus according to claim 55, wherein the inner mold includes corners with recesses for respectively being in receipt of the projections of the outer mold.

57. A method of manufacturing, the method comprising:

closing a blank in a forming tool, so that the blank is formed into a construct that is at least partially contained in the closed forming tool, wherein the forming tool comprises a male mold and a female mold, and the closing of the blank in the forming tool comprises

engaging a first part of the male mold against a portion of the blank,

thereafter using at least the first part of the male mold to at least partially force the portion of the blank into a cavity of the female mold and thereby partially form the construct,

thereafter engaging a second part of the male mold against a portion of the blank to further form the construct, and

moving the first part of the male mold relative to the second part of the male mold at a period of time that occurs during the closing of the blank in the forming tool and is after the engaging of the first part of the male mold against the blank.

58. A method according to claim 57, comprising providing the blank so that the blank includes microwave interactive material prior to and during the closing of the blank in a forming tool, and so that the construct includes the microwave interactive material.

59. A method according to claim 57, wherein the closing of the blank in the forming tool comprises

engaging a first part of the female mold against a portion of the blank,

thereafter engaging a second part of the female mold against a portion of the blank to further form the construct, and

moving the first part of the female mold relative to the second part of the female at the period of time that occurs during the closing of the blank in the forming tool and is after the engaging of the first part of the female mold against the portion of the blank

60. A method according to claim 57, further comprising forming at least one injection-molded feature on the construct while the construct is at least partially contained in the closed forming tool.

61. A method according to claim 60, wherein the forming of the injection-molded feature comprises:

defining a channel at least between a corner of the construct and a corner of the male mold, so that the channel extends along both the corner of the construct and the corner of the male mold, and so that the channel does not extend across a boundary between the first and second parts of the male mold; and

introducing molding material into the channel.

62. A method according to claim 57, wherein the moving of the first part of the male mold relative to the second part of the male comprises:

moving the first part of the male mold at least partially into a cavity of the second part of the male mold.

63. A method of manufacturing, the method comprising:

forming a construct in a forming tool, wherein the forming of the construct comprises arranging a first part of the construct and a second part of the construct so that

there is an overlapping relationship between the first part and the second part, and

an edge of the first part is positioned between the second part and a channel; and

forming an injection-molded feature on the construct, wherein the forming of the injection-molded feature includes forcing molding material to flow in the channel, so that the molding material flows along the first part, then across the edge of the first part, and then along the second part.

64. The method of claim 63, wherein:

the construct comprises microwave energy interactive material, paperboard and polymer film,

the microwave energy interactive material is positioned between the paperboard and the polymer film, and

the forming of the injection-molded feature comprises adhering the injection-molded feature to the polymer film.

65. The method of claim 63, wherein:

the forming of the construct comprises closing a blank in the forming tool;

the forming of the injection-molded feature on the construct occurs while the construct is closed in the forming tool; and

the method further comprises removing the construct, which has the injection-molded feature formed thereon, from the forming tool.

66. The method of claim 63, wherein:

the forming of the construct comprises closing a blank in the forming tool,

the arranging of the first part and the second part comprises causing relative movement between the first part and the second part, and

the causing of the relative movement comprises forcing the blank into a cavity of a female mold and engaging the second part against a predetermined portion of the female mold prior to any engaging of the first part against the predetermined portion of the female mold.

67. The method of claim 66, wherein the engaging of the second part against a predetermined portion of the female mold comprises engaging a protruding portion of the second part against a shoulder of the female mold.

68. A method of manufacturing, the method comprising:

closing a construct in a forming tool; and

forming an injection-molded feature on the construct, wherein the forming of the injection-molded feature comprises bending at least a portion of the construct while the construct is closed in the forming tool, and the bending of the portion of the construct comprises forcing fluid molding material against at least the portion of the construct so that the portion of the construct bends under the force of the fluid molding material.

69. The method of claim 68, wherein:

the construct comprises microwave energy interactive material, paperboard and polymer film,

the microwave energy interactive material is positioned between the paperboard and the polymer film, and

the forming of the injection-molded feature comprises adhering the injection-molded feature to the polymer film.

70. The method of claim 68, wherein the forcing of the fluid molding material against the portion of the construct comprises:

forcing the portion of the construct against a surface of the forming tool so that a surface of the portion of the construct becomes shaped substantially like the surface of the forming tool.

71. The method of claim 70, wherein the forcing of the portion of the construct against the surface comprises:

enlarging a channel that is for receiving the fluid molding material.