Multilayer article and method for making a multilayer article, blank, and insulating cup

Abstract

Method of making a multilayer article including providing a first substrate and providing a second substrate. The method further includes disposing an expandable insulating material on an inner surface of at least one of the first substrate and the second substrate, wherein the expandable insulating material is in a first condition during disposing. The second substrate is adhered to the first substrate with the expandable insulating material therebetween to form a blank, wherein an insulating space is defined between the first substrate and the second substrate with the expandable insulating material therein and the insulating space includes a first volume. The method further includes forming the blank into the article and expanding the expandable insulating material to a second condition by application of energy, wherein the expandable insulating material in the second condition increases the insulating space to a second volume.

Description

CROSS-REFERENCE TO RELATED APPLICATION[0001]This application claims priority to U.S. Application No. 61 / 726,446, entitled “Multilayer Article and Method for Making a Multilayer Article, Blank, and Insulating Cup” and filed on Nov. 14, 2012, the disclosure of which is incorporated herein by reference in its entirety.BACKGROUND[0002]1. Field[0003]The presently disclosed subject matter relates to a disposable cup for serving beverages, such as water and coffee, and food items, such as soup or ice cream. Particularly, the presently disclosed subject matter is directed to a blank having a multilayer structure to provide improved insulating properties, among other benefits.[0004]2. Description of Related Art[0005]Some known types of disposable cups include those made from polystyrene, expanded polystyrene or paper. Although polystyrene cups can be aesthetically pleasing, such cups tend to not have an outer surface more suitable for printing graphics or logos. Further, polystyrene cups are...

AI Technical Summary

Benefits of technology

The disclosed subject matter is a method for making a multilayer article, which involves disposing an expandable insulating material between two substrates and expanding it to increase the insulating space between the substrates. This results in a blank that can be used to form an article. The insulating material can be in a first condition at room temperature and can be expanded by applying energy to increase its volume. The result is a multilayer article with an expanded insulating material that provides better insulation. The patent also describes an insulating cup that includes a sidewall and a bottom portion. The insulating material is applied to the inner surface of the substrates and is expanded when energy is applied, resulting in an insulating space between the substrates. The cup also includes a base when the insulating material is in its first condition. Overall, the disclosed subject matter provides a simplified method for making a multilayer article with improved insulation.

Problems solved by technology

Although polystyrene cups can be aesthetically pleasing, such cups tend to not have an outer surface more suitable for printing graphics or logos.

Further, polystyrene cups are generally not biodegradable or easily recyclable.

However, expanded polystyrene is also generally not biodegradable or easily recyclable.

Additionally, as expanded polystyrene cups are typically printed after they have been formed, and the relatively rough surface of the cup can be incompatible with high-resolution printing, relatively slow and costly processes are typically used for printing on expanded polystyrene cups.

However, paper cups, particularly single-layer paper cups, can have relatively poor thermal insulation properties.

Furthermore, paper cups constructed with a single wall or layer can be susceptible to weakening after exposure to liquids.

Although relatively strong and thermally efficient, multilayer cups generally are more expensive due to the complicated manufacturing processes and excess material typically required.

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