Abstract: A solid state foamed microcellular foam sheet for use in forming a container is provided. The solid state foamed microcellular foam sheet includes a central foamed section defining a foam layer within the microcellular foam sheet having a first population of cells within which are interspersed a second population of cells.

Abstract: A recloseable lid for closing an open top of a cup terminating in an annular upper edge includes a cup mount defining an annular channel configured to receive the annular upper edge of the cup and a cap having an annular side wall extending upwardly from the cup mount and terminating in a top having an annular floor spaced above the cup mount. A drink opening is disposed in the top and a plug assembly having a drink opening plug is provided. The drink opening plug can be selectively moveable between a closed position in which the drink opening plug is received within the drink opening for closing the drink opening and an open position in which the drink opening plug is not disposed within the drink opening. The lid can also include a plug retainer disposed in the cap and configured to retain the drink opening plug in the open position.

Abstract: Processes, assemblies, and sleeve blanks for forming a two-piece paper container are provided in which the sleeve blank includes an adhesive printed onto the sleeve blank while the sleeve blank is still part of the paper web. The adhesive can optionally be printed onto the sleeve blank in-line with printing a graphic on the sleeve blank prior to providing the sleeve blank to a container forming machine that wraps and seals the sleeve blank to a bottom blank.

Abstract: A paperboard blank stacker assembly for supplying a stack of paperboard blanks to a container forming machine includes a stacker. The stacker has multiple blank stops arranged to hold a peripheral edge of a bottom blank of the stack of paperboard blanks, with the multiple blank stops defining an interior region. A blank carrier has at least one suction device moveable into a grasp position, where the suction device applies a suction force to the bottom blank, and a removal position, where the suction device is moved to remove the bottom blank from the stack of paperboard blanks by pulling the bottom blank through the interior region.

Abstract: Aspects of the present disclosure relate to a polyolefin composition and processes suitable for use in forming a lid for a hot food or beverage container that has a stiffness comparable to a similar lid made using high impact polystyrene and a density less than water at 23° C.

Abstract: Aspects of the present disclosure relate to compositions and processes suitable for use in forming a lid for a hot food or beverage container, the lid being made from a multi-layer sheet that includes a substrate layer and a cap layer made from polyolefin-based compositions. The lid has a density less than water at 23° C., allowing the lid to be recycled in a recycling stream.

Abstract: A recloseable lid for closing an open top of a cup terminating in an annular upper edge includes a cup mount defining an annular channel configured to receive the annular upper edge of the cup and a cap having an annular side wall extending upwardly from the cup mount and terminating in a top having an annular floor spaced above the cup mount. A drink opening is disposed in the top and a plug assembly having a drink opening plug is provided. The drink opening plug can be selectively moveable between a closed position in which the drink opening plug is received within the drink opening for closing the drink opening and an open position in which the drink opening plug is not disposed within the drink opening. The lid can also include a plug retainer disposed in the cap and configured to retain the drink opening plug in the open position.

Abstract: A solid state foaming process for generating a microcellular foam sheet for use in forming a container is provided includes a pre-foaming treatment phase prior to a solid state impregnation and foaming phase. The solid state microcellular foam sheet includes a central foamed section defining a foam layer within the microcellular foam sheet having a first population of cells within which are interspersed a second population of cells.

Abstract: An assembly system for wrapping an outer wrapper to an inner sleeve to form an outer wall of a double-wall container can include a suction arm. The suction arm can be configured to couple to a suction source and can have a portion defining a suction surface. At least one suction opening can be provided within the suction surface and fluidly coupled to the suction source. A sealing edge can circumscribe at least a portion of the suction surface.

Abstract: An apparatus (un-interleaver) for unwinding a roll of material interleaved with another material, and for separating the materials, includes a first platform, a second platform, a tension-sensor, an edge-sensor, and a controller. The controller monitors signals generated by the tension sensor and the edge sensor, and in response to the signals: a) causes the speed at which the second platform rotates to change to maintain a predetermined tension in the second material as the second material travels from the first platform toward the second platform, and b) causes the second platform to move relative to the first platform to align the edge of the second material traveling toward the roll of second material with the edge of the second material in the roll.

Abstract: A method of making a double-wall cup having an inner cup defining an inner wall and an outer wrapper defining an outer wall, the method comprising applying an adhesive on the inner wall, holding a portion of the wrapper, at a location between opposing ends of the wrapper, in contact with the adhesive while in spaced relationship with the inner wall to define a spaced condition, and wrapping the wrapper about the inner wall.

Abstract: A method for saturating a thermoplastic polymer material includes continuously moving the polymer material through a pressurized pressure vessel. To do this, the method includes sealing the pressure vessel with a series of dynamic seals that allows the polymer material to continuously move through the pressure vessel while maintaining the pressure inside the pressure vessel.

Abstract: The present invention is directed to a deep draw microcellularly foamed polymeric container comprising a polymeric sidewall integrally connected to a polymeric base along a bottom edge. The polymeric sidewall and base are contiguous with each other and define a shape of an open top container. The polymeric sidewall and base have a contiguous inner microcellular foam structure (having average cell diameters ranging from about 5 to about 100 microns) surrounded by a smooth outer skin layer integrally connected therewith. The polymeric sidewall defines a container height and a top opening, wherein the top opening defines a top opening width, and wherein the polymeric base defines a container base width, and wherein the area defined by the top opening is greater than the area defined by the polymeric base, and wherein the ratio of the container height (h) to the top opening width (w) is greater than about 1:1 (h:w).

Abstract: An assembly system for wrapping an outer wrapper to an inner sleeve to form an outer wall of a double-wall container can include a moveable suction arm. The moveable suction arm can be configured to couple to a suction source and can have a portion defining a suction surface. A plurality of suction openings can be provided within the suction surface and fluidly coupled to the suction source. A sealing edge can circumscribe at least a portion of the suction surface.

Abstract: A method for generating a microstructure that includes microcellular bubbles, in a material that includes molecules of a thermoplastic polymer, comprises: determining a size-index for the material that represents an average size of the thermoplastic polymer molecules included in the material, and in response to the determined size-index, setting a parameter of a process to generate a microstructure in the material that includes microcellular bubbles. The process to generate a microstructure in the material includes: 1) infusing into the material, during a first period, a gas that does not react with the material, 2) making the gas-infused material thermodynamically unstable.

Abstract: A multi-layer sheet for forming an expanded foam container, the multi-layer sheet including a first layer of an expanded foam material including a first polyolefin-based material including at least one polypropylene-based polymer and a second layer of an unexpected material including a second polyolefin-based material including at least one polypropylene-based polymer that is co-extruded, extrusion coated, or laminated on a first side of the first layer.

Abstract: A bottom heater for use in assembling a container bottom and a sleeve includes a body having a peripheral wall and a heated air passage terminating in an outlet in the peripheral wall. A shape of at least a portion of the peripheral wall defining the outlet is such that heated air exiting the outlet is fluidly attached to an adjacent portion of the peripheral wall after exit because of the Coanda effect.

Abstract: The invention disclosed herein relates to relates to foamed thermoplastic material objects and articles of manufacture having an internal layered cellular structure, as well as to methods of making the same. In one embodiment, the invention is directed to a multi-layer foamed polymeric article of manufacture, comprising: a non-laminated multi-layer thermoplastic material sheet, wherein the multi-layer thermoplastic material sheet has first and second discrete outer layers sandwiching a plurality of discrete inner foamed layers, and wherein the two outer layers and plurality discrete inner foamed layers are integral with one another. The thermoplastic material may be a semi-crystalline polymer such as, for example, PET (polyethylene terephthalate), PEEK (polyetheretherketone), PEN (polyethylene naphthalate), PBT (polybutylene terephthalate), PMMA (polymethyl methacrylate), PLA (polylactide), polyhydroxy acid (PHA), thermoplastic urethane (TPU), or blends thereof.

Abstract: A container having tamper evident and resistant features comprises a tray having a bottom wall and a peripheral side wall extending upwardly from the bottom wall, which collectively define a compartment, and terminating in a tray rib to at least partially define an open top providing access to the compartment. The container further comprises a cover comprising a top wall that terminates in a cover rib having a peripheral cover lip, an interference element extending from the container, at least one tab provided in the container and associated with the interference element, and at least one line of weakness coupling the tab to the container. The tab is moveable between a first position where the line of weakness is not severed and a second position where the line of weakness is severed.