CONTAINER WITH SKIM COAT LAYER FOR IMPROVED PUNCTUREABILITY
Containers having a skim coat layer for improved punctureability, and sheet stock materials for and methods of making such containers are provided. A container is formed of a first material layer that contains a monolayer of polypropylene homopolymer in an amount of at least 70 percent by weight, or a multilayer material in which at least one layer comprises a polypropylene homopolymer in an amount of at least 70 percent by, and a second material layer adjacent the first material layer and forming an innermost layer adjacent the cavity, the second material layer containing a polypropylene copolymer in an amount of at least 60 percent by weight.
1 . A container, comprising:
a substantially circular base comprising a puncture region;
a frustoconically shaped wall extending from an edge of the base and defining a cavity therein;
wherein the container is formed of a first material layer comprising a monolayer of polypropylene homopolymer in an amount of at least 70 percent by weight, or a multilayer material in which at least one layer comprises a polypropylene homopolymer in an amount of at least 70 percent by weight of the at least one layer,
wherein the container is formed of a second material layer adjacent the first material layer and forming an innermost layer adjacent the cavity, the second material layer comprising a polypropylene copolymer in an amount of at least 60 percent by weight of the second material layer, and
wherein the second material layer has a thickness that is from about 0.5 percent to about 20 percent of a total thickness of the first material layer and the second material layer.
2 . (canceled)
3 . The container of claim 1 , wherein the second material layer comprises the polypropylene copolymer in an amount of at least 75 percent by weight of the second material layer.
4 . The container of claim 1 , wherein the second material layer has a thickness that is from about 5 percent to about 15 percent of a total thickness of the first material layer and the second material layer.
5 . (canceled)
6 . The container of claim 1 , wherein the base is punctureable by a single needle and displays a puncture load of less than 3 kg, measured using a sharp needle, or of less than 5 kg, measured using a dull needle.
7 .- 13 . (canceled)
14 . The container of claim 1 , wherein the first material layer comprises the multilayer material and the multilayer material further comprises a barrier layer.
15 . The container of claim 14 , wherein the barrier layer comprises ethylene vinyl alcohol.
16 . The container of claim 14 , wherein the multilayer material further comprises at least one tie layer adjacent the barrier layer.
17 . The container of claim 1 , wherein the first material layer comprises the multilayer material and the multilayer material further comprises a second layer comprising the polypropylene homopolymer in an amount of at least 70 percent by weight of the second layer.
18 . The container of claim 1 , wherein:
the first material layer comprises the multilayer material and the multilayer material further comprises at least one buffer layer adjacent the at least one layer comprising the polypropylene homopolymer in an amount of at least 70 percent by weight of the at least one layer, and
the buffer layer comprises the polypropylene homopolymer in an amount from at least 70 up to 97 percent by weight of the layer, a nucleating agent in an amount from 0.5 to 5 percent by weight of the layer, and talc in an amount from 3 to 15 percent by weight of the layer.
19 . The container of claim 1 , wherein the first material layer comprises the multilayer material and the multilayer material further comprises at least one regrind layer.
20 . The container of claim 19 , wherein the at least one regrind layer comprises the polypropylene copolymer in an amount of at least 5 percent by weight of the layer.
21 . The container of claim 1 , wherein the first material layer is asymmetric.
22 . The container of claim 1 , wherein the second material layer is adjacent the monolayer of polypropylene homopolymer or the at least one layer comprising the polypropylene homopolymer of the multilayer material, with no tie layer being disposed therebetween.
23 . A container for forming a beverage comprising the container of claim 1 , and further comprising:
a filter disposed in the cavity of the container and defining first and second chambers in the cavity;
a beverage medium disposed in the cavity and arranged to interact with a liquid introduced into the container to form a beverage; and
a lid attached to a rim of the container to contain the beverage medium and filter disposed therein.
24 . A sheet stock material for a container, comprising:
a first material layer comprising a monolayer of polypropylene homopolymer in an amount of at least 70 percent by weight, or a multilayer material in which at least one layer comprises a polypropylene homopolymer in an amount of at least 70 percent by weight of the at least one layer; and
a second material layer adjacent the first material layer, the second material layer comprising a polypropylene copolymer in an amount of at least 60 percent by weight of the second material layer,
wherein the second material layer has a thickness that is from about 0.5 percent to about 20 percent of a total thickness of the first material layer and the second material layer, and
wherein the container comprises a substantially circular base and a frustoconical shaped wall extending from an edge of the base and defining a cavity therein.
25 . (canceled)
26 . The sheet stock material of claim 24 , wherein the second material layer comprises the polypropylene copolymer in an amount of at least 75 percent by weight of the second material layer.
27 . The sheet stock material of claim 24 , wherein the second material layer has a thickness that is from about 5 percent to about 15 percent of a total thickness of the first material layer and the second material layer.
28 .- 30 . (canceled)
31 . The sheet stock material of claim 24 , wherein the first material layer comprises the multilayer material and the multilayer material further comprises a barrier layer.
32 . The sheet stock material of claim 31 , wherein the barrier layer comprises ethylene vinyl alcohol.
33 . The sheet stock material of claim 31 , wherein the multilayer material further comprises at least one tie layer adjacent the barrier layer.
34 . The sheet stock material of claim 24 , wherein the first material layer comprises the multilayer material and the multilayer material further comprises a second layer comprising the polypropylene homopolymer in an amount of at least 70 percent by weight of the second layer.
35 . The sheet stock material of claim 24 , wherein:
the first material layer comprises the multilayer material and the multilayer material further comprises at least one buffer layer adjacent the at least one layer comprising the polypropylene homopolymer in an amount of at least 70 percent by weight of the at least one layer, and
the buffer layer comprises the polypropylene homopolymer in an amount from at least 70 up to 97 percent by weight of the layer, a nucleating agent in an amount from 0.5 to 5 percent by weight of the layer, and talc in an amount from 3 to 15 percent by weight of the layer.
36 . The sheet stock material of claim 24 , wherein the first material layer comprises the multilayer material and the multilayer material further comprises at least one regrind layer.
37 . The sheet stock material of claim 36 , wherein the at least one regrind layer comprises the polypropylene copolymer in an amount of at least 5 percent by weight of the layer.
38 . The sheet stock material of claim 24 , wherein the first material layer is asymmetric.
39 . The sheet stock material of claim 24 , wherein the second material layer is adjacent the monolayer of polypropylene homopolymer or the at least one layer comprising the polypropylene homopolymer of the multilayer material, with no tie layer being disposed therebetween.
40 . A method of making a container, comprising:
providing the sheet stock material of claim 24 ;
heating the sheet stock material; and
drawing the heated sheet stock material into a mold to form a container.
41 .- 48 . (canceled)
49 . The container of claim 1 , wherein the second material layer comprises a material that is softer than the first material layer, has a lower melting point than the first material layer, or both.
50 . The sheet stock of claim 26 , wherein the second material layer comprises a material that is softer than the first material layer, has a lower melting point than the first material layer, or both.
51 . (canceled)