Granted Patent B2

US 12,275,180 · App. 17/135,048 · Granted Apr 15, 2025

Inventors: David Dezhou Sun (Evansville, IN); Philip A. Driskill (Newburgh, IN); Rolland Strasser (Hamden, CT)

Assignee: Berry Plastics Corporation

B29C49/22B29C44/22B29C49/0005B29C49/04B65D81/3846B29K2023/12B29K2023/14B29K2105/043B29K2105/258B29K2995/0015B29K2995/0063B29L2009/00B29L2031/712

Abstract

Claims (37)

1. A container comprising

a first layer formed from a first formulation comprising polypropylene, and

a core layer comprising an insulative cellular non-aromatic polymeric material formed from a second formulation comprising a first polypropylene resin, a second polypropylene resin, and at least one nucleating agent,

wherein the first layer has been extruded onto the core layer so that the core layer and the first layer are in direct contact,

wherein the first layer has a density of about 0.9 g/cm 3 ,

wherein the first polypropylene resin and the second polypropylene resin together are at least 85 wt % of the insulative cellular non-aromatic polymeric material, and the at least one nucleating agent is up to about 15 wt % of the insulative cellular non-aromatic polymeric material, and

wherein the first formulation is different from the second formulation.

2. The container of claim 1 , wherein the container has a density of about 0.5 g/cm 3 to about 0.8 g/cm 3 .

3. The container of claim 1 , wherein the first layer is a solid layer having a density of about 0.9 g/cm 3 .

4. The container of claim 1 , wherein the first layer comprises solid polypropylene, wherein the container has a density of about 0.5 g/cm 3 to about 0.8 g/cm 3 , and wherein insulative cellular non-aromatic polymeric material has a density of about 0.3 g/cm 3 to about 0.6 g/cm 3 .

5. The container of claim 1 , wherein the insulative cellular non-aromatic polymeric material further comprises a third polypropylene resin.

6. The container of claim 5 , wherein the first, second, and third polypropylene resins are at least about 96% wt % to about 99.9% wt %.

7. The container of claim 6 , wherein the first polypropylene resin is a polypropylene homopolymer and the second polypropylene resin is a polypropylene homopolymer.

8. The container of claim 7 , wherein the third polypropylene is a polypropylene homopolymer.

9. The container of claim 1 , wherein the at least one nucleating agent is about 0.1 wt % to about 0.5 wt % of the insulative cellular non-aromatic material.

10. The container of claim 9 , wherein insulative cellular non-aromatic polymeric material further comprises a third polypropylene resin and the first, second, and third polypropylene resins together are at least about 96% wt % to about 99.9% wt %.

11. The container of claim 10 , wherein the insulative cellular non-aromatic polymeric material further comprises regrind of the insulative cellular non-aromatic polymeric material.

12. The container of claim 10 , wherein the ratio of the first polypropylene resin to the second polypropylene resin is 45% to 55%, and the first polypropylene resin is different from the second polypropylene resin.

13. The container of claim 12 , wherein the container has a density of about 0.5 g/cm 3 to about 0.8 g/cm 3 .

14. The container of claim 12 , wherein the first layer is a solid layer having a density of about 0.9 g/cm 3 .

15. The container of claim 1 , wherein the insulative cellular non-aromatic polymeric material further comprises a third polypropylene resin, wherein the first, second, and third polypropylene resins are at least about 96 wt % to about 99.9 wt %.

16. The container of claim 15 , wherein the first polypropylene resin is a polypropylene homopolymer, the second polypropylene resin is a polypropylene homopolymer, and the third polypropylene is a polypropylene homopolymer.

17. A container comprising

a first layer formed from a first formulation comprising polypropylene, and

a core layer comprising an insulative cellular non-aromatic polymeric material formed from a second formulation comprising a first polypropylene resin, a second polypropylene resin, and at least one nucleating agent,

wherein the first layer has been extruded onto the core layer so that the core layer and the first layer are in direct contact,

wherein the first polypropylene resin and the second polypropylene resin together are at least 85 wt % of the insulative cellular non-aromatic polymeric material, and the at least one nucleating agent is up to about 15 wt % of the insulative cellular non-aromatic polymeric material,

wherein the insulative cellular non-aromatic polymeric material further comprises regrind of the insulative cellular non-aromatic polymeric material, and

wherein the first formulation is different from the second formulation.

18. A container comprising

a first layer formed from a first formulation comprising polypropylene, and

a core layer comprising an insulative cellular non-aromatic polymeric material formed from a second formulation comprising a first polypropylene resin, a second polypropylene resin, and at least one nucleating agent, wherein the first formulation is different from the second formulation;

wherein the first layer has been extruded onto the core layer so that the core layer and the first layer are in direct contact,

wherein the first layer has a density of about 0.9 g/cm 3 , the insulative cellular non-aromatic polymeric material has a density of about 0.3 g/cm 3 to about 0.6 g/cm 3 , and the container has a density of about 0.5 g/cm 3 to about 0.8 g/cm 3 ,

wherein the first polypropylene resin and the second polypropylene resin together are at least 85 wt % of the insulative cellular non-aromatic polymeric material, and the at least one nucleating agent is up to about 15 wt % of the insulative cellular non-aromatic polymeric material.

19. The container of claim 18 , wherein the insulative cellular non-aromatic polymeric material further comprises regrind of the insulative cellular non-aromatic polymeric material.

20. The container of claim 18 , wherein the first layer comprises a high stiffness polypropylene, a high impact polypropylene, or a combination thereof.

Assignments (21)

Continuity (5)

References Cited (400)