Laminate Container
A container and a method of producing the container are disclosed, wherein the container is formed of a laminate having a base layer and a sheet.
1 . A container, comprising:
a side wall having a side wall area;
a bottom having a bottom area;
wherein the side wall and bottom are formed from a laminate having a base layer and a sheet;
wherein the base layer has a base layer thickness and the sheet has a sheet thickness;
wherein the laminate has a laminate thickness that is at least the sum of the base layer thickness and the sheet thickness;
wherein the sheet has at least one sheet layer and the at least one sheet layer has a thickness that is equal to or less than 5% of the laminate thickness; and
wherein the side wall and bottom at least partially define a part area, wherein the container is formed from the laminate having a laminate area used to form the container, and wherein the formed container has an areal draw ratio of greater than about 2.5.
2 . The container of claim 1 , wherein the laminate area is substantially circular in the form of a disk.
3 . The container of claim 1 , wherein the laminate area is substantially rectangular in the form of a blank.
4 . The container of claim 1 , further including a flange having a rim area, and wherein the areal draw ratio is calculated including the rim area.
5 . The container of claim 1 , wherein the areal draw ratio is greater than about 2.8.
6 . The container of claim 5 , wherein the areal draw ratio is greater than about 3.1.
7 . The container claim 6 , wherein the areal draw ratio is greater than about 3.4.
8 . The container of claim 1 , wherein the at least one sheet layer has an average thickness that is equal to or less than 0.6 mil.
9 . The container of claim 1 , wherein the at least one sheet layer includes a barrier material.
10 . A container, comprising:
a side wall having a side wall area;
a bottom having a bottom area;
wherein the side wall and bottom are formed from a laminate having a base layer and a sheet;
wherein the sheet has a sheet thickness, the sheet includes at least one barrier layer having a barrier layer thickness, and wherein the base layer has a base layer thickness;
wherein the laminate has a laminate thickness;
wherein the barrier layer thickness is less than about 5% of the laminate thickness; and
wherein the side wall and bottom at least partially define a part area, wherein the container is formed from a portion of laminate having a laminate area, and wherein the container has an areal draw ratio of greater than about 2.5.
11 . The container of claim 9 , wherein the barrier layer thickness is less than about 3% of the laminate thickness.
12 . A process for forming a container, comprising the steps of:
providing a base layer formed from a base layer material;
providing a sheet having at least one layer;
laminating the base layer to the sheet to form a laminate; and
thermoforming the laminate into a part with an areal draw ratio of at least about 2.5.
13 . The process of claim 12 , wherein the laminate is substantially circular in the form of a disk.
14 . The process of claim 13 , wherein the part is substantially a truncated cone.
15 . The process of claim 14 , wherein the part includes a flange having a rim area, and wherein the areal draw ratio is calculated including the rim area.
16 . The process of claim 12 , wherein the areal draw ratio is greater than about 2.8.
17 . The process of claim 16 , wherein the areal draw ratio is greater than about 3.1.
18 . The process of claim 17 , wherein the areal draw ratio is greater than about 3.4.
19 . The process of claim 12 , further comprising the step of blowing a multilayer film to form the sheet.
20 . The process of claim 19 , wherein the at least one layer of the multilayer film is a barrier layer.