CA2643577A1 - Injection-molded composite construct - Google Patents

Injection-molded composite construct Download PDF

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Publication number
CA2643577A1
CA2643577A1 CA002643577A CA2643577A CA2643577A1 CA 2643577 A1 CA2643577 A1 CA 2643577A1 CA 002643577 A CA002643577 A CA 002643577A CA 2643577 A CA2643577 A CA 2643577A CA 2643577 A1 CA2643577 A1 CA 2643577A1
Authority
CA
Canada
Prior art keywords
panel
construct
mold
corner
injection
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
CA002643577A
Other languages
French (fr)
Other versions
CA2643577C (en
Inventor
Brian R. O'hagan
Peter W. Blaas
Scott W. Middleton
Kevin J. Hjort
Bruce Barnard
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Graphic Packaging International LLC
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of CA2643577A1 publication Critical patent/CA2643577A1/en
Application granted granted Critical
Publication of CA2643577C publication Critical patent/CA2643577C/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/22Boxes or like containers with side walls of substantial depth for enclosing contents
    • B65D1/26Thin-walled containers, e.g. formed by deep-drawing operations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467Joining articles or parts of a single article
    • B29C45/14475Joining juxtaposed parts of a single article, e.g. edges of a folded container blank
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P19/00Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/08Deep drawing or matched-mould forming, i.e. using mechanical means only
    • B29C51/082Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
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    • B65D1/00Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
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    • B65D5/20Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form
    • B65D5/209Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form the adjacent edges of folded-up portions being joined by moulding seams in situ
    • BPERFORMING OPERATIONS; TRANSPORTING
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    • B65D81/3453Rigid containers, e.g. trays, bottles, boxes, cups
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2791/00Shaping characteristics in general
    • B29C2791/004Shaping under special conditions
    • B29C2791/006Using vacuum
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/18Thermoforming apparatus
    • B29C51/20Thermoforming apparatus having movable moulds or mould parts
    • B29C51/22Thermoforming apparatus having movable moulds or mould parts rotatable about an axis
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/26Component parts, details or accessories; Auxiliary operations
    • B29C51/46Measuring, controlling or regulating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
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    • B29C65/482Drying adhesives, e.g. solvent based adhesives
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
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    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/4326Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms for making hollow articles or hollow-preforms, e.g. half-shells
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    • B65D2581/3489Microwave reflector, i.e. microwave shield
    • B65D2581/3493Microwave reflector, i.e. microwave shield attached to the base surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2581/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D2581/34Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within
    • B65D2581/3437Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents for packaging foodstuffs or other articles intended to be cooked or heated within specially adapted to be heated by microwaves
    • B65D2581/3486Dielectric characteristics of microwave reactive packaging
    • B65D2581/3494Microwave susceptor
    • B65D2581/3498Microwave susceptor attached to the base surface
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00Metal working
    • Y10T29/49Method of mechanical manufacture
    • Y10T29/49815Disassembling
    • Y10T29/49822Disassembling by applying force
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/13Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1303Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/13Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352Polymer or resin containing [i.e., natural or synthetic]

Abstract

A frame is injection molded onto a group of panels to form a container. The panels extend at least partially around, and at least partially define, a cavity of the container.

Claims (71)

1. A container, comprising:
a plurality of panels that extends at least partially around and at least partially defines a cavity of the container; wherein the plurality of panels includes a base panel, a first side panel extending upwardly from the base panel, and a second side panel extending upwardly from the base panel, the first side panel includes an edge, the second side panel includes an edge that is proximate the edge of the first side panel, at least a first portion of the edge of the first side panel extends along an elongate corner of the container, at least a first portion of the edge of the second side panel extends along the elongate corner of the container, a gap is defined between the first portion of the edge of the first side panel and the first portion of the edge of the second panel, and an overlap exists between a second portion of the edge of the first side panel and a portion of the second side panel; and an injection-molded structure extends along and at least partially defines the corner of the container, wherein the injection-molded structure obstructs the gap and at least partially covers the overlap.
2. The container according to claim 1, wherein at least one panel of the plurality of panels comprises microwave energy interactive material.
3. The container according to claim 2, wherein:
the at least one panel comprises paperboard and polymer film, the microwave energy interactive material is positioned between the paperboard and the polymer film, and at least a portion of the injection-molded structure is adhered to the polymer film.
4. The container according to claim 1, wherein:
the first side panel includes an upright portion and a flange that extends outwardly from an upper edge of the upright portion;
the second side panel includes an upright portion and a flange that extends outwardly from an upper edge of the upright portion; and the flange of the first side panel at least partially overlaps the flange of the second side panel.
5. The container according to claim 4, wherein the injection-molded structure includes:
a band that is injection-molded onto at least the flange of the first side panel and the flange of the second side panel, and a strip that is injection-molded into the corner of the container.
6. The container according to claim 5, wherein the strip includes a concave face that at least partially defines the cavity of the container.
7. The container according to claim 5, wherein the strip is injection-molded onto at least the first and second side panels.
8. The container according to claim 5, wherein the strip includes an outwardly projecting protrusion that is elongate, extends along the corner, and extends into the gap.
9. The container according to claim 8, wherein the protrusion comprises a bead that fills the gap.
10. A container, comprising:
a base panel;

a plurality of side panels that extends upwardly from the base panel and extends at least partially around and at least partially defines a cavity of the container;
a plurality of multi-part flanges, wherein multi-part flanges of the plurality of multi-part flanges respectively extend outwardly from upper edges of side panels of the plurality of side panels, and wherein at least one of the multi-part flanges includes a lower flange that extends outwardly from the upper edge of the respective side panel, an upright panel that extends upwardly from an outer edge of the lower flange, and an upper flange that extends outwardly from an upper edge of the upright panel; and a band that is injection-molded onto both an upper surface of the upper flange, and an upper surface of the lower flange.
11. The container according to claim 10, wherein:
at least one panel, which is selected from the group consisting of the base panel and the side panels, comprises microwave energy interactive material, paperboard and polymer film, the microwave energy interactive material is positioned between the paperboard and the polymer film, the band is part of an injection-molded structure, and at least a portion of the injection-molded structure is adhered to the polymer film.
12. The container according to claim 10, wherein:
the band includes a flat upper surface, the upper surface of the upper flange is beneath the flat upper surface of the band, and the upper surface of the lower flange is beneath the flat upper surface of the band.
13. The container according to claim 10, further comprising a polymeric cover, wherein the polymeric cover is heat sealed to the upper surface of the band so that the polymeric cover closes an opening to the container.
14. A container, comprising:
a plurality of panels that extends at least partially around and at least partially defines a cavity of the container, wherein the plurality of panels includes a panel that at least partially defines an elongate corner of the container, the panel includes a curved portion, an outward surface of the curved portion of the panel defines an outwardly projecting protrusion of the panel, an inward surface of the curved portion of the panel defines a recess; and an injection-molded strip that extends along and at least partially defines the corner of the container, wherein the strip includes an outwardly projecting protrusion that extends into the recess of the curved portion of the panel.
15. The container according to claim 14, wherein:
at least one panel of the plurality of panels comprises microwave energy interactive material, paperboard and polymer film, the microwave energy interactive material is positioned between the paperboard and the polymer film, and at least a portion of the injection-molded strip is adhered to the polymer film.
16. The container according to claim 14, wherein a bulbous portion is proximate an end of the corner and comprises:
the outwardly projecting protrusion of the curved portion of the panel, and the outwardly projecting protrusion of the strip, which extends into the recess of the curved portion of the panel.
17. The container according to claim 14, wherein:
the outwardly projecting protrusion of the panel is elongate and extends along the corner, the recess of the curved portion of the panel is elongate and extends along the corner, and the outwardly projecting protrusion of the strip is elongate and extends along the corner.
18. The container according to claim 17, wherein an elongate rib comprises:
the outwardly projecting protrusion of the curved portion of the panel, and the outwardly projecting protrusion of the strip, which extends into the recess of the curved portion of the panel.
19. The container according to claim 17, wherein the strip is injection-molded onto the panel.
20. The container according to claim 17, wherein:
the curved portion is a first curved portion;
the plurality of panels includes a second curved portion;
an outward surface of the second curved portion defines an outwardly bulbous portion of the panels;
an inward surface of the second curved portion defines a substantially bowl-shaped recess;
the strip includes an outwardly bulbous portion that extends into the substantially bowl-shaped recess;
the outwardly bulbous portion of the panels and the outwardly bulbous portion of the strip are positioned at a lower end of the corner; and the protrusion of the panel and the protrusion of the strip respectively extend upwardly from the outwardly bulbous portion of the panels and the outwardly bulbous portion of the strip.
21. The container according to claim 17, wherein:
the protrusion of the panel is convex;

the protrusion of the strip is convex; and the recess is concave.
22. The container according to claim 17, wherein the curved portion of the panel is not pleated.
23. The container according to claim 17, wherein the strip includes a concave face that at least partially defines the cavity of the container.
24. The container according to claim 17, wherein:
the corner includes an elongate centerline that extends along the corners' length; and the centerline is spaced apart from each of the protrusion of the panel, the protrusion of the strip, and the recess.
25. The container according to claim 24, wherein:
the protrusion of the strip is a first protrusion of the strip;
the panel is a first panel;
the plurality of panels further includes a second panel that is proximate to the first panel and together with the first panel at least partially defines the corner of the container;
the second panel, includes a curved portion, an outward surface of the curved portion of the second panel defines an outwardly projecting protrusion of the second panel, the outwardly projecting protrusion of the second panel is elongate and extends along the corner, an inward surface of the curved portion of the second panel defines a recess that is elongate and extends along the corner; and the strip includes, an outwardly projecting second protrusion that is elongate, extends along the corner, and extends into the recess defined by the curved portion of the second panel.
26. The container according to claim 25, wherein:
a gap is defined between at least a portion of an edge of the first panel and at least a portion of an edge of the second panel;
the strip includes an outwardly projecting third protrusion that is elongate, extends along the corner, and extends into the gap; and the third protrusion of the strip is positioned between the first and second protrusions of the strip.
27. A container, comprising:
a plurality of panels that extends at least partially around and at least partially defines a cavity of the container; wherein the container includes an elongate corner, panels of the plurality of panels include a curved portion, an outward surface of the curved portion defines an outwardly bulbous portion of the panels, an inward surface of the curved portion defines a substantially bowl-shaped recess; and an injection-molded strip that extends along and at least partially defines the corner of the container, wherein the strip includes an outwardly bulbous portion that extends into the substantially bowl-shaped recess, and the outwardly bulbous portion of the panels and the outwardly bulbous portion of the strip are positioned at a lower end of the corner.
28. The container according to claim 27, wherein:

at least one panel of the plurality of panels comprises microwave energy interactive material, paperboard and polymer film, the microwave energy interactive material is positioned between the paperboard and the polymer film, and at least a portion of the strip is adhered to the polymer film.
29. The container according to claim 27, wherein:
the plurality of panels includes a first panel and a second panel that together at least partially define the corner;
a gap is defined between at least a portion of an edge of the first panel and at least a portion of an edge of the second panel;
the gap extends into the outwardly bulbous portion of the panels; and the strip covers the gap.
30. A blank, comprising:
a base panel;
a plurality flaps respectively connected to and extending outwardly from the base panel, wherein the plurality of flaps includes a first flap and a second flap that is adjacent to the first flap;
a gap is defined between the first and second flaps, at least an inner portion of the gap becomes wider farther from the base panel, the first flap has a feature that has a reducing effect on how width of the gap changes as a function of increased distance outwardly from the base panel.
31. The blank according to claim 30, wherein:
at least a portion of the blank comprises microwave energy interactive material, paperboard and polymer film, and the microwave energy interactive material is positioned between the paperboard and the polymer film.
32. The blank according to claim 30, wherein:
the feature is a protruding portion of the first flap, the second flap has a protruding portion that has a reducing effect on how width of the gap changes as a function of increased distance outwardly from the base panel, and the protruding portion of the second flap extends farther into the gap than does the protruding portion of the first flap.
33. The blank according to claim 30, wherein the feature is a protruding portion of the first flap, and wherein the protruding portion of the first flap and the second flap are configured so that the protruding portion of the first flap and a portion of the second flap are in an overlapping relationship with respect to one another when the blank is erected into a construct in which the gap is at least partially maintained.
34. A construct erected from the blank of claim 33 and including an injection-molded frame, wherein:
the blank has been erected so that the gap has been at least partially maintained, and the protruding portion of the first flap and the portion of the second flap are in an overlapping relationship with respect to one another; and a portion of the frame covers the gap.
35. The construct according to claim 34, wherein the gap is filled by a protruding portion of the frame.
36. The blank according to claim 30, wherein:
the first flap includes an outwardly extending edge;
the second flap includes an outwardly extending edge that is proximate to the edge of the first flap;

at least portions of the edges of the first and second flaps are spaced apart from one another so that the gap is defined between the edge of the first flap and the edge of the second flap;
an outer portion of the gap is farther from the base panel than the inner portion of the gap, an inner portion of the edge of the first flap partially defines the inner portion of the gap, an outer portion of the edge of the first flap at least partially defines both the outer portion of the gap and the feature, which has the reducing effect on how the width of the gap changes as a function of increased distance outwardly from the base panel, an angle is defined between the inner and outer portions of the edge of the first flap, and the angle is less than 180 degrees so that that the angle at least partially provides the reducing effect on how width of the gap changes as a function of distance outwardly from the base panel.
37. The blank according to claim 36, wherein the angle, which is defined between the inner and outer portions of the edge of the first flap, is an obtuse angle.
38. The blank according to claim 36, wherein width of the inner portion of the gap changes at a greater rate, as a function of distance outwardly from the base panel, than width of the outer portion of the gap.
39. The blank according to claim 36, wherein with respect to extending outwardly from the base panel, the outer portion of the edge of the first flap extends convergently with respect to a centerline of the gap.
40. The blank according to claim 36, wherein with respect to extending outwardly from the base panel, the outer portion of the edge of the first flap extends divergently with respect to a centerline of the gap.
41. The blank according to claim 40, wherein:
an inner portion of the edge of the second flap partially defines the inner portion of the gap, an outer portion of the edge of the second flap partially defines the outer portion of the gap, and an angle of less than 180 degrees is defined between the inner and outer portions of the edge of the second flap, and with respect to extending outwardly from the base panel, the outer portion of the edge of the second flap extends convergently with respect to the centerline of the gap.
42. A construct, comprising:
a laminate including a releasable adhesive positioned between and at least indirectly joining together a substrate and a polymer film; and at least one injection-molded feature that is at least indirectly joined to the polymer film.
43. The construct according to claim 42, wherein:
the laminate further includes microwave energy interactive material, and the microwave energy interactive material is positioned between the substrate and the polymer film.
44. The construct according to claim 42, wherein the substrate comprises cellulosic material.
45. The construct according to claim 42, wherein the construct comprises a container and the injection-molded feature comprises a band.
46. The construct according to claim 42, wherein:

the releasable adhesive provides an adhesive bond between the substrate and the polymer film;
the adhesive bond between the substrate and the polymer film has a peel strength;
there is an adhesive bond between the injection-molded feature and the polymer film;
the adhesive bond between the injection-molded feature and the polymer film has a peel strength;
the peel strength of the adhesive bond between the substrate and the polymer film is less than the peel strength of the adhesive bond between the injection-molded feature and the polymer film.
47. A method of at least partially dismantling the construct of claim 42, with the method comprising:
separating the construct into separate parts, wherein the separating of the construct comprises separating the substrate and the polymer film from one another so that the injection-molded feature remains at least indirectly joined to the polymer film.
48. The method according to claim 47, further comprising recycling at least one of the parts.
49. The method according to claim 47, wherein the separating of the substrate and the polymer film from one another comprises:
manually separating the substrate and the polymer film from one another.
50. An apparatus for use in at least partially forming a container, the apparatus comprising:
a mold that includes a cavity having an elongate interior corner that extends into the cavity, wherein the interior comer includes (a) an elongate central region that projects into the cavity and extends along the interior corner and partially defines the cavity and the interior corner, (b) an elongate first recess that extends along the interior corner and partially defines the cavity and the interior corner, and (c) an elongate second recess that extends along the interior corner and partially defines the cavity and the interior corner, and the central region is positioned between the first recess and the second recess.
51. The apparatus according to claim 50, wherein:
the mold includes a base of the cavity and an opening to the cavity, the opening to the cavity is distant from and diametrically opposite from the base, and the central region and the first and second recesses extend from proximate the base toward the opening.
52. The apparatus according to claim 51, wherein:
the mold includes a substantially bowl-shaped recess that partially defines the cavity and the interior corner, the substantially bowl-shaped recess is proximate the base, and the central region and the first and second recesses extend from the substantially bowl-shaped recess toward the opening.
53. The apparatus according to claim 50, wherein:
the mold is a female mold, the apparatus further comprises a male mold for being inserted into the cavity of the female mold, the male mold includes a outer mold and a inner mold that is movably mounted to the outer mold for moving between an extended configuration and a retracted configuration, the outer mold includes a plurality of corners, the plurality of corners of the outer mold extend at least partially around the inner mold while the inner mold is in the retracted configuration, and the plurality of corners of the outer mold are for being respectively positioned in the interior corners of the female mold when the male mold is inserted into the cavity of the female mold, so that the plurality of corners of the outer mold are respectively positioned between the interior corners of the female mold and the inner mold while the male mold is inserted into the cavity of the female mold.
54. An apparatus for use in at least partially forming a container, the apparatus comprising:
a female mold that includes a cavity having a plurality of elongate interior corners that extend into the cavity; and a male mold for being inserted into the cavity of the female mold, wherein the male mold includes an outer mold and an inner mold that is movably mounted to the outer mold for moving between an extended configuration and a retracted configuration, the outer mold includes a plurality of corners, the plurality of corners of the outer mold extend at least partially around the inner mold while the inner mold is in the retracted configuration, and the plurality of corners of the outer mold are for being respectively positioned in the interior corners of the female mold when the male mold is inserted into the cavity of the female mold, so that the plurality of corners of the outer mold are respectively positioned between the interior corners of the female mold and the inner mold while the male mold is inserted into the cavity of the female mold.
55. The apparatus according to claim 54, wherein,for each corner of the plurality of corners of the outer mold, the corner includes a projection which lengthens the corner.
56. The apparatus according to claim 55, wherein the inner mold includes corners with recesses for respectively being in receipt of the projections of the outer mold.
57. A method of manufacturing, the method comprising:
closing a blank in a forming tool, so that the blank is formed into a construct that is at least partially contained in the closed forming tool, wherein the forming tool comprises a male mold and a female mold, and the closing of the blank in the forming tool comprises engaging a first part of the male mold against a portion of the blank, thereafter using at least the first part of the male mold to at least partially force the portion of the blank into a cavity of the female mold and thereby partially form the construct, thereafter engaging a second part of the male mold against a portion of the blank to further form the construct, and moving the first part of the male mold relative to the second part of the male mold at a period of time that occurs during the closing of the blank in the forming tool and is after the engaging of the first part of the male mold against the blank.
58. A method according to claim 57, comprising providing the blank so that the blank includes microwave interactive material prior to and during the closing of the blank in a forming tool, and so that the construct includes the microwave interactive material.
59. A method according to claim 57, wherein the closing of the blank in the forming tool comprises engaging a first part of the female mold against a portion of the blank, thereafter engaging a second part of the female mold against a portion of the blank to further form the construct, and moving the first part of the female mold relative to the second part of the female at the period of time that occurs during the closing of the blank in the forming tool and is after the engaging of the first part of the female mold against the portion of the blank.
60. A method according to claim 57, further comprising forming at least one injection-molded feature on the construct while the construct is at least partially contained in the closed forming tool.
61. A method according to claim 60, wherein the forming of the injection-molded feature comprises:

defining a channel at least between a corner of the construct and a corner of the male mold, so that the channel extends along both the corner of the construct and the corner of the male mold, and so that the channel does not extend across a boundary between the first and second parts of the male mold; and introducing molding material into the channel.
62. A method according to claim 57, wherein the moving of the first part of the male mold relative to the second part of the male comprises:
moving the first part of the male mold at least partially into a cavity of the second part of the male mold.
63. A method of manufacturing, the method comprising:
forming a construct in a forming tool, wherein the forming of the construct comprises arranging a first part of the construct and a second part of the construct so that there is an overlapping relationship between the first part and the second part, and an edge of the first part is positioned between the second part and a channel;

and forming an injection-molded feature on the construct, wherein the forming of the injection-molded feature includes forcing molding material to flow in the channel, so that the molding material flows along the first part, then across the edge of the first part, and then along the second part.
64. The method of claim 63, wherein:
the construct comprises microwave energy interactive material, paperboard and polymer film, the microwave energy interactive material is positioned between the paperboard and the polymer film, and the forming of the injection-molded feature comprises adhering the injection-molded feature to the polymer film.
65. The method of claim 63, wherein:
the forming of the construct comprises closing a blank in the forming tool;
the forming of the injection-molded feature on the construct occurs while the construct is closed in the forming tool; and the method further comprises removing the construct, which has the injection-molded feature formed thereon, from the forming tool.
66. The method of claim 63, wherein:
the forming of the construct comprises closing a blank in the forming tool, the arranging of the first part and the second part comprises causing relative movement between the first part and the second part, and the causing of the relative movement comprises forcing the blank into a cavity of a female mold and engaging the second part against a predetermined portion of the female mold prior to any engaging of the first part against the predetermined portion of the female mold.
67. The method of claim 66, wherein the engaging of the second part against a predetermined portion of the female mold comprises engaging a protruding portion of the second part against a shoulder of the female mold.
68. A method of manufacturing, the method comprising:
closing a construct in a forming tool; and forming an injection-molded feature on the construct, wherein the forming of the injection-molded feature comprises bending at least a portion of the construct while the construct is closed in the forming tool, and the bending of the portion of the construct comprises forcing fluid molding material against at least the portion of the construct so that the portion of the construct bends under the force of the fluid molding material.
69. The method of claim 68, wherein:

the construct comprises microwave energy interactive material, paperboard and polymer film, the microwave energy interactive material is positioned between the paperboard and the polymer film, and the forming of the injection-molded feature comprises adhering the injection-molded feature to the polymer film.
70. The method of claim 68, wherein the forcing of the fluid molding material against the portion of the construct comprises:
forcing the portion of the construct against a surface of the forming tool so that a surface of the portion of the construct becomes shaped substantially like the surface of the forming tool.
71. The method of claim 70, wherein the forcing of the portion of the construct against the surface comprises:
enlarging a channel that is for receiving the fluid molding material.
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US78122906P 2006-03-10 2006-03-10
US60/781,229 2006-03-10
US83440206P 2006-07-31 2006-07-31
US60/834,402 2006-07-31
PCT/US2007/005956 WO2007106367A2 (en) 2006-03-10 2007-03-08 Injection-molded composite construct

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JP (1) JP4995892B2 (en)
AT (2) ATE508956T1 (en)
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US8784959B2 (en) 2014-07-22
US8124201B2 (en) 2012-02-28
US9850020B2 (en) 2017-12-26
US20180072449A1 (en) 2018-03-15
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US11472592B2 (en) 2022-10-18
US20120118900A1 (en) 2012-05-17
US20140291337A1 (en) 2014-10-02
US20070262487A1 (en) 2007-11-15

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