SECOND PROVISIONAL PATENT APPLICATION
`
`of
`
`CHRIS K. LESER,
`
`CHARLES T. WALLACE,
`
`PHILIP A. DRISKILL,
`
`JOHN B. EULER,
`
`JASON I . PALADINO,
`
`MILAN C. MARAVICH,
`
`DAN DAVIS,
`
`and
`
`JEFFREY A. MANN,
`
`for
`
`EXPANDED POLYPROPYLENE MATERIAL FOR AN INSULATED CONTAINER
`
`Client Reference BP-356
`
`Attorney Docket 5723-220357
`
`INDSD2 JBERNSTEIN I2 I 405 1 V1
`
`Page 1 of 52
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`BOREALIS EXHIBIT 1036
`
`Page 1 of 52
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`BOREALIS EXHIBIT 1036
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`

`

`5'/'23—220357
`
`EXPANDED POLYPROPYLENE MATERIAL FOR AN INSULATED CONTAINER
`
`BACKGROUND
`
`[0001]
`
`The present disclosure relates to a polypropylene material which can be
`
`manufactured into containers, and in particular to insulated containers, such as cups, for
`
`containing hot or cold beverages or food. More particularly, in one embodiment the
`
`present disclosure relates to an expanded polypropylene material.
`
`SUMMARY
`
`[0002]
`
`One aspect of the present disclosure provides an expanded polypropylene
`
`material having predominately closed cells. The sheet can be formed into a cup or other
`
`container. For convenience, a cup may be referred to illustratively herein, and the term is
`
`intended to broadly include conventional cups, bottles, tubs, bowls, and other containers
`
`and structures.
`
`[0003]
`
`One aspect of the present disclosure provides a composition for forming a
`
`foamed sheet, comprising (a) a first material comprising at least one high melt strength
`
`polypropylene polymer; (b) a second material comprising at least one polypropylene
`
`polymer selected from the group consisting of impact copolymers and high crystalline
`
`homopolymers; (c) at least one nucleating agent selected from the group consisting of
`
`chemical nucleating agents, physical nucleating agents and combinations thereof; ((1) a
`
`slip agent; and, (e) an inert gas.
`
`[0004]
`
`One aspect of the present disclosure provides a composition for forming a
`
`foamed sheet, comprising (a) a first material comprising a polylactic acid; (b) at least one
`
`nucleating agent selected from the group consisting of chemical nucleating agents,
`
`physical nucleating agents and combinations thereof; (c) at least one slip agent; and, (d)
`
`at least one gas.
`
`[0005]
`
`One aspect of the present disclosure provides a foamed sheet material
`
`formed by a process, comprising (a) providing a first material comprising at least one
`
`high melt strength polypropylene polymer; (b) providing a second material comprising at
`
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`Page 2 of 52
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`5723-22035”/'
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`least one polypropylene polymer selected from the group consisting of impact
`
`copolymers and high crystalline homopolymers; (c) mixing the first and second material
`
`to form a resin mixture; (d) adding to the resin mixture at least one nucleating agent
`
`selected from the group consisting of chemical nucleating agents, physical nucleating
`
`agents and combinations thereof; (e) adding to the resin mixture a slip agent; (f) adding to
`
`the resin mixture an inert gas; (g) expanding the resin mixture to form a foamed mixture
`
`having cells therein; and, (h) forming a sheet of the foamed mixture.
`
`[0006]
`
`Additional features of the present disclosure will become apparent to those
`
`skilled in the art upon consideration of illustrative embodiments exemplifying the best
`
`mode of carrying out the disclosure as presently perceived.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0007]
`
`which:
`
`The detailed description particularly refers to the accompanying figures in
`
`[0008]
`
`Fig. 1 is a perspective View of an insulated cup formed of a material in
`
`accordance with the present disclosure showing a cup including a body formed to include
`
`an interior region, a rolled brim coupled to a top portion of a side wall included in the
`
`body, and a floor having an integrated support flange coupled to a bottom portion of the
`
`side wall;
`
`[0009]
`
`Fig. 2 is a partial sectional View taken along line 3-3 of Fig. 1 showing the
`
`rolled brim coupled to the top portion of the side wall;
`
`[0010]
`
`Fig. 3 is a sectional view taken along line 3-3 of Fig. 1 showing that the
`
`side wall included in the body of the insulated cup includes a generally uniform thickness
`
`and showing that the floor is coupled to the cup side wall which has been folded under
`
`the cup so that the floor is suspended above the bottom portion of the side wall;
`
`[0011]
`
`Fig. 4 is an exploded assembly View of the insulated cup of Fig. 1 showing
`
`the insulated cup includes a body including the rolled brim, the side wall, and the floor;
`
`Page 3 of 52
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`5723-2320357
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`[0012]
`
`Fig. 5 is a top plan view of a brim of a cup formed according to one
`
`exemplary embodiment of the present disclosure;
`
`[0013]
`
`Fig. 6 is a detailed View of a portion of side wall of a cup of Fig. 5
`
`showing two compressed portions which overlap when bonded; and
`
`[0014]
`
`Fig. 7 is a detailed View of a portion of a side wall according to one
`
`exemplary embodiment of the present disclosure showing one compressed portion.
`
`[0015]
`
`Fig. 8 is a graph of insulation temperature test results.
`
`DETAILED DESCRIPTION
`
`[0016]
`
`One exemplary embodiment of the present disclosure provides an
`
`expanded polypropylene material. The material may be made of a single resin or may be
`
`comprise a base resin and a secondary resin. It is also possible to use more than two
`
`resins.
`
`[0017]
`
`One exemplary embodiment provides a two-resin material system. The
`
`base resin may be a polypropylene resin, such as, but not limited to, a high melt strength
`
`polypropylene. Polypropylene resins which are generally considered high melt strength
`
`resins that have a high molecular branched structure (typically an altered base resin
`
`resulting in a branched structure). Suitable resins can hold the gas, produce desirable cell
`
`size, have a satisfactory smooth surface finish, have an acceptable odor level, and have
`
`sufficient long chain branching One illustrative example of a suitable polypropylene base
`
`resin is DAPLOYTM WBl4O homopolymer (available from Borealis A/S), a high melt
`
`strength structural isomeric modified polypropylene homopolymer (melt strength = 36
`
`using the Borealis test method), melting temperature = 163°C [using ISO 1l357]).
`
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`Page 4 of 52
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`5723 —220357
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`Borealis DAPLOY properties:
`
`Melt Flow Rate (230/2.16)
`Flexural Modulus
`
`T ical Value
`.1
`
`Test Method
`1801133
`
`E-
`
`Tensile Strenth at Yield
`Elonation at Yield _
`2
`Tensile Modulus
`Cha -
`im act strenth, notched +23°C
`Cha -
`im act strenth, notched (-20°C)
`Heat Deflection Ternerature
`Heat Deflection Temerature
`
`ISO 527-2
`
`ISO 527-2
`
`[0018I
`
`Other polypropylene polymers having similar structure, melt strength, and
`
`melting temperature to the above may also be used.
`
`[0019]
`
`Other possible highmelt strength base resins include, but are not limited
`
`to, high melt strength homopolymers available from Total Petrochemicals USA under the
`
`trade name 3354 and N1 1106. In one exemplary embodiment with either of these resins
`
`one can incorporate additives to retain and/or improve resin properties, including but not
`
`limited to zinc stearate (ZnSt) and calcium stearate (CaSt). Other base resins may include
`
`high melt strength homopolymers available from LyndellBasell Industries Holdings,
`
`B.V., available as X11844-30-1 and X1 1844-35-1. It is possible to use a resin stabilizer
`
`named X11844-34-1, also available from LyndellBasell Industries Holdings, B.V., to be
`
`used with both resins.
`
`[0020]
`
`The secondary resin may be, for example, a high crystalline polypropylene
`
`homopolymer or an impact copolymer. One illustrative example is a polymer
`
`commercially available as PRO-FAX SC204T” (available from LyndellBasell Industries
`
`Holdings, B.V.).
`
`[0021]
`
`Other possible secondary resins include impact copolymers and high
`
`crystalline homopolymers. Examples include, but are not limited to, Homo PP — INSPIRE
`
`Page 5 of 52
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`Page 5 of 52
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`5723-22035’?
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`222, available from Braskem, and high crystalline polypropylene homopolyrner, available
`
`as FOZOHC from Braskem.
`
`[0022]
`
`One or more nucleating agents are used to provide sites for bubble or cells
`
`to form during the manufacturing process. Nucleating agents may be physical agents or
`
`chemical agents. Suitable physical nucleating agents will have desirable particle size,
`
`aspect ratio and top cut properties. Examples include, but are not limited to, talc, CaCO3,
`
`mica and mixtures of at least two of the foregoing. For example, a chemical foaming
`
`agent can be used as a primary nucleation agent. One illustrative example of a chemical
`
`foaming agent is citric acid or a citric acid-based material. One example is Hydrocerolm
`
`CF-40ETM (available from Clariant Corporation). Another example is CF40E, Clarient
`
`NC-Polyfil (available from Clarient). A secondary nucleating agent may be incorporated.
`
`An illustrative example of a secondary nucleation agent is talc, which is a physical
`
`nucleator used to create small cell sizes. The resin or resins may be blended with the
`
`nucleating agents.
`
`[0023]
`
`At least one slip agent may be incorporated into the resin mixture to aid in
`
`increasing production rates. Slip is a term used to describe a general class of materials,
`
`usually fats, which are added to reduce or eliminate die drool. Example of slip materials
`
`are erucamide, olearnide, linear low density polyethylene polymers and mixtures of at
`
`least two of the foregoing. Slip is typically provided in a master batch pellet form and
`
`added to the resin during resin blending.
`
`[0024]
`
`One or more additional components and additives optionally may be
`
`incorporated, such as, but not limited to, impact modifiers, colorants (such as, but not
`
`limited to, titanium dioxide), blowing catalysts and compound regrind.
`
`[0025]
`
`The resins may be blended with any additional desired components and
`
`melted to form a resin mixture.
`
`[0026]
`
`A gas, such as, but not limited to, carbon dioxide, nitrogen, haloalkane,
`
`other relatively inert gas, a mixture of at least two of the foregoing gases, or the like, is
`
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`5723-22035?
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`-5-
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`introduced into the molten resin mixture to expand the resin mixture and reduce density
`
`by fonning cells in the molten polypropylene. Alternatively, the gas may be pentane,
`
`butane or other alkane. In one exemplary embodiment l,l,1,2-tetrafluoroethane, also
`
`known as Rl34a, or other haloalkane refiigerant may be used as or with the gas.
`
`[0027]
`
`In one exemplary embodiment a material formed according to the present
`
`disclosure has an average cell size in the machine direction: Length .0l642”; Width
`
`00301” and an average cell size in the transverse direction: Length .01756”; Width
`
`.00304”.
`
`[0028]
`
`In one aspect of the present disclosure, the polypropylene resin (either the
`
`base or the combined base and secondary resin) may have a density in a range of 0.01-0.1
`
`g/cm3. In one exemplary embodiment, the density is in a range of 0.05-0.19 g/cm3. In one
`
`exemplary embodiment, the density is in a range of 0.15-O.l85g/crn3.
`
`[0029]
`
`In an alternative exemplary embodiment, instead of polypropylene, a
`
`polylactic acid (“PLA”) material may be used, such as, but not limited to, a food~based
`
`material, for example, corn starch. Alternatively, polyethylene may be used.
`
`[0030]
`
`In one exemplary aspect of the present disclosure, one general formulation
`
`for a material includes the following:
`
`a base resin comprising a high melt strength polypropylene,
`
`a secondary resin comprising a high crystalline polypropylene homopolymer or an
`
`impact copolymer,
`
`a nucleating agent,
`
`a slip agent to reduce or eliminate the occurrence of die drool, and
`
`a gas, such as carbon dioxide, nitrogen, haloalkane, such as R1343, or other inert
`
`gas.
`
`Page 7 of 52
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`5723—220357
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`Optionally, a colorant may be incorporated.
`
`[0031]
`
`The polypropylene resin material thus fonned may be extruded into a
`
`sheet by conventional extrusion apparatus and methods. Cups or other containers or
`
`structures may be formed from the sheet according to conventional apparatus and
`
`methods.
`
`[0032]
`
`The material of the present disclosure may also be formed into a flexible
`
`sheet which can be wrapped around other structures. For example, a sheet of the present
`
`material may be formed and wrapped around a pipe, conduit or other structure to provide
`
`improved insulation.
`
`[0033]
`
`For the purposes of non-limiting illustration only, a cup will be described;
`
`however, the container may be in any of a variety of possible shapes or structures or for a
`
`variety of applications, such as, but not limited to, a conventional beverage cup, storage
`
`container, bottle, or the like. For the purpose of nonlimiting illustration only, a liquid
`
`beverage will be used as the material which can be contained by the container; however,
`
`the container may hold liquids, solids, gels, combinations thereof, or other material. An
`
`insulated drink cup 10 in accordance with one exemplary embodiment of the present
`
`disclosure, shown in Figs. 1-4, includes a body 12 formed to include an interior region 14
`
`and a rolled brim 16 coupled to body 12. Body 12 includes a side wall 18 and a floor 20
`
`coupled to side wall 18 to define interior region 14.
`
`[0034]
`
`Side wall 18 extends between rolled brim 16 and floor 20, as shown in
`
`Fig. 3. Side wall 18 includes a top portion 22 of body 12 that is coupled to rolled brim 16.
`
`Side wall 18 further includes a bottom portion 24. Top portion 22 is arranged to extend in
`
`a downward direction 28 toward floor 20 and is coupled to bottom portion 24 that is
`
`arranged to extend in an opposite upward direction 30 toward rolled brim 16. Top portion
`
`22 and rolled brim 16 cooperate to form a mouth 32 that is arranged to open into interior
`
`region 14 as shown in Fig. 1. Floor 20 includes a flange 26 which fits within a receiving
`
`Page 8 of‘52
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`5723-22035?
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`well 27 formed at bottom portion 24 so as to suspend the floor 20 above the surface on
`
`which cup 10 can rest.
`
`[0035]
`
`An unexpected property of the material (in sheet form) as described herein
`
`is the high insulation value obtained at a given thickness compared to beaded polystyrene
`
`and other conventional materials, particularly those for forming insulated containers. The
`
`polypropylene foam material of the present disclosure has roughly equivalent insulation
`
`properties as expanded polystyrene, but at a thinner wall thickness and a higher density.
`
`In one exemplary embodiment of a cup formed from a composition described herein, the
`
`cup material having a density of, for example, 0.1902 g/cm3 and a wall thickness of 0.089
`
`inches, in which a hot liquid at 200°F (93.3°C) was placed in the cup, the temperature
`
`measured on the outside wall of the cup was about l40.5°F (60.3°C), i.e., a S9.5°F (33°C)
`
`drop. The maximum temperature over a five-minute period was observed to peak at
`
`l40.5°F (60.3°C) Thus, a desirable insulation value can be obtained using a thinner wall
`
`than has heretofore been available for a cup. The result is the need for less material and
`
`the formation of a lighter, thinner container which still possesses the requisite strength
`
`and rigidity. Additionally, the cup fonned as described was recyclable.
`
`[0036]
`
`A feature of a cup formed of the material according to the present
`
`disclosure is that the cup has considerably less material loss than current foamed
`
`products. Furthermore, the material of the present disclosure has significantly less off-gas
`
`(less than 50%) when subjected to heat from conventional kitchen-type microwave oven
`
`for periods of time up to several minutes. This is in comparison to the substantial off-
`
`gassing levels produced by subjecting beaded expanded polystyrene cups to comparable
`
`microwave 6Xp0Sl1I'6.
`
`[0037]
`
`Another feature of a cup formed of the material according to the present
`
`disclosure is that the cup can be placed in and go through a conventional dishwasher
`
`cleaning cycle (top rack) without material breakdown or adverse affect on material
`
`properties. This is in comparison to beaded polystyrene cups or containers which can
`
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`5723-220357
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`break down under similar cleaning processes. Accordingly, a cup made according to the
`
`present disclosure can be cleaned and reused.
`
`[0038]
`
`Yet another feature of a cup formed of the material according to the
`
`present disclosure is that the cup can be recycled, meaning that the cup can be ground up
`
`and the particles can be incorporated into virgin (or other) polypropylene resin and re-
`
`extruded into new cups, thus reducing the amount of non-disposable waste. This is in
`
`comparison to beaded polystyrene cups that break up into beads and do not break down
`
`and thus cannot be reused or recycled in a manufacturing process.
`
`[0039]
`
`A feature of the cup formed of the material according to one exemplary
`
`embodiment (a non-laminate process) of the present disclosure is that the outside (or
`
`inside or both) wall surface of the expanded polypropylene sheet (prior to being formed
`
`into a cup, or during cup formation, depending on the manufacturing process employed)
`
`can accept printing of high~resolution graphics. Conventional beaded polystyrene cups
`
`have a surface which typically is not smooth enough to accept printing other than low-
`
`resolution graphics. Similarly, known paper cups also typically do not have a smooth
`
`enough surface for such high-resolution graphics. Paper cups can be coated to have the
`
`desired surface finish and can achieve high resolution. Paper has difficulty reaching
`
`insulation levels and requires a designed air gap incorporated into the cup to achieve
`
`insulation. Accordingly, solutions have been to use low-resolution printing, laminate to
`
`the outside wall a film which has been printed, or to have a printed sleeve (either bonded
`
`or removable) inserted over the outside wall.
`
`[0040]
`
`A feature of a cup formed of the material according to the present
`
`disclosure is that it possesses unexpected strength as measured by rigidity. Rigidity is a
`
`measurement done at room temperature and at an elevated temperature (eg, by filling
`
`the cup with a hot liquid) and measuring the rigidity of the material. A material that
`
`softens appreciably when heated will be less rigid compared to a material which does not
`
`soften as readily. The strength of the cup material is important to reduce the potential for
`
`the cup being deformed by a user and the lid popping off or the lid seal leaking.
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`5723 -220357
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`-10-
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`[0041]
`
`A feature of a cup formed of the material according to the present
`
`disclosure is that the sleeve is resistant to puncture, such as by a straw, fork, spoon, finger
`
`nail, or the like, as measured by standard impact testing, as described hereinbelow. Test
`
`materials demonstrated substantially higher impact resistance when compared to a beaded
`
`polystyrene cup having a similar insulation value. Accordingly, a cup formed as
`
`described herein can reduce the likelihood of puncture, which could leak hot liquid onto a
`
`1186!’.
`
`[0042]
`
`A feature of a cup formed of the material according to the present
`
`disclosure is that the brim can be compressed at the seam area, thereby providing a cross-
`
`section thickness that is substantially uniform around the entire brim. Conventional brims
`
`of cups made from paper or other cellulosic material have an increased thickness at the
`
`seam, both at the side wall and the brim. A feature of a sheet of the present material is
`
`that it can be compressed. According to one exemplary embodiment of the present
`
`disclosure, shown in Fig. 5-6, the sheet of the present material to be formed into a cup
`
`may have a first side 98 having a compressed portion 120 and a second side 100 having a
`
`compressed portion 122. When the cup is formed from the sheet as suggested in Fig. 5,
`
`the compressed portion 120 of first side 98 overlaps the compressed portion 122 of
`
`second side 100. The overlapped edges are bonded together (such as, but not limited to,
`
`by welding, fusing, gluing, or other bonding techniques) to form side—wall seam 34. The
`
`seam 34 thus formed has substantially the same thickness as the rest of the side wall 18,
`
`thereby presenting an aesthetically pleasing appearance and feel.
`
`[0043]
`
`In one exemplary embodiment, the brim 16 of the cup 10 is formed by
`
`brim rolling the top portion 22 of the side wall 18. Side wall 18 is formed from a
`
`compressed side-wall blank that has not had top side 96 compressed. As a result, the
`
`seam 34 of the cup 10 may have substantially the same thickness as the rest of the side
`
`wall and the rolled brim will similarly have a substantially uniform thickness that is about
`
`the same as the side wall. The uniform thickness of the rolled brim is adapted to mate
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`5723—220357
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`-11-
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`with a lid and minimize leakage. Also, such a rolled brim provides a more aesthetically
`
`and tactilely pleasing cup.
`
`[0044]
`
`The compressed portions 120, 122 may extend for the length of the sheet
`
`which forms the side wall 18, or, the compressed portion 120, 122 may extend for a
`
`portion of the length of the side. In certain applications, where desired, the compressed
`
`portion may be formed along different separate portions along the side.
`
`[0045]
`
`In one exemplary embodiment, the first side 98 has a compressed portion
`
`120 on the top surface which is compressed and the second side 100 has a compressed
`
`portion 122 on the bottom surface which is compressed as shown in Fig. 6. In one
`
`exemplary embodiment, the compression on each side is about 50%. In another
`
`exemplary embodiment, the degree of compression may be different on each side.
`
`[0046]
`
`In one exemplary embodiment of a compressed side wall blank 200, as
`
`shown in Fig. 7 first side 98 is compressed as described hereinabove, but a second side
`
`210 is not compressed.
`
`[0047]
`
`A feature of a cup with a compressed brim and seam formed of the
`
`material as described herein is that a greater number of such cups can be nested in a given
`
`sleeve length because the seam is thinner and the side wall angle can be minimized (i.e.,
`
`more approaching 90° with respect to the cup bottom) while providing a sufficient air gap
`
`to permit easy de-nesting. Conventionally seam—formed cups having a seam substantially
`
`thicker than the side wall requires a greater side wall angle (and air gap) to allow for de-
`
`nesting, resulting in fewer cups being able to be nested in a given sleeve length.
`
`[0048]
`
`A feature of a cup formed of the material according to the present
`
`disclosure is that the brim may have a cross-section profile of less than 0.150 inches.
`
`Such a small profile is more aesthetically pleasing than a larger profile.
`
`[0049]
`
`A feature of a cup formed of the material according to the present
`
`disclosure is that the rolled brim diameter can be the same for cups of different volumes,
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`5723-220357
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`-12-
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`enabling one lid size to be used for different cup sizes, assuming the cup rims outside
`
`diameters are the same. As a result, the number of different size lids in inventory and at
`
`the point of use may be reduced.
`
`[0050]
`
`The material formulation has properties that allow the sheet to be
`
`compressed without fracturing.
`
`EXAMPLES
`
`{0051]
`
`The following examples are set forth for purposes of illustration only.
`
`Parts and percentages appearing in such examples are by weight unless otherwise
`
`stipulated. All ASTM citations herein are incorporated by reference in their entirety.
`
`Example 1
`
`[0052]
`
`DAPLOYTM WB140 homopolymer (available from Borealis A/S) was
`
`used as the polypropylene base resin. FOZOHC, available from Braskem, a polypropylene
`
`copolymer resin, was used as the secondary resin. The two resins were blended with
`
`Hydrocerolm CF—40ETM as a primary nucleation agent, talc was used as a secondary
`
`nucleation agent, and titanium dioxide as a colorant. Percentages were:
`
`79 % Primary resin: high melt strength polypropylene Borealis WB140 HMS
`
`15% Secondary resin: FOZOHC (Braskem)
`
`0.05% Primary nucleating agent: Clariant Hyrocerol CF-4OETM
`
`2%
`
`Secondary nucleating agent: Talc (physical nucleator to create smaller
`
`cells)
`
`Additives:
`
`2%
`
`Colorant: TiO2 PE (alternatively, PP can be used)
`
`Page 13 of 52
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`5723—220357
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`-13-
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`2%
`
`Slip agent: Arnpacetm 102823 LLDPE (linear low-density polyethylene),
`
`available from Ampacet Corporation (used to lubricate the system to reduce die
`
`drool and sheet defects)
`
`0.74% Gases: 1.10 lbs/hr C02 (physical blowing agent, to achieve density)
`
`0.53% 0.7 lbs/hr R134a (physical blowing agent, increases the solubility C0; of
`
`into solution)
`
`[0053]
`
`The carbon dioxide with R1343 was injected into the resin blend to expand
`
`the resin and reduce density. The mixture thus formed was extruded into a sheet. The
`
`sheet was then cut and formed into a Cup.
`
`Example 2
`
`[0054]
`
`The test results of the material fonned according to Example 1 showed the
`
`material had a density of 0.l902g/cc and a nominal sheet gauge of 0.089 inches.
`
`Microwavability:
`
`[0055]
`
`Containers produced using this material can be microwave reheated using
`
`an FISO Microwave Station (1200 Watts) for 2.5 min without burning or scorching as
`
`compared to typical paper cups which are generally considered not suitable for
`
`microwave use.
`
`Rigidity
`
`Test Method
`
`Samples should be at 73°F and 50% relative humidity. Cup Stiffness/Rigidity test should
`
`be conducted with a horizontal force gauge containing a load cell to measure the resisting
`
`force of the cup when exposed to the following test conditions: (a) Test location on Cup is
`
`1/3 down from the rim of the cup. (b) Testing travel distance is Ms”. (0) Testing travel
`
`time is 10 seconds.
`
`Page 14 of 52
`
`Page 14 of 52
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`

`

`5723-220357
`
`Test Results
`
`-14-
`
`With an average wall thickness of 0.064”, average density of 0.1776 g/cc, and average
`
`cup weight of 9.86 g, the rigidity of the material are shown in the tables below.
`
`Rigidity Test Results
`
`unlidded/unfilled
`
`
`
`STD DEV
`
`3sigma
`High Range
`Low Range
`
`0.028
`
`0.085
`0.716
`0.545
`
`lidded/unfilled
`
`
`
`STD DEV
`
`3sigma
`High Range
`Low Range
`
`0.055
`
`0.165
`1.01 1
`0.680
`
`Page 15 of 52
`
`Page 15 of 52
`
`

`

`5723-220357
`
`-15-
`
`
`
`STD DEV
`
`3sigma
`High Range
`Low Range
`
`0.014
`
`0.043
`0.324
`0.238
`
`0354
`0.422
`
`0 364
`
`0 374
`0.272
`
`STD DEV
`
`Ssigma
`High Range
`Low Range
`
`0.042
`
`0.125
`0.476
`0.227
`
` 2
`
`
`
`
`
`0.818
`
`
`
`0.033
`
`0.098
`0.894
`0.698
`
`STD DEV
`
`3sigma
`High Range
`Low Range
`
`
`
`0.776
`0.804
`
`25
`
`Page 16 of 52
`
`Page 16 of 52
`
`

`

`5723-220357
`
`-15-
`
`
`
`
`
`
`
`
`
`Seam
`1-044
`II!!!
`0.988
`
`
`
`
`
`
`0-826
`
`
`
`0.059
`
`0.177
`1.192
`0.83’?
`
`STD DEV
`
`3sigma
`High Range
`Low Range
`
`Summary of Rigidity Test Results
`
`Hot Fill 200°F K-F
`Unlidded
`
`0.352
`
`Ice Water Fill 35°F
`K -F
`Unlidded
`
`Wall
`Thickness
`
`0-064
`
` Densit
`
`-. cc
` 0.1776
`
`
`Unfilled Kg-F
`kilo rams—force)
`
`Unlidded
`
`
`
`0.845
`
`
`
`
`
`
`
`Test material
`
`Insulation
`
`Test Method
`
`[0056]
`
`A typical industrial cup insulation test method as follows was used:
`
`Attach the (cup exterior )surface temperature thermocouple to cup with
`
`glue.
`
`Tape attached thermocouple to cup with cellophane tape so that the
`
`thermocouple is in the middle of the cup opposite the seam.
`
`Heat water or other aqueous liquid to near boiling, such as in a
`
`microwave.
`
`Continually stir the hot liquid with a bulb thermometer while observing
`
`the liquid temperature.
`
`Record thermocouple temperature.
`
`When the liquid gets to 200 °F pour into cup to near full.
`
`Page 17 of 52
`
`Page 17 of 52
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`

`

`5723-220357
`
`-17-
`
`0
`
`a
`
`Place lid on cup.
`
`Record surface temperature for a minimum of 5 minutes.
`
`Material thickness was 0.089 inches. The density was 0.1902 g/cc.
`
`Test Results
`
`[0057]
`
`The results of the testing is the maximum exterior surface temperature
`
`reached during the test, as shown in the graph in Fig. 8. The maximum wall temperature
`
`that was measured was 140.5 °F. The lower the temperature, the better the insulation
`
`property of the cup material as the material reduces the heat transferring from the liquid
`
`to the cup material exterior.
`
`Frangibility
`
`[0058]
`
`Frangibility can be defined as resistance to tear or punctures causing
`
`fragmentation.
`
`Test Method
`
`The Elmendorf test method described in ASTM D1922-93 was used. The radius of tear
`
`was 1.7 inches.
`
`Test Results
`
`The test results are shown in the table below. The material as formed in one exemplary
`
`embodiment of the present disclosure provides superior resistance to tear forces when
`
`compared to EPS.
`
`Page 18 of 52
`
`Page 18 of 52
`
`

`

`5723-220357
`
`-13-
`
`Test Results
`
`Tag
`
`Machine Direction ( am force)
`Test Test Test Test Test mean
`1
`2
`3
`4
`5
`
`5
`
`5
`
`Transverse Direction ram force)
`Test Test Test Test Test mean
`1
`2
`3
`4
`5
`
`std
`dev.
`
`std
`dev.
`
`
`
`Test
`
`Material
`
`288
`
`58
`
`315
`
`282
`
`23 232
`
`213
`
`178
`
`205
`
`112 111111:
`
`Summary of Test Results
`
`
`
`Sample ID -9
`
`Test
`material cu
`
`Expanded
`ol st
`ene
`
`
`
`-z‘
`
`
`
`
`
`[0059]
`
`Note that there was no data obtained for the transverse direction test for
`
`EPS because EPS does not have a material orientation, i.e., a “machine” or “transverse”
`
`direction, as such. The range (calculated as: lower range = mean — (3); std dev); upper
`range = mean + (3x std dev)) for the tested material of the present disclosure was 213-
`
`351 g-f in the machine direction and 143-281 g—f in the transverse direction. In
`
`comparison, the range of the expanded polystyrene material tested was 103-121 g—f.
`
`Puncture Resistance
`
`Test method
`
`Determine the force and travel needed to puncture cup sidewall and bottom. An
`
`Instron instrument is used in compression mode set to 10 inches per minute travel
`
`speed.
`
`The cup puncture test fixture on base of Instron is used. This fixture allows the
`
`cup to fit over a shape that fits inside the cup with a top surface that is
`
`perpendicular to the travel of the Instron tester. The one inch diameter hole of the
`
`fixture should be positioned up.
`
`Page 19 of 52
`
`Page 19 of 52
`
`

`

`5723-220357
`
`-19-
`
`The portion of the Instron that moves should be fitted with a 0.300” diameter
`
`punch.
`
`The punch with the hole is aligned in the test fixture.
`
`The cup is placed over the fixture and the force and travel needed to puncture the
`
`cup sidewall is recorded.
`
`The sidewall puncture test is repeated in three evenly spaced locations while not
`
`puncture testing on the seam of the cup.
`
`The bottom of the cup is tested. This should be done in the same manner as the
`
`sidewall test except no fixture is used. The cup is just placed upside down on the
`
`base of the Instron while bringing the punch down on the center of the cup
`
`bottom.
`
`Test Results
`
`Force curves and pictures of the typical sidewall puncture and the bottom puncture are
`
`shown in the table below.
`
`Puncture Test Results
`
`
`
`
`
`
`
`
`present test material No
`
`Rim
`
`Max Load (lbf)
`
`22.18
`
`Ext.
`
`
`
`: Max Load (in)
`0-300
`0.292
`
`Slow Puncture — Straw
`
`Test Method
`
`The material as formed in one exemplary embodiment of the present disclosure provides
`
`superior resistance to punctures when compared to EPS using the Slow Puncture
`
`Resistance Test Method as described in ASTM D-3763-86.
`
`Page 20 of 52
`
`Page 20 of 52
`
`

`

`5723—220357
`
`Test Results
`
`-20-
`
`Present disclosure material
`
`Break m
`
`‘’‘”‘‘‘g‘‘’
`13876-49 _
`13684-33 -
`—
`
`-l_
`
`-i
`“-
`
`1 3 E
`--
`
`xpanded Polypropylene
`
`Specimen #
`
`Peak Load g(f)
`
`Elongation At
`Break (mm)
`
`140.42
`
`7
`
`11
`12
`13
`14
`Mean
`Std. Dev.
`
`Page 21 of 52
`
`Page 21 of 52
`
`

`

`5723-220357
`
`-21-
`
`Paper wrapped expanded polypropylene
`
`-—
`
`————n
`-—BZ
`
`_—
`__
`--
`--
`--
`
`
`
`Summary of Slow Puncture-Straw Test Results
`
`Sample ID -)
`
`Test
`material cu
`15210
`
`Expanded
`0] st
`ene
`2752
`
`Paper wrapped
`exanded ol st
`8969
`
`ene
`
`[0060]
`
`Although only a number of exemplary embodiments have been described
`
`in detail above, those skilled in the art will readily appreciate that many modifications are
`
`possible in the exemplary embodiments without materially departing from the novel
`
`teachings and advantages. Accordingly, all such modifications are intended to be
`
`included within the scope of this disclosure as defined in the following claims.
`
`[0061]
`
`As used in the specification and the appended claims, the singular forms
`
`“a,” “an” and “the” include plural referents unless the context clearly dictates otherwise.
`
`Ranges may be expressed herein as from “about” one particular value, and/or to “about”
`
`another particular value. When such a range is expressed, another embodiment includes
`
`from the one particular value and/or to the other particular value. Similarly, when values
`
`are expressed as approximations, by use of the antecedent “about,” it will be understood
`
`that the particular value forms another embodiment. It will be further understood that the
`
`endpoints of each of the ranges are significant both in relation to the other endpoint, and
`
`independently of the