INJECTION-MOLDED COMPOSITE CONSTRUCT AND TOOL FOR

FORMING CONSTRUCT

Cross-Reference to Related Application

[0001] This application claims the benefit of U.S. Provisional Application No.

61/017,348, which was filed on December 28, 2007. The entire contents of the above- referenced provisional application is hereby incorporated by reference for all purposes as if presented herein in their entirety.

Background of the Disclosure

[0002] The present disclosure generally relates to composite constructs and, more particularly, to cartons with injection-molded features.

Summary of the Disclosure

[0003] In general, one aspect of the disclosure is generally directed to 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 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 portion that extends outwardly from the upper edge of the respective side panel. An intermediate portion extends upwardly from an outer edge of the lower flange portion, and an upper flange portion extends outwardly from the intermediate portion. A band is injection-molded onto both an upper surface of the upper flange portion, and an upper surface of the lower flange portion. The band comprises an elongate portion that extends outwardly from an edge of the upper flange portion.

[0004] In another aspect, the disclosure is generally directed to a blank for forming a container having an injection-molded feature. The blank comprises a base panel, and a plurality of flaps respectively connected to and extending outwardly from the base

panel. 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 first corner tab and the second flap has a second corner tab. The first corner tab and the second corner tab project inward to narrow a width of the gap at a marginal portion of the blank. The first corner tab and the second corner tab are shaped to facilitate forming the injection-molded feature.

[0005] In another aspect, the disclosure is generally directed to a tool for forming a container. The tool comprises a cavity operable to receive a blank. The cavity has at least one sidewall for forming at least one sidewall of the container and at least one flange wall for forming at least one flange of the container. A core is operatively connected to the cavity. The core is operable to enter the cavity to at least partially form the blank into the container. The tool comprises an injection cavity at least partially formed from the cavity and the core. The injection cavity is for receiving liquid resin and directing liquid resin around at least a portion of the perimeter of the blank. The injection cavity comprising an advanced-flow section and a delayed-flow section. The advanced-flow section has a greater cross-sectional area than the delayed- flow section. The advanced-flow section is located adjacent the at least one sidewall of the cavity and the delayed-flow section extends outwardly from the advanced-flow section beyond the flange wall.

[0006] In another aspect, the disclosure is generally directed to a method for forming a container having an injection-molded feature. The method comprises providing a blank, placing the blank in a forming tool. The tool comprises an injection cavity having an advanced-flow section and a delayed-flow section. The method comprising then closing the tool while the blank is in the tool, so that the blank is formed into a three-dimensional article that is in the closed tool. The three-dimensional article having at least one sidewall and a flange that extends from the sidewall. The method comprising then forming the injection-molded feature on the article while the article is in the closed tool. The forming the injection-molded feature comprises injecting resin into the injection cavity so that resin flows in the advanced-flow section at a higher

flow rate than resin in the delayed-flow section. The advanced-flow section being adjacent the at least one sidewall and the delayed-flow section extending outwardly from the advanced-flow section beyond the flange. The method comprising then removing the article with the injection-molded feature from the tool.

[0007] Those skilled in the art will appreciate the above-stated advantages and other advantages and benefits of various additional embodiments reading the following detailed description of the embodiments with reference to the below-listed drawing figures.

[0008] According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the disclosure.

Brief Description of the Drawings

[0009] Fig. 1 is a plan view of a blank for forming a container of one embodiment of the disclosure.

[0010] Fig. 2 is an enlarged portion of Fig. 1.

[0011] Fig. 3 is an enlarged portion of Fig. 1.

[0012] Fig. 4 is a top view of a container formed from the blank of Fig. 1.

[0013] Fig. 5 is a cross-section taken along the plane 5-5 of Fig. 4.

[0014] Fig. 6 is a bottom view of a corner of the container of Fig. 4.

[0015] Fig. 7 is a perspective of the interior of a corner of the container of Fig. 4.

[0016] Fig. 8 is a top view of the blank of Fig. 1 partially formed into the container.

[0017] Fig. 9 is a perspective of an injection-molded frame removed from the container.

[0018] Fig. 10 is a schematic of a tool for forming the container.

[0019] Fig. 1 IA is a schematic of the tool in a closed state with a portion of the blank being formed into the container.

[0020] Fig. 1 IB is a view similar to Fig. 1 IA but with the container further formed.

[0021] Fig. 12 is a perspective of a cavity of the forming tool.

[0022] Fig. 13 is a top view of the cavity.

[0023] Fig. 13 A is an enlarged portion of the cavity.

[0024] Fig. 14 is a cross-section of the cavity.

[0025] Corresponding parts are designated by corresponding reference numbers throughout the drawings.

Detailed Description of the Exemplary Embodiment

[0026] Fig. 1 illustrates a blank 1 for forming a construct, namely a container 2 (Fig.

4). The container 2 comprises an injection-molded structure or frame 5 (Fig. 4) that comprises a band 7 extending around the perimeter of the container. The band 7 cooperates with portions of the blank 1 to form a flange 8 of the container 2 with the band forming a top surface of the container. In the illustrated embodiment, the container 2 is generally rectangular-shaped having four corners 9, 11, 13, 15 and the injection molded structure 5 comprises a respective strip 17, 19, 21, 23 at each corner of the container. The blank 1 can be formed into the container 2 by the forming tool 27 at least partially illustrated in Figs. 10-14.

[0027] As shown in Fig. 1, the blank has a longitudinal axis Ll and a lateral axis L2.

In the illustrated embodiment, the blank 1 has a longitudinal centerline CL and a lateral centerline CT. In one embodiment, the blank 1 is symmetrical about the lateral centerline CT but the blank could be otherwise shaped. The blank 1 comprises a base panel 31 and four side panels or flaps 33, 35, 37, 39. In the illustrated embodiment, the

side panels 33, 35, 37, 39 are foldably connected to the base panel 31, but the blank 1 is free from preformed fold lines that foldably connect the side panels to the base panel 31. Alternatively, the blank 1 could include preformed fold lines without departing from the disclosure. Each of the side panels 33, 35, 37, 39 includes a flange portion 41, 43, 45, 47 at a respective marginal edge of the side panels for being formed into the flange 8 of the container 2. As shown in Fig. 1, each of the flange portions 41, 43, 45, 47 are defined by a line 49, 51, 53, 57 that extends across a respective side panel 33, 35, 37, 39. The lines 49, 51, 53, 57 can be preformed fold lines, the lines could be lines of demarcation or indicia that represent the top edges of the side panels 33, 35, 37, 39 of the container 2, or the lines could be formed by the forming tool 27 when the blank 1 is formed into the container.

[0028] Figs. 2 and 3 are enlarged views of respective portions of the blank 1, with

Fig. 2 showing a first corner gap 51 between adjacent side panels 33, 35 and Fig. 3 showing a second corner gap 53 between adjacent side panels 35, 37. The side panels 33, 35 have respective corner tabs 57, 59 with edges 61, 63. In the illustrated embodiment, the corner tab 57 overlaps that corner tab 59 when the blank 1 is formed into the container. As shown in Fig. 3, the side panel 35 has a corner tab 65 at the opposite longitudinal end of the side panel from the corner tab 59, and the side panel 37 has a corner tab 67 at the corner gap 53. . The corner tab 65 overlaps the corner tab 67 when the blank 1 is formed into the container 2. The corner tab 65 has an edge 69 and the corner tab 67 has an edge 71. The corner tabs 57, 59 of the first corner gap 51 each project inward to narrow the width of the first corner gap at the edge margin of the blank 1. The corner tabs 65, 67 of the second corner gap 53 each project inward to narrow the width of the second corner gap at the edge margin of the blank 1. The first corner gap 51 is further defined by edges 73, 75 of the flaps 33, 35 that extend inward from respective edges 61, 63 of the corner tabs 57 59. The second corner gap 53 is further defined by edges 77, 79 of flaps 35, 37 that extend inward from respective edges 69, 71 of the corner tabs 65, 67.

[0029] In one embodiment the corner tab 59 has a length Dl that is less than a length

D2 of the corner tab 65 at an opposite longitudinal end of the side panel 35. Further,

the corner tab 67 is shaped to have the same length D2 as the corner tab 65 defining the corner gap 53. In on embodiment, the length D2 is at least approximately 1.25 times the length Dl, but the blank could be otherwise configured without departing from the disclosure.

[0030] As shown in Fig 4., the container 2 is formed from the blank 1 such that the side panels 33, 35, 37, 39 extend upwardly from the base panel 31 to define a cavity 85 for receiving a food product (not shown). Each of the strips 17, 19, 21, 23 of the injection-molded structure 5 fill a respective corner gap 51, 53 between respective side panels 33, 35, 37, 39. As shown in Fig. 5 for one of the side panels 33, the flange 8 of the container 2 comprises a lower flange portion 87 extending upwardly from an upper edge 89 of the side panel, an intermediate portion 91 extending upwardly from the lower flange portion, and an upper flange portion 93 that extends outwardly from the intermediate portion. In the illustrated embodiment, the flange 8 in the other side panels 35, 37, 39 is shaped substantially the same as shown in the partial cross-section of Fig. 5, however, the flange could be otherwise shaped, arranged, and/or configured.

[0031] As shown in Fig. 5, the flange 8 comprises the band 7 of the injection-molded structure 5 that overlays the upper flange portion 93 and the lower flange portion 87. The band 7 comprises an inner portion 95 that overlays the lower flange portion 87 and is adjacent the upper edge 89 of the side panel and the intermediate portion 91. The band 7 comprises an outer portion 97 that extends from the inner portion 95 and overlays the upper flange portion 93. In the illustrated embodiment, the outer portion 97 is an elongate portion that extends beyond an outer radial edge 99 of the upper flange portion 93. In one embodiment, the inner portion 95 of the band 7 is of greater cross-sectional area than the elongated outer portion 97 of the band. The band 7 comprises a flat upper surface that is substantially continuous between the inner portion 95 and the outer portion 97 of the band.

[0032] As shown in Fig. 6, the overlapped corner tabs 65, 67 form a retention portion

103 at the corner 11 of the container 2. The retention portion 103 comprises the upper flange portion 93 of the flange 8 that extends outward at the corners 9, 11, 13, 15 of the

container 2 so that the amount of the outer portion 97 of the band 7 that extends beyond the edge 99 of the upper flange portion is reduced in the corners of the container 2. The retention portion 103 facilitates formation of the band 7 at the corners 9, 11, 13, 15 of the container 2 and increases the rigidity of the container at the corners.

[0033] As shown in Fig. 7, the strip 19 that extends down from the band 7 at the corner 11 has a first upper corner 107 and a second upper corner 109. The first upper corner 107 has a larger radius of curvature than the second upper corner 109. Similarly, the strip 21 at the corner 13 is similarly shaped as the strip 19. As discussed below, the larger radius of curvature of the first upper corner 107 facilitates the flow of injection molded material that forms the strip 19. In the illustrated embodiment, the strips 17, 23 of the corners 9, 15 of the container 2 have first upper corners 108 and second upper corners 119 that are similarly shaped to the second upper corner 109 of the strips 19, 21.

[0034] As shown in Figs. 8 and 9 the injection-molded structure 5 (Fig. 9) has been separated from the blank 1 (Fig. 8). As shown in Fig. 8, the edge margin of the side panels 33, 35, 37, 39 have the shape of the flange 8 of the container. Each of the corner tabs 57, 59 and the corner tabs 65, 67 have been separated to expand the corner gaps 51, 53. A depression 111 is defined by a marginal fold line 113 that is spaced inward from the edge of the blank 1. The marginal fold line 113 corresponds to an innermost edge 114 of the injection-molded frame 5 in the container 2. At each of the corner gaps 53, the marginal fold line 113 has a first upper corner 115 and a second upper corner 117 respectively corresponding to the first upper corner 107 and the second upper corner 109 at each of the strips 19, 21 of the injection-molded structure at respective corner 11, 13 of the container 2. At each of the corner gaps 51, the marginal fold line 113 has a first upper corner 115 and a second upper corner respectively corresponding to the first upper corner 108 and the second upper corner 110 of the strips 17, 23. At each of the corner gaps 51, 53, the first upper corner 115 of the marginal fold line 113 has a larger radius of curvature than the second upper corner 117 of the marginal fold line. The marginal fold line 113, the blank 1, and/or the injection-molded structure 5 could be otherwise shaped, arranged, and/or configured.

[0035] Fig. 10 illustrates one embodiment of a forming tool 151 for forming the container 2. The forming tool 151 comprises a cavity 153 and a core 155 that are operable to form the blank 1 into the shape of the container 2. Further, the forming tool 151 includes an injection cavity 157 for injecting injection-molding material (e.g., resin) around the perimeter of the blank 1 to form the injection-molded structure 5 of the container 2. The container 2 could be otherwise formed from tools other than forming tool 151 without departing from this disclosure.

[0036] In the illustrated embodiment, the cavity 153 has a base portion 159 and an articulated portion 161 that is moveably connected to the base portion. The core 155 has a base portion 163 and an articulated portion 165 that is moveably connected to the base portion of the core. Springs 167, 169 are connected to respective articulate portions 161, 165. The core 155 is operable to enter the cavity 153 when the tool 151 is closed to press form a blank 1 into the shape of the cavity.

[0037] As shown in Figs. 12-14, the cavity 153 includes four side walls 171, 173,

175, 177 corresponding to the shape of the side walls 33, 35, 37, 39 of the container 2. The cavity 153 includes a flange wall 181 extending generally perpendicular to the side walls 171, 173, 175, 177 and extending around the perimeter of the cavity 153. The flange wall 181 is shaped to form the flange 8 of the container 2 that includes the shape of the flange portions 41, 43, 45, 47 of the side panels 33, 35, 37, 39. The cavity 153 has corners 183, 185, 187, 189 that are shaped to from the corners 9, 11, 13, 15 of the container.

[0038] When the core 155 and the cavity 153 are closed, the injection cavity 157 is formed. As shown in Fig. 1 IA, the injection cavity includes an advanced-flow section 191 adjacent the side walls 171, 173, 175, 177 for forming the inner portion 95 of the band 7 of the injection-molded structure 5. A delayed-flow section 193 is located laterally outward from the advanced flow section 191 and extends laterally outward from the flange wall 181. The delayed flow region 193 forms the outer portion 97 of the band 7 of the injection-molded structure 5. The advanced-flow section 191 has a greater cross-sectional area than the delayed-flow section 193 so the injection-molding

material (e.g., resin) flows around the perimeter of the cavity 153 at a higher flow rate than the injection-molding material in the delayed-flow region. The higher flow rate of injection-molding material in the advanced-flow region 191 presses the lower flange 87 and the upper flange 93 tight against the flange wall 181 of the cavity 153 to prevent injection-molding material from flowing between the lower flange and/or the upper flange and the flange wall of the cavity.

[0039] In one embodiment, the advanced-flow section 191 of the injection cavity 157 includes corner regions 195, 197, 199, 201 in each of the corners 183, 185, 187 of the cavity 153. The corner regions 195, 197, 199, 201 are shaped to form the strips 17, 19, 21, 23 of the injection-molded structure 5. Injection-molded material is introduced to the injection cavity 157 at an injection port 205 or gate valve located below the flange wall at one end of the cavity 153 adjacent the side wall 171. In the illustrated embodiment, the injection port 205 is located on the longitudinal centerline LC of the cavity 153 but the injection port could be otherwise located. The injection port 205 forms a imperfection 207 on the injections molded structure 5.

[0040] As shown in Figs. 4 and 7, when injection-molding material is introduced through the injection port 205 it flows in the direction of arrows Al, A2 around the perimeter of the container 2. The arrows Al are longer than the arrows A2 to indicate the general location of the advanced-flow section 191 where injection-molding material flows at a higher flow rate than the injection-molding material in the delayed- flow section 193. The flow of injection-molding material in the advanced-flow region 191 forms a flow front 215 (illustrated schematically in Fig. 7) of injection-molding material that is in front of a flow front 217 (illustrated schematically in Fig. 7) of the injection-molding material in the delayed-flow region 193.

[0041] As shown in Figs. 12 and 13, the corners 185, 187 of the cavity 153 that are farthest away from the injection portion 205 include cutouts 211 that form the first upper corners 107 of the strips 19, 21. The cutouts 211 facilitate flow of the injection- molding material in the advanced-flow sections 191 at the corners 185, 187. As shown in Fig. 7, the cutouts 211 allow flow in the direction of arrow Al in the advanced-flow

section 193 to form the strips 19, 21 at each corner 11, 13 of the container. The cutouts 211 allow the flow front 215 of the injection-molding material in the advanced-flow section 191 to stay in front of the flow front 217 of the injection-molding material in the delayed-flow section 193 of the injection cavity 157.

[0042] The container 2 and injection-molded structure 5 may have similar characteristics as the container and injection-molded structure described in co-assigned U.S. Patent Application No. 11/715,718 filed March 8, 2007 ("the '718 application"), the entire contents of which is incorporated by reference herein for all purposes. Further, the container 2 and injection-molded structure 5 may be formed by similar methods, tools, apparatus, etc. as disclosed in the '718 application. The container 2 and the injection-molded structure 5 can be formed from similar materials as disclosed in the '718 application. The injection-molded structure 5 is typically constructed of polymeric material; however, the structure can also be constructed of other types of materials.

[0043] The container 2 and blank 1 can be formed from a laminate that includes more than one layer, but alternatively the laminate can be replaced with a single ply of material, such as, but not limited to, paperboard, cardboard, paper or a polymeric sheet. In accordance with the exemplary embodiments of the present disclosure, the laminate can includes a polymer film that is supported by, and secured to, a substrate that can be in the form of cardboard, paperboard or any other suitable material. Alternatively, the paperboard and polymer film can be replaced with any other suitable materials, for example such that the substrate of the present disclosure is not limited to paperboard or the like. Nonetheless and in accordance with the exemplary embodiments, the substrate typically is a clay-coated paperboard. As should be apparent, the paperboard can be more generally characterized as a substrate, and a suitable substrate can include paperboard with or without typical supplemental materials, such as coatings that can include clay coatings, colorants, indicia and the like. Further, the container 2 can include other materials, laminates, substrates, etc. such as the materials disclosed in the '718 application, the entire contents of which is incorporated by reference herein for all purposes. The container 2 can include microwave energy interactive material such as

the microwave interactive material described in the '718 application. The container 2 may include other microwave energy interactive materials or other materials without departing from the disclosure.

[0044] In accordance with the exemplary embodiments of the present disclosure, the blanks can be formed from paperboard, corrugated cardboard or other materials having properties suitable for at least generally enabling respective functionalities described above. Paperboard is typically of a caliper such that it is heavier and more rigid than ordinary paper, and corrugated cardboard is typically of a caliper such that it is heavier and more rigid than paperboard. Typically, at least the side of the paperboard or cardboard that will be an exterior surface in the carton erected therefrom will be coated with a clay coating, or the like. The clay coating can be printed over with product, advertising, price-coding, and other information or images. The blanks may then be coated with a varnish to protect any information printed on the blanks. The blanks may also be coated with, for example, a moisture barrier layer, on one or both sides. The blanks can also be laminated to or coated with one or more sheet-like materials.

[0045] The foregoing description of the disclosure illustrates and describes various embodiments of the present disclosure. As various changes could be made in the above construction without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Furthermore, the scope of the present disclosure covers various modifications, combinations, and alterations, etc., of the above-described embodiments. Additionally, the disclosure shows and describes only selected embodiments of the disclosure, but the disclosure is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art. Furthermore, certain features and characteristics of each embodiment may be selectively interchanged and applied to other illustrated and non- illustrated embodiments of the disclosure without departing from the scope of the disclosure.