HK1192424A - Insulated sleeve for a cup - Google Patents

Abstract

A container includes a cup formed to include and interior region and an insulated sleeve. The insulated sleeve is coupled to an outer surface of the cup.

Description

Insulating sleeve for cup

Priority

This application is in accordance with 35u.s.c. § 119(e) priority of united states provisional application serial No. 61/498,415 filed 2011, 6, 17 and serial No. 61/618,637 filed 2012, 3, 30, which are expressly incorporated herein by reference.

Background

The present disclosure relates to containers, such as cups, and in particular to thermoformed containers. More particularly, the present disclosure relates to an insulative sleeve for a cup.

SUMMARY

A vessel according to the present disclosure is configured to contain a product in an interior region formed in the container. In an exemplary embodiment, the container is a cup.

In an exemplary embodiment, the insulated container comprises a cup and an insulated sleeve. The insulative sleeve is coupled to the outer surface of the cup to insulate a customer holding the cup from hot or cold temperatures associated with the substance or beverage stored in the cup.

In an exemplary embodiment, the insulative sleeve is made from a sheet comprising an insulative cellular non-aromatic polymeric material. In some embodiments of the present disclosure, the sheet comprises a strip of insulative cellular non-aromatic polymeric material and a skin coupled to the strip and configured to display a artwork and a body. In other embodiments of the present disclosure, the body and artwork are printed directly on the outer surface of the insulating cellular non-aromatic polymeric material strip. In an exemplary embodiment, the bottom panel also comprises an insulative cellular non-aromatic polymeric material.

In illustrative embodiments, the insulative sleeve is arranged to surround and enclose the outer surface of a hot beverage cup to provide a graspable, low temperature thermal barrier that can be grasped by a consumer. The sleeve includes a sheet comprising an insulative cellular non-aromatic polymeric material configured to provide means for enabling localized plastic deformation in the sheet to provide a plastically deformed first material segment having a first density in a first portion of the sheet and a second material segment having a second density lower than the first density in an adjacent second portion of the sheet without rupturing the insulative cellular non-aromatic polymeric material to maintain predetermined insulative characteristics in the sheet.

The insulative cellular non-aromatic polymeric material included in the insulative sleeve is configured in accordance with the present disclosure to provide means for enabling localized plastic deformation in the insulative sleeve to provide (1) a plastically deformed first material segment having a first density in a first portion of the insulative sleeve and (2) a relatively lower second material segment having a second density in an adjacent second portion of the insulative sleeve. In an exemplary embodiment, the more dense first section of material is thinner than the second section of material.

Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of the exemplary embodiments exemplifying the best mode for carrying out the disclosure as presently perceived.

Brief description of the drawings

The detailed description refers specifically to the accompanying drawings, in which:

FIG. 1 is a perspective view of a first embodiment of an insulated container according to the present disclosure, showing that the insulated container comprises: a cup comprising a rolled edge and a base, the base comprising a sleeve-shaped sidewall and a floor; and an insulative sleeve coupled to the outer surface of the sidewall to extend around the sidewall of the cup;

FIG. 2 is a partial cross-sectional view taken along line 8-8 of FIG. 6, showing an upper portion of another embodiment of the insulative sleeve coupled to the sidewall and shown in greater detail in FIGS. 6-8;

FIG. 3 is a cross-sectional view taken along line 3-3 of FIG. 1, showing the insulative sleeve coupled to the sidewall included in the base of the cup and positioned between and in spaced relation to each of the brim curl and the floor;

FIG. 3A is an enlarged cross-sectional view of a portion of the sidewall and a portion of the insulative sleeve included in the body of the insulative cup of FIG. 3, and shows that the sidewall is made of a sheet comprising, from left to right: a skin layer comprising a film, an ink layer, and an adhesive layer; and a strip of an insulative cellular non-aromatic polymeric material;

FIG. 3B is a cross-sectional view taken along line 3B-3B of FIG. 1, showing the insulative sleeve being formed of insulative cellular non-aromatic polymeric material that has undergone plastic deformation in localized areas along the overlapping first and second upstanding tabs included in the sleeve to provide a bridge having a reduced thickness that is similar to the thickness of the remainder of the insulative sleeve;

FIG. 4 is a diagrammatic perspective view of a sleeve forming process according to the present disclosure, showing the sleeve forming process including the steps of: loading the laminate roll to provide a sheet comprising an insulative cellular non-aromatic polymeric material; plastically deforming the sheet to form a deformed sheet; cutting the deformed sheet to form a sleeve blank and a scrap; collecting waste materials; and stacking the sleeve blanks to form a stack of sleeve blanks; storing the stack of sleeve blanks for transport or storage; loading the sleeve blanks; heating the sleeve blank; winding the sleeve blank around a mandrel of a sleeve forming machine; forming the insulating sleeve by overlapping and joining the upstanding tabs included in the sleeve blank; stacking the insulative sleeves to form a stack of insulative sleeves; and storing the stack of insulative sleeves for subsequent use in the exemplary container forming process shown in fig. 5;

FIG. 5 is a simplified perspective view of the container forming process shown in FIG. 4, illustrating the container forming process including the steps of: loading a stack of cups into a container forming machine; loading a stack of insulative sleeves into the container forming machine; positioning the insulating sleeve over the cup; coupling the insulative sleeve to the cup to form an insulative container; and inspecting the insulated container for defects;

FIG. 6 is a perspective view of another embodiment of an insulated container according to the present disclosure, showing the insulated container including the cup and an insulating sleeve coupled to the sidewall of the cup and arranged to extend from the brim curl to the floor of the cup;

FIG. 7 is a partial cross-sectional view taken along line 8-8 of FIG. 6;

FIG. 8 is a partial cross-sectional view taken along line 8-8 of FIG. 6 showing the insulating sleeve extending between the curl and the bottom panel of the container and the insulating sleeve comprising: upstanding inner and outer tabs (visible on the right side of figure 8) arranged to overlap each other and form a bridge along the right side of the insulated container; and a fence extending around the sidewall and interconnecting the upright inner tab and the upright outer tab;

figure 8 ' is a dead section view (ignoring the side wall of the insulative cup) taken along line 8 ' -8 ' of figure 1 and shows that the insulative sleeve includes a C-rail, an upstanding outer tab coupled to one end of the C-rail, and an upstanding inner tab coupled to an opposite end of the C-rail, and shows that the first tab and the second tab are arranged to overlap one another to establish a bridge extending between the ends of the C-rail to define the interior region therebetween.

FIG. 8A is an enlarged, fragmentary view of a bridge according to the present disclosure, showing how the insulative cellular non-aromatic polymeric material is compressed in the first tab and the second tab to produce a bridge having a reduced thickness that is similar to the thickness of the sidewall in the C-shaped fence opposite the bridge;

FIG. 8B is an enlarged, fragmentary view of a portion of the C-shaped fence of FIG. 8A, showing the insulative cellular non-aromatic polymeric material not compressed;

FIG. 8C is an enlarged fragmentary view of the first tab and the second tab prior to mating with one another to establish the bridge;

FIG. 9 is a plan view of a sleeve blank used to form the sleeve of FIG. 6 during a sleeve forming process;

FIG. 10 is an exploded assembly view of the insulated container of FIG. 6, showing the insulated container including, from top to bottom: the cup comprising the rolled edge, a sleeve-shaped sidewall, and a floor; and the insulating sleeve having a height substantially equal to the height of the sleeve-shaped sidewall;

FIG. 11 is a perspective view of another embodiment of an insulative sleeve according to the present disclosure, showing that the insulative sleeve includes a series of generally horizontal ribs formed on an inner surface of the sleeve;

FIG. 12 is a plan view of a sleeve blank used to form the insulative sleeve of FIG. 11 during a sleeve forming process;

FIG. 13 is a cross-sectional view taken along line 13-13 of FIG. 12;

FIG. 14 is a perspective view of another embodiment of an insulative sleeve according to the present disclosure, showing that the insulative sleeve includes a series of generally vertical ribs formed on an inner surface of the sleeve;

FIG. 15 is a plan view of a sleeve blank used to form the insulative sleeve of FIG. 14 during a sleeve forming process;

FIG. 16 is a cross-sectional view taken along arc 16-16 of FIG. 15;

FIG. 17 is a perspective view of another embodiment of an insulative sleeve according to the present disclosure, showing that the insulative sleeve includes a series of ribs formed on the inner surface of the sleeve and arranged to slope downwardly in a spiral fashion;

FIG. 18 is a plan view of a sleeve blank used to form the insulative sleeve of FIG. 17 during a sleeve forming process;

FIG. 19 is a cross-sectional view taken along line 19-19 of FIG. 18;

FIG. 20 is a perspective view of another embodiment of an insulative sleeve according to the present disclosure, showing that the insulative sleeve includes a series of nubs (nub) formed on an inner surface of the insulative sleeve;

FIG. 21 is a plan view of a sleeve blank used to form the insulative sleeve of FIG. 20 during a sleeve forming process;

FIG. 22 is a cross-sectional view taken along line 22-22 of FIG. 20;

FIG. 23 is a perspective view of another embodiment of an insulative sleeve according to the present disclosure, showing that the insulative sleeve includes a plurality of raised ribs formed in the sleeve, the ribs being created by displacing portions of the sleeve;

FIG. 24 is a plan view of a sleeve blank used to form the insulative sleeve of FIG. 23 during a sleeve forming process;

FIG. 25 is a cross-sectional view taken along line 25-25 of FIG. 23;

FIG. 26 is an enlarged portion of FIG. 25, showing the material in the sleeve having been displaced to form the raised ribs;

FIG. 27 is a perspective view of another embodiment of an insulative sleeve according to the present disclosure, showing the insulative sleeve including a sleeve wall and a sleeve floor coupled to the sleeve wall to define a cup-receiving space therebetween;

FIG. 28 is a plan view of a sleeve blank used to form the insulative sleeve of FIG. 27 during a sleeve forming process;

FIG. 29 is a perspective view of another embodiment of an insulative sleeve according to the present disclosure, showing the insulative sleeve including a sleeve wall and a sleeve floor coupled to the sleeve wall to define a cup-receiving space therebetween;

FIG. 30 is a plan view of a sleeve wall blank used to form a sleeve wall during a sleeve forming process;

FIG. 31 is a plan view of a sleeve floor blank used to form a sleeve floor during the sleeve forming process, the sleeve floor being coupled to the sleeve wall to form the insulative sleeve;

FIG. 32 is a perspective view of another embodiment of an insulative sleeve according to the present disclosure, showing the insulative sleeve comprising: a sleeve wall having a first bridge on a left side of the insulating sleeve and a second bridge opposite the first bridge on a right side of the insulating sleeve; and a sleeve floor coupled to the sleeve wall to define a cup-receiving space therebetween;

FIG. 33 is a plan view of a sleeve blank used to form the insulative sleeve of FIG. 27 during the sleeve forming process, showing the sleeve blank from left to right including a first wall panel, a sleeve bottom panel, and a second wall panel;

FIG. 34 is a perspective view of another embodiment of an insulated container according to the present disclosure, showing the insulated container including a cup and an insulated sleeve including a rail having a rail thickness and a bridge having a bridge thickness that is about twice the rail thickness;

FIG. 35 is a cross-sectional view taken along line 35-35 of FIG. 34;

36-40 are a series of views illustrating another embodiment of an insulative sleeve according to the present disclosure and illustrating assembly of the insulative sleeve in the field;

FIG. 36 is a perspective view of another embodiment of an insulative sleeve according to the present disclosure, shown in a disassembled state, including: a sleeve wall having a first panel and a second panel, the first panel and the second panel being connected together along a fold line by a connecting web; and a sleeve wall retainer comprising an upstanding tab, a layer of adhesive applied to the upstanding tab, and a release liner coupled to the layer of adhesive;

FIGS. 37-40 are a series of views illustrating an exemplary method of applying the insulative sleeve of FIG. 36 to a cup in the field;

FIG. 37 is a perspective view showing the cup and the insulative sleeve of FIG. 36 in a disassembled state;

fig. 38 is a view similar to fig. 37, with the second panel of the sleeve wall folded back along the connecting web back toward the first panel of the sleeve wall to expose the sleeve wall retainer, and showing the release liner peeled away from the adhesive layer to expose the adhesive layer;

fig. 39 is a view similar to fig. 38, showing the release liner removed from the adhesive layer and showing the sleeve wall retainer arranged to overlap the distal end of the second panel, as shown in fig. 40; and is

Fig. 40 is a view similar to fig. 39, showing the sleeve wall retainer having been arranged to overlap the distal end of the second panel to establish the insulative sleeve, forming a cup-receiving space therebetween.

Detailed Description

An insulated container 110 according to a first embodiment of the present disclosure is shown, for example, in fig. 1-3. As an example, as shown in fig. 1-3, the insulated container 110 includes a cup 11 and a first embodiment of an insulating sleeve 113. A container forming process 46, 47 for making the insulated container 110 is illustrated in fig. 4 and 5. Another embodiment of an insulated container 210 according to the present disclosure is illustrated in fig. 6-10. Other embodiments 313, 413, 513, 613, 713, 813, 913, 1013, 1113, 1213, and 1313 of insulative sleeves according to the present disclosure are shown in fig. 11-36.

As shown in fig. 1,3 and 4, the insulated container 110 according to the present disclosure includes a cup 11 and an insulating sleeve 113. For example, as shown in fig. 1, cup 11 includes a body 12 shaped to include an interior region 14 and a brim curl 16 coupled to body 12. The body 12 includes sidewalls 18 and a floor 20 coupled to the sidewalls 18 to define the interior region 14 therebetween. In one illustrative example, cup 11 may be formed from polypropylene using a thermoforming process.

The insulative sleeve 113 illustratively comprises a strip 82 of insulative cellular non-aromatic polymeric material. The insulative strip of cellular non-aromatic polymeric material 82 is configured to provide a means for insulating beverages, desserts, or other substances placed in the interior region 14 of the cup 11 while providing resistance to deformation and puncture and for providing an outer surface suitable for printing graphics and other information thereon.

As shown in fig. 1 and 3, the insulative sleeve 113 includes a region 101 having localized plastic deformation that provides a section of the insulative sleeve 113 that exhibits a higher material density than adjacent sections of the insulative sleeve 113 according to the present disclosure. As an example, the insulative sleeve 113 is made using the exemplary sleeve forming method 46 shown in FIG. 4. As shown in fig. 5, the insulated container 110 is formed from a sleeve blank 300 using an exemplary container forming process 47. A strip 82 of insulative cellular non-aromatic polymeric material used to form the insulative sleeve 113 is shown in fig. 3A and 3B.

As shown in fig. 8', insulating sleeve 113 includes upright inner tab 114, upright outer tab 112, and upright rail 111 extending between inner and outer tabs 114, 112. The upstanding inner tab 114 is configured to provide a first section of material having a higher first density in the region 101 of the sleeve 113. As shown in fig. 8', the upstanding outer tab 112 is arranged to mate with the upstanding inner tab 114 along the interface I therebetween. An upright fence 111 is arranged to interconnect the upright inner and outer tabs 114, 112 and to surround the inner region 14. As shown in fig. 8', upright fence 111 is configured to provide a second section of material having a lower second density in this region 101 of insulating sleeve 113, and cooperates with upright inner and outer tabs 114, 112 to form insulating sleeve 113. As shown in fig. 8', the region 101 of the insulating sleeve 113 that is capable of local plastic deformation by the insulating cellular non-aromatic polymeric material is where the upstanding inner and outer tabs 114, 112 overlap along interface I.

As shown in fig. 8', the upright fence 111 of the insulating sleeve 113 is C-shaped in horizontal cross-section, and the upright inner and outer tabs 114, 112 each have an arcuate shape in horizontal cross-section. The upright fence 111 includes an upright left side edge 111L and an upright right side edge 111R arranged in spaced, face-to-face relationship with the upright left side edge 111L. The upright outer tabs 112 are configured to have the higher first density and mate with upright inner tabs 114 also characterized by the higher first density to establish bridges 112, 114 arranged to interconnect upright left and right side edges 111L, 111R of the upright fence 111. The bridges 112, 114 are formed of plastically deformed material having the higher first density.

For example, as shown in fig. 1, upright fence 111 of insulated sleeve 113 has a sleeve height H1. Cup 11 has a cup height D1. As shown in fig. 1, the sleeve height H1 is less than the cup height D1.

In the exemplary embodiment shown in fig. 8', 8A and 8C, the insulating sleeve 113 includes a pair of tabs 114, 112 that mate to provide the insulating sleeve 113 with a frustoconical shape. As shown in fig. 8' and 8C, the upstanding inner tab 114 includes an inner surface 114i that defines a portion of the interior region 14 and an outer surface 114o that faces the upstanding outer tab 112. The upstanding outer tab 112 includes an inner surface 112I that faces the interior region 14 and mates with an outer surface 114o of the upstanding inner tab 114 to define the interface I between the upstanding inner and outer tabs 114, 112. The upright outer tab 112 further includes an outer surface 112o facing away from the upright inner tab 114. As shown in fig. 8C, each of the inner and outer surfaces of the upstanding inner and outer tabs 114, 112 has an arcuate shape in horizontal cross-section and subtends an acute angle of less than 20 ° as shown in fig. 8'.

As shown in fig. 8', the upright fence 111 is C-shaped in horizontal cross-section, and each of the upright inner and outer tabs 114, 112 has an arcuate shape in horizontal cross-section. In fig. 8C, the upright fence 111 includes an upright left side edge 111L and an upright right side edge 111R arranged in spaced, face-to-face relationship with the upright left side edge 111L. The upright outer tab 112 is configured to have the higher first density and mate with an upright inner tab 114 also characterized by the higher first density to establish a bridge 112, 114 arranged to interconnect upright left and right side edges 111L, 111R of the upright fence 111. The bridges 112, 114 are formed of a plastically deformed material having the higher first density.

As shown in fig. 8', for example, the upright fence 111 has an inner surface 111i that defines a portion of the interior region 14 and an outer surface 111o that faces away from the interior region 14 and surrounds the inner surface 111i of the upright fence 113. Outer surface 111o cooperates with inner surface 111i of upright fence 113 to define a first thickness T1 therebetween. The upstanding inner tab 114 includes an inner surface 114i that defines a portion of the interior region 14 and an outer surface 114o that faces the upstanding outer tab 112. The upstanding outer tab 112 includes an inner surface 112I that faces the interior region 14 and mates with an outer surface 114o of the upstanding inner tab 114 to define the interface I between the upstanding inner and outer tabs 114, 112. The upright outer tab 112 further includes an outer surface 112o facing away from the upright inner tab 114. The inner and outer surfaces of the upstanding inner tab 114 cooperate to define a second thickness T2I therebetween that is less than the first thickness T1. The inner and outer surfaces of the upstanding outer tab 112 cooperate to define a third thickness T2O that is less than the first thickness T1.

The insulating sleeve 113 is made from a strip 82 of insulating cellular non-aromatic polymeric material. The insulative cellular non-aromatic polymeric material includes, for example, a polypropylene base resin having a high melt strength, one or both of a polypropylene copolymer and homopolymer resin, and one or more voiding agents. As one example, the pore former may include primary nucleating agents, secondary nucleating agents, and blowing agents defined by gas means (means) for expanding and reducing the density of these resins. In one example, the gas device includes carbon dioxide. In another example, the base resin includes a broadly distributed molecular weight polypropylene characterized by a unimodal rather than bimodal distribution. Reference is hereby made to the disclosure of such AN INSULATIVE cellular non-aromatic POLYMERIC MATERIAL in U.S. application No. 13/491,327 filed on 7/6/2012 and entitled POLYMERIC MATERIAL FOR INSULATIVE CONTAINERs, which is hereby incorporated herein in its entirety.

As shown in fig. 12-26, an insulative sleeve according to the present disclosure may optionally include ribs or rib sections, rings, bumps, nubs or other protrusions, or vertical, horizontal, spiral or other configurations of grooves, slots, channels, recesses, etc., on the inner surface of the sleeve to form an air gap between the sidewall 18 of the cup 11 and the insulative sleeve. This air gap forms an insulating barrier to minimize heat transfer from the hot beverage to the user's hand through cup 11 and/or the insulative sleeve (and, in turn, from the user's hand to the beverage through insulative sleeve 113 and sidewall 18). As shown in fig. 4 and 5, an insulated container 110 is formed in exemplary container forming processes 46, 47.

As shown in fig. 2 and 3, the insulative sleeve 113 is formed during the sleeve forming process 46. The upright fence 111 has a first thickness T1 and the first and second upright tabs 114, 112 each have a second thickness 11T 2. As shown in FIG. 1, the second thickness T2 is approximately half the first thickness T1. Thus, the bridges 114, 112 formed by overlapping and coupling the upstanding tabs 114, 112 have a third thickness T3 that is substantially equal to the first thickness T1. In an exemplary embodiment, the insulative sleeve 113 may be formed in a forming apparatus and coupled to the cup 11. The insulative sleeve 113 may be manufactured, stored, shipped and/or sold separately along with a self-locking die-cut feature. The self-locking feature may have different shapes to promote retention.

The insulating sleeve 113 is made using a sleeve forming process 46 such as that shown in fig. 4. As shown in fig. 4, the sleeve forming method 46 includes a lap-roll loading step 461A, a compression step 462A, a cutting step 463A, a sleeve blank stacking step 464A, a sleeve blank storing step 465A, a sleeve blank loading step 461B, a sleeve blank heating step 462B, a sleeve blank winding step 463B, a sleeve forming step 464B, a sleeve stacking step 465B, and a sleeve stack storing step 466B.

Stack roll loading step 461A loads stack roll 86 onto a cutting machine, such as a die cutter or a metal-to-metal stamping machine. Therefore, the laminated sheet 80 is drawn into the cutter for processing. The compressing step 462A compresses portions of the laminated sheet 80 to form a compressed sheet. The cutting step 463A cuts the compressed sheet so that the sleeve blank 300 is cut from the blank-carrying sheet 94. As one example, cutting step 463A may be combined with compression step 462A such that these steps are typically performed simultaneously on the same piece of equipment. The stack sleeve blank step 464A stacks the sleeve blanks 300 into a stack of sleeve blanks 95. The store sleeve blank step 465A stores the stack of sleeve blanks 95 until ready for use in the load sleeve blank step 461B. A load sleeve blank step 461B loads the stack of sleeve blanks 95 for processing by the sleeve forming machine. The heat sleeve blank step 462B applies heat 102 to the sleeve blank 300. The wind sleeve blank step 463B winds the heated sleeve blank 300 around a mandrel included in the sleeve forming machine. The form sleeve step 464B forms the bridges 112, 114 by overlapping and compressing the upstanding tabs 112, 114 with the primary and secondary clips included in the sleeve forming machine. The stack sleeve step 465B stacks the sleeve 113 into the sleeve stack 97. The store sleeve stack step 466B stores the sleeve stack 97 for use in a subsequent container forming process 47.

The insulated container 110 is made using a container forming process 47 as shown in fig. 5. As shown in fig. 5, the container forming method 47 includes a load cup step 471, a load sleeve step 472, a position sleeve on cup step 473, a sleeve coupling step 474, and an inspection step 475. A load container step 471 loads the container stack 124 onto a container forming machine. The load sleeve step 472 loads the sleeve stack 97 onto the container forming machine. The position sleeve on cup step 473 positions sleeve 113 on cup 11. The sleeve coupling step 474 couples the sleeve 113 to the cup 11 using, for example, heat to create the insulated container 110. However, the sleeve 113 may be coupled by adhesive, friction fit, or any other suitable alternative. As shown in fig. 5, inspection step 475 inspects insulated container 110 for defects and then passes the good containers to container packaging stage 48.

As shown in fig. 3A, the heat insulating sleeve 113 is made of the sheet 80. The sheet 80 comprises a skin 81 and a strip of insulating porous polymeric material 82. As shown in fig. 3A, the skin layer 81 includes, for example, a film layer 811, an ink layer 812, and an adhesive layer 810. The adhesive layer 810 is used, for example, to laminate the skin layer 81 to the strip 82 so as to sandwich the ink layer 812 between the film layer 811 and the adhesive layer 810.

In another exemplary embodiment of the sleeve forming method, the sleeve forming method 46 is modified by not laminating the skin 81 to the insulating cellular non-aromatic polymeric material strip 82. Thus, the skin is omitted entirely and printing can be performed directly on the insulating cellular non-aromatic polymeric material strip 82.

As shown in fig. 3, sidewall 18 of cup 11 extends between brim curl 16 and floor 20. Sidewall 18 includes a top 22 of body 12 coupled to bead 16, and a bottom 24 arranged to interconnect floor 20 and top 22. The top portion 22 is arranged to extend in a downward direction towards the floor 20 and is coupled to a bottom portion 24 arranged to extend in an opposite upward direction towards the bead 16. The crown 22 cooperates with the bead 16 to form a mouth 32, shown in fig. 1, that is arranged to open into the interior region 14.

The insulative sleeve 113 is arranged to surround and encase the outer surface of the hot beverage mug 11 to provide a graspable low temperature thermal barrier that can be grasped by a consumer. The insulative sleeve 113 comprises a sheet 80 comprising insulative cellular non-aromatic polymeric material configured to provide means for enabling localized plastic deformation in the sheet 80 to provide a plastically deformed first material section having a first density in a first portion of the sheet 80 and a second material section having a second density lower than the first density in an adjacent second portion of the sheet 80 without rupturing the insulative cellular non-aromatic polymeric material to maintain a predetermined insulative characteristic in the sheet 80.

As shown in fig. 1 and 3, the lamellae 80 are arranged around a vertical central axis 113A. The sheet 80 includes an upstanding inner tab 114 arranged to extend upwardly along and in spaced relation to the vertical central axis 113A and configured to provide the first section of material having the first density. The sheet 80 further comprises: an upright outer tab 112 arranged to extend upwardly along a vertical central axis 113A and in spaced relation thereto and to mate with an upright inner tab 114 along an interface I therebetween; and an upright fence 111 arranged to interconnect the upright inner and outer tabs 114, 112 and about a vertical central axis 113A, and configured to provide the second section of material having the second density and to cooperate with the upright inner and outer tabs 114, 112 to form the sleeve-shaped sidewall 18. As shown in fig. 1 and 3, the rail 111 has a substantially frustoconical shape. Each of the upstanding inner and outer tabs 114, 112 has an arcuate shape.

As shown in fig. 8' and 8C, upstanding inner tab 114 includes an inner surface that provides a means of mating with hot beverage cup 11 and an outer surface that faces upstanding outer tab 112. The upstanding outer tab 112 includes an inner surface that mates with the outer surface of the upstanding inner tab 114 to define the interface I between the upstanding inner and outer tabs 114, 112. The upright outer tab 112 further includes an outer surface facing away from the upright inner tab 114. Each of the inner and outer surfaces of the upstanding inner and outer tabs 114, 112 has an arcuate shape in horizontal cross-section and subtends an acute angle of less than 20 °. The upright fence 111 is C-shaped in horizontal cross section. Each of the upstanding inner and outer tabs 114, 112 has an arcuate shape in horizontal cross-section.

The upright fence 111 includes an upright left side edge 111L and an upright right side edge 111R arranged in spaced, face-to-face relationship with the upright left side edge 111L. The upright outer tab 112 is configured to have the first density and mate with the upright inner tab to establish a bridge arranged to interconnect the upright left and right side edges 111L, 111R of the upright fence and formed of plastically deformed material having the first density.

Upright fence 111 has an inner surface facing vertical central axis 113A and providing a means for mating with hot beverage cup 11. The upright fence 111 also has an outer surface facing away from the central vertical axis 113A of the interior region 14 and surrounding an inner surface of the upright fence 111 and cooperating with the inner surface of the upright fence 111 to define a first thickness therebetween.

Upright inner tab 114 includes an inner surface facing vertical central axis 113A and providing a means for mating with hot beverage cup 11, and an outer surface facing upright outer tab 112. The upright outer tab 112 includes an inner surface facing the vertical central axis 113A and mating with an outer surface of the upright inner tab 114 to define an interface I between the upright inner and outer tabs 114, 112.

The upright outer tab 112 further includes an outer surface facing away from the upright inner tab 114. As shown in fig. 8', the inner and outer surfaces of the upstanding inner tab 114 cooperate to define a second thickness therebetween that is approximately half the first thickness. As shown in fig. 8', the inner and outer surfaces of the upstanding outer tab 112 cooperate to define a third thickness that is approximately one-half of the first thickness.

Another embodiment of an insulated container 210 according to the present disclosure is shown in fig. 6-10. As shown in fig. 6, the heat insulating container 210 includes a cup 11 and a heat insulating sleeve 213. As shown in fig. 6, the insulative sleeve 213 is similar to sleeve 113, but the insulative sleeve 213 has a sleeve height H1 that is approximately equal to the cup height D1.

As one example, such as shown in fig. 4, the insulative sleeve 213 is formed during the sleeve forming method 46 using a sleeve blank 300. The blank 300 includes a first side 302 and an opposing second side (not shown). The blank 300 has a first arcuate edge 306 that conforms to a radius 308 centered on an axis 310. A second arcuate edge 312 that conforms to a radius 314 centered on the axis 310. The first linear edge 316 coincides with a first ray emanating from the axis 310 and the second linear edge 318 coincides with a second ray emanating from the axis 310. As shown in fig. 6, the insulative sleeve 113 defines a frustoconical surface 320 when the blank 300 is wound such that the first linear edge 316 is in overlapping juxtaposition with the second linear edge 318. The overlapping linear edges 316 and 318 can be secured in any of a variety of ways, including by heating the edges 316 and 318 to bond the mechanical connection formed by the insulative cellular non-aromatic polymeric material. These edges 316 and 318 may be treated with an adhesive to secure these edges 316 and 318 to each other.

As shown in fig. 11-13, in yet another embodiment of an insulative sleeve 313 formed from a sleeve blank 322, the insulative sleeve 313 includes a plurality of generally horizontal ribs 328 on an inner surface 326 of the assembled insulative sleeve 313. As shown in fig. 13, the sleeve blank 322 is formed to have a first thickness 322T1, and in the step of compressing the sheet of material of a sleeve forming method, a plurality of recesses 324 are formed by reducing the thickness to 322T 2. Upon completion of this sheet of compressed material step, blank 322 includes a plurality of locally plastically deformed regions forming depressions 324 having a thickness 322T2 and a plurality of ribs 328 having no deformation and having a thickness 322T 1. As shown diagrammatically in fig. 11, the recesses 324 cooperate with the ribs 328 to form an air gap 301 between the inner surface 326 of the insulative sleeve 313, the outer surface 102 of the cup 11, and a pair of adjacent ribs 328A, 328B.

The blank 322 is formed to have a first linear edge 330 and a second linear edge 334. The rib 328 is shaped to abut the second linear edge 334 at the first end and is spaced a distance 332 from the first linear edge 330 such that the first end of the rib 328 does not overlap the second end when the first linear edge 330 overlaps the second linear edge 334 during the step of winding the sleeve blank of the sleeve forming method. This allows a reduction in the amount of material that must be compressed during the step of winding the sleeve blank. The ribs 328 are positioned to engage an outer surface of a cup (such as cup 11) such that the inner surface 336 of the recess 324 is spaced from the outer surface of the cup to provide an air gap, while only the ribs 328 engage the outer surface of the cup. The air gap is insulated such that when a user grips the outer surface 338 of the insulating sleeve 313, heat transfer from the cup to the user's hand is impeded.

As shown in fig. 14-16, in yet another embodiment of the insulative sleeve 413 formed from the sleeve blank 422, the insulative sleeve 413 includes a plurality of vertical ribs 428 on an inner surface 426 of the assembled insulative sleeve 413. As shown in fig. 13, the sleeve blank 422 is formed to have a first thickness 422T1 and the plurality of depressions 424 are formed by reducing the thickness to 422T2 during the step of compressing the sheet of material of the sleeve forming method. Upon completion of this sheet of compressed material step, the blank 422 includes a plurality of locally plastically deformed regions forming depressions 424 having a thickness 422T2 and a plurality of ribs 428 having no deformation and having a thickness 422T 1.

The blank 422 is formed to have a first linear edge 430, a first arcuate edge 440, a second linear edge 434, and a second arcuate edge 442. The rib 428 is shaped to extend from the first arcuate edge 440 to the second arcuate edge 442. First linear edge 430 and second linear edge 434 are each disposed along a ray emanating from a common axis that defines a center of curvature for both first arcuate edge 440 and second arcuate edge 442. Each rib 428 is also disposed along a ray extending from the common axis 444. The ribs 428 are positioned to engage the outer surface of a cup (such as cup 11) such that the inner surface 436 of the recess 424 is spaced from the outer surface of the cup to provide an air gap, while only the ribs 428 engage the outer surface of the cup. The air gap is insulated such that heat transfer from the cup to the user's hand is impeded when the user grips the outer surface 438 of the insulating sleeve 413.

In yet another embodiment of an insulative sleeve 513 formed from a sleeve blank 522, as shown in fig. 17-19, the insulative sleeve 513 includes a plurality of helical ribs 528 on an inner surface 526 of the assembled insulative sleeve 513. As shown in fig. 13, the sleeve blank 522 is extruded to have a first thickness 522T1 and a plurality of depressions 524 are formed by reducing the thickness to 522T2 during the compression material web step of the sleeve forming method. Upon completion of this step of compressing the sheet of material, blank 522 includes a plurality of locally plastically deformed regions forming depressions 524 having a thickness 522T2 and a plurality of ribs 528 having no deformation and having a thickness 522T 1.

The blank 522 is formed to have a first linear edge 530, a first arcuate edge 540, a second linear edge 534, and a second arcuate edge 542. The plurality of ribs 528 are shaped to extend along a plurality of axes perpendicular to the second linear edge 534. The rib 528 extends to abut either the second arcuate edge 542 or the first linear edge 530. The ribs 528 are positioned to engage the outer surface of a cup, such as cup 11, such that the inner surface 536 of the recess 524 is spaced from the outer surface of the cup to provide an air gap, and such that only the ribs 528 engage the outer surface of the cup 11. The air gap is insulated such that heat transfer from the cup to the user's hand is impeded when the user grips the outer surface 538 of the insulating sleeve 513.

As shown in fig. 20-22, in another embodiment of the insulative sleeve 613 formed from the sleeve blank 622, the insulative sleeve 613 includes a plurality of nubs or protrusions 628 on an inner surface 626 of the assembled insulative sleeve 613. As shown in fig. 13, the sleeve blank 622 is extruded to have a first thickness 622T1 and the protrusions 628 are left behind after the remainder of the blank 622 is reduced to the thickness 622T2 in the sheet of compressed material step of the sleeve forming process. Upon completion of this step of compressing the sheet of material, the blank 622 includes a plurality of protrusions 628 having no deformation and having a thickness 622T 1.

The blank 622 is formed having a first linear edge 630, a first arcuate edge 640, a second linear edge 634, and a second arcuate edge 642. The protrusions 628 are spaced apart in a plurality of rows 624, each row 624 lying along an arc parallel to the first and second curved edges 640, 642. The protrusions 628 are positioned to engage the outer surface of a cup (such as cup 11) such that the inner surface 636 of the insulative sleeve 613 is spaced from the outer surface of the cup to provide an air gap, while only the protrusions 628 engage the outer surface of the cup. The air gap is insulated such that heat transfer from the cup to the user's hand is impeded when the user grips the outer surface 638 of the insulating sleeve 613.

As shown in fig. 23-26, in yet another embodiment of an insulative sleeve 713 formed from a sleeve blank 722, the insulative sleeve 713 includes a plurality of generally horizontal ribs 728 on an inner surface 726 of the assembled insulative sleeve 713. The sleeve blank 722 is extruded to have a first thickness 722T1 and a plurality of ribs 728 are formed by displacing the material during the displacing material web step of the sleeve forming process. Upon completion of the step of displacing the sheet of material, the blank 722 includes localized plastically deformed regions that form ribs 728 having a thickness 722T1, but portions of the blank 722 are offset to define the ribs 728. Portions of the blank 722 are reduced to a thickness 722T2 due to plastic deformation and elongation when the material is displaced.

The step of displacing the sheet of material may be performed by a thermoforming process that thermoforms the blank 722. Thus, the thicknesses 722T1 and 722T2 are maximized, such that the insulating properties of the insulating sleeve 713 are maximized.

The blank 722 is formed to have a first linear edge 730 and a second linear edge 734. Rib 728 is shaped to abut second linear edge 734 at a first end and is spaced apart from first linear edge 730 by a distance 732 such that the first end of rib 728 does not overlap the second end when first linear edge 730 overlaps second linear edge 734 during the step of winding the sleeve blank of the sleeve forming method. This results in a reduction in the amount of material that must be compressed during the sleeve blank winding process. The ribs 728 are positioned to engage an outer surface of a cup (such as cup 11) such that the inner surface 736 of the recess 724 is spaced apart from the outer surface of the cup to provide an air gap, while only the ribs 728 engage the outer surface of the cup. The air gap is insulated such that when a user grips the outer surface 738 of the insulating sleeve 713, heat transfer from the cup to the user's hand is impeded.

Another embodiment of an insulative sleeve 813 according to the present disclosure is shown in fig. 27 and 28. As shown in fig. 27, the insulative sleeve 813 includes an upstanding sleeve wall 818 and a sleeve floor 820. The sleeve blank 822 is extruded to have a first thickness and the fold lines 828 are formed by compressing the material to a relatively thinner second thickness during the compression material web step of the sleeve forming process. As shown in fig. 27, the sleeve floor 820 includes a floor platform 821 and a floor retention tab 822 that is coupled to the sleeve wall 818 during sleeve formation. After the sleeve is formed, the sleeve floor 820 cooperates with the sleeve wall 818 to define a cup-receiving space 814 therebetween.

Yet another embodiment of an insulative sleeve 913 in accordance with the present disclosure is shown in fig. 29-31. As shown in fig. 29-31, insulative sleeve 913 includes an upstanding sleeve wall 918 and a sleeve floor 920. As shown in fig. 31, the sleeve wall blank 922 and the sleeve floor blank 924 are extruded to have a first thickness and a plurality of fold lines 928 are formed by compressing the material in the sleeve floor blank 924 to a relatively thinner second thickness in the sleeve forming method sheet compressing step. As shown in fig. 29, sleeve mount 920 includes a mount deck 921 and four mount retaining tabs 922A, 922B, 922C, 922D that are coupled to sleeve wall 918 during sleeve formation. After the sleeve is formed, the sleeve floor 920 cooperates with the sleeve wall 918 to define a cup-receiving space 914 therebetween.

In another embodiment, as shown in fig. 32, insulating sleeve 1013 has a generally cylindrical shape and has a lower tab 1002. The lower tab 1002 is used to support a cylindrical beverage vessel, such as an aluminum can, for example, when the insulating sleeve 1013 is positioned on the cylindrical beverage vessel. The insulating sleeve 1013 includes an opening to locate the vessel therein, and the lower tab 1002 provides a barrier so that the vessel is supported on the lower tab 1002 to locate the insulating sleeve 1013. Insulating sleeve 1013 differs from sleeves 213 and 113 in that insulating sleeve 1013 has two seams 1006 and 1008 where material is joined to form insulating sleeve 1013.

As shown in fig. 33, a blank 1022 for an insulative sleeve 1013 includes two generally rectangular portions 1012, 1014 interconnected by a lower tab 1002. First linear edge 1016 of portion 1012 matches first linear edge 1018 of portion 1014 and these edges overlap and are juxtaposed so that they can be joined to form seam 1006. Similarly, a second linear edge 1020 of portion 1012 mates with a second linear edge 1021 of portion 1014 that overlaps and is juxtaposed thereto to form seam 1008. The seams 1006 and 1008 are formed by heating the material and positioning the edges so that the insulative cellular non-aromatic polymeric material is coupled together. In other embodiments, the seams may be formed by applying adhesive to the respective edges. In either approach, pressure may be applied to assist in this bonding. In other embodiments, the seams may be formed by forming a slit along one edge and a tab along the opposite edge, and inserting the tab into the slit and retaining it therein.

In other embodiments, the seams 1006 and 1008 can be fastened by using a hook and loop fastening system (such as, for example) To be fastened. The insulative cellular non-aromatic polymeric material is sufficiently flexible to allow the insulative sleeve 1013 to be formed as a blank in a flat condition and to be assembled by a customer. Similarly, in some embodiments, sleeves 213 and 113 may use a hook and loop fastening system, such that these sleeves 213 and 113 may be shipped to and assembled by a customer or at a point of sale as flat blanks. It should be appreciated that the insulative sleeve 1013 may be formed with different surface discontinuities, including those described above with respect to sleeves 313, 413, 513, 613, and 713.

Another embodiment of an insulative sleeve 1113 according to the present disclosure is shown in fig. 34 and 35. As shown in fig. 34 and 35, insulative sleeve 1113 includes upright inner tab 1114, upright outer tab 1112, and upright fence 1111 extending between inner and outer tabs 1114, 1112. Upright inner tab 1114 is arranged to extend upwardly from floor 20 of cup 11. As shown in fig. 35, upright outer tab 1112 is arranged to extend upwardly from floor 20 and mate with upright inner tab 1114 along interface I therebetween. Upright fence 1111 is arranged to interconnect upright inner and outer tabs 1114, 1112 and to surround cup-receiving space 1115.

Upright fence 1111 of insulative sleeve 1113 is C-shaped in horizontal cross-section, and each of upright inner and outer tabs 1114, 1112 has an arcuate shape in horizontal cross-section. Upright fence 1111 has a first thickness 11T1 and first and second upright tabs 1114, 1112 each have a second thickness 11T 2. As shown in fig. 34 and as shown in fig. 35, the second thickness 11T2 is substantially equal to the first thickness 11T 1. Thus, bridges 1114, 1112 formed by overlapping and coupling upstanding tabs 1114, 1112 have a third thickness 11T3 that is approximately equal to twice the first and second thicknesses 11T1, 11T 2.

Another embodiment of an insulative sleeve 1213 according to the present disclosure is shown in fig. 36-40. For example, as shown in fig. 36, insulative sleeve 1213 comprises a sleeve wall 1218 and a sleeve wall retainer 1220. As shown in fig. 36 and 38, sleeve wall 1218 includes a first sleeve panel 1218A, a second sleeve panel 1218B spaced from first sleeve panel 1218A, and a connecting web 1218C positioned to fit between and interconnect first and second sleeve panels 1218A, 1218B.

As shown in fig. 36, sleeve wall retainer 1220 includes upstanding tabs 1220A, adhesive layer 1220B, and release liner 1220C. An upstanding tab 1220A is coupled to a free end of first sleeve panel 1218A opposite connecting web 1218C. Adhesive layer 1220B is placed on upstanding tab 1220A and release liner 1220C is placed on adhesive layer 1220B such that adhesive layer 1220B is between release liner 1220C and upstanding tab 1220 until insulative sleeve 1213 is assembled in the field.

In a use example, insulative sleeve 1213 can be assembled and coupled to cup 11 on site. As shown in fig. 37, insulative sleeve 1213 is in a disassembled state in spaced relation to cup 11. As shown in fig. 38, second sleeve panel 1218B is folded back around connecting web 1218C away from first sleeve panel 1218A to expose sleeve retainer 1220. As shown in fig. 39, release liner 1220C is pulled away from adhesive layer 1220B to expose adhesive layer 1220B. As shown in fig. 40, upstanding tab 1220A and adhesive 1220B are arranged to overlap the free end of second sleeve panel 1218B, forming insulating sleeve 1213. As shown in fig. 40, the cup 11 is inserted into and coupled to the insulative sleeve 1213. As one example, insulative sleeve 1213 may be coupled to cup 11 by frictional interference or any other suitable method.

The insulative cellular non-aromatic polymeric material used to make the insulative sleeves 213 and 113 and variants of the sleeves is somewhat flexible and capable of expanding slightly under load to allow an appropriately sized sleeve to grip a vessel at some deflection level.

It is within the scope of the present disclosure that insulating sleeves 913, 1013, 1113, and 1213 (including those described above with respect to sleeves 313, 413, 513, 613, and 713) can be formed having different patterns. These different patterns may be formed by forming localized areas of plastic deformation in each insulative sleeve. For example, the patterns may be formed by compressing portions of the sleeve such that the pattern is made from uncompressed portions. As another example, the patterns may be formed by compressing portions of the sleeve such that the pattern is made from the compressed portions. In yet another example, the patterns may be formed by deforming portions of the sleeve to maximize the thickness of the entire sleeve. In yet another example, a combination of deformation and compression may be used.

The insulative sleeve as described above provides strength and thermal insulation to the cup. One feature of the thermoformed cup with the insulative sleeve of the present disclosure is that the thermoformed cup is seamless, which in turn provides the desired strength, thermal insulation, and a printable surface. The thermoformed cup has a seamless rim, thereby providing a lid seal that reduces potential leakage compared to expanded polypropylene cups (with seams). Another feature of the thermoformed cup and insulative sleeve of the present disclosure is that the desired level of strength and insulation is achieved, but the cup sidewall has a desired level of puncture resistance. The present disclosure also provides an insulative sleeve that may be provided separately from the cup.

An insulative sleeve made of an insulative cellular non-aromatic polymeric material as described in this disclosure may also be used or adapted for use in structures other than containers. As an example, the insulative cellular non-aromatic polymeric material may be used as, but not limited to, a sill seal, duct wrap, or other applications requiring a low density, lightweight, thin material with good thermal insulation.

In alternative exemplary embodiments, the cup, base or body may be made of a material other than a thermoformable material. By way of example, the cup, base or body may be made of an injection molded material or any other suitable alternative material.

Claims (76)

1. An insulative sleeve for surrounding and embracing the outer surface of a hot beverage cup to provide a graspable, low temperature thermal barrier that can be grasped by a consumer, the sleeve comprising a sheet comprising insulative cellular non-aromatic polymeric material configured to provide means for enabling localized plastic deformation in the sheet to provide plastically deformed first material segments of a first density in a first portion of the sheet and second material segments of a second density lower than the first density in an adjacent second portion of the sheet without rupturing the insulative cellular non-aromatic polymeric material such that predetermined insulative characteristics are maintained in the sheet.

2. The insulative sleeve of claim 1, wherein the sheet is arranged about a vertical central axis and the sheet includes: an upstanding inner tab arranged to extend upwardly along and in spaced relation to the vertical central axis and configured to provide the first section of material having the first density; an upright outer tab arranged to extend upwardly along the vertical central axis and in spaced relation to the vertical central axis and mate with the upright inner tab along an interface therebetween; and an upright fence arranged to interconnect the upright inner tab and the upright outer tab and around the vertical central axis, and configured to provide the second section of material having the second density and to cooperate with the upright inner tab and the upright outer tab to form the sleeve-shaped sidewall.

3. The insulative sleeve of claim 2, wherein the rail has a substantially frustoconical shape and each of the upright inner and outer tabs has an arcuate shape.

4. The insulative sleeve of claim 2, wherein the upright inner tab includes an inner surface providing means for mating with a hot beverage cup and an outer surface facing the upright outer tab, the upright outer tab includes an inner surface mating with the outer surface of the upright inner tab to define the interface between the upright inner tab and the upright outer tab, and the upright outer tab further includes an outer surface facing away from the upright inner tab.

5. The insulative sleeve of claim 4, wherein each of the inner and outer surfaces of the upright inner and outer tabs has an arcuate shape in horizontal cross-section and subtends an acute angle of less than 20 °.

6. The insulative sleeve of claim 2, wherein the upright fence is C-shaped in horizontal cross-section and each of the upright inner and outer tabs has an arcuate shape in horizontal cross-section.

7. The insulative sleeve of claim 2, wherein the upright fence includes an upright left side edge and an upright right side edge arranged in spaced face-to-face relationship with the upright left side edge, and the upright outer tab is configured to have the first density and mate with the upright inner tab to establish a bridge arranged to interconnect the upright left and right side edges of the upright fence and formed of plastically deformed material having the first density.

8. The insulative sleeve of claim 7, wherein the upright fence has an inner surface facing the vertical central axis and providing means for mating with a hot beverage cup and an outer surface facing away from the central vertical axis of the inner region and surrounding and cooperating with the inner surface of the upright fence to define a first thickness therebetween; the upstanding inner tab includes an inner surface facing the vertical central axis and providing a means for mating with the hot beverage cup and an outer surface facing the upstanding outer tab; the upright outer tab includes an inner surface facing the vertical central axis and mating with an outer surface of the upright inner tab to define the interface between the upright inner tab and the upright outer tab, and the upright outer tab further includes an outer surface facing away from the upright inner tab; the inner surface and the outer surface of the upstanding inner tab cooperate to define a second thickness therebetween that is about one-half the first thickness, and the inner surface and the outer surface of the upstanding outer tab cooperate to define a third thickness that is about one-half the first thickness.

9. The insulative sleeve of claim 1, wherein the first material segment in the sheet of insulative cellular non-aromatic polymeric material has a relatively thin first thickness and the second material segment in the sheet of insulative cellular non-aromatic polymeric material has a relatively thicker second thickness.

10. The insulative sleeve of claim 9, further comprising a cellular non-aromatic skin comprising a biaxially oriented polypropylene film adhered to the insulative cellular non-aromatic polymeric material.

11. The insulative sleeve of claim 1, further comprising a graphic skin coupled to an outer surface of the insulative cellular non-aromatic polymeric material and configured to include a film, an adhesive interposed between the film and the outer surface, and ink printed on the film to provide a graphic design.

12. The insulative sleeve of claim 11, wherein the film is biaxially oriented polypropylene.

13. The insulative sleeve of claim 1, wherein the insulative cellular non-aromatic polymeric material includes a polypropylene base resin having a high melt strength, a polypropylene copolymer resin, at least one nucleating agent, and a gas means for expanding the resins to reduce density.

14. The insulative sleeve of claim 13, wherein the gas means comprises carbon dioxide.

15. The insulative sleeve of claim 13, wherein the polypropylene base resin comprises a broadly distributed molecular weight polypropylene characterized by a distribution that is unimodal.

16. The insulative sleeve of claim 13, wherein the polypropylene base resin further comprises a polypropylene homopolymer resin.

17. The insulative cup of claim 1, wherein the insulative cellular non-aromatic polymeric materials include a polypropylene base resin having a high melt strength, a polypropylene homopolymer resin, at least one nucleating agent, and gas means for expanding the resins to reduce density.

18. The insulative cup of claim 17, wherein the gas means comprises carbon dioxide.

19. The insulative cup of claim 17, wherein the polypropylene base resin comprises a broadly distributed molecular weight polypropylene characterized by a distribution that is unimodal.

20. The insulative cup of claim 1, wherein the insulative cellular non-aromatic polymeric material comprises a broadly distributed molecular weight polypropylene characterized by a unimodal distribution.

21. The insulative cup of claim 1, wherein the first density is about 0.350g/cm³And the second density is about 0.175g/cm³。

22. The insulative cup of claim 1, wherein the insulative cellular non-aromatic polymeric material is formed to include cells filled with a gas and each cell is bounded by a cell wall provided in the insulative cellular non-aromatic polymeric material and configured to be non-elastically deformable during exposure to localized plastic deformation.

23. The insulative cup of claim 1, wherein the insulative cellular non-aromatic polymeric material comprises a high melt strength polypropylene characterized by long chain branching to provide a predetermined balance of processability and high melt elasticity.

24. An insulating sleeve for surrounding the outer surface of a cup, the insulating sleeve comprising

A sheet comprising an insulative cellular non-aromatic polymeric material, the sheet being formed to include air gap means for separating portions of the sheet from the outer surface of the cup to space the outer surface of the insulative sleeve from the outer surface of the cup such that heat transfer between the outer surface of the insulative sleeve and the outer surface of the cup is minimized.

25. The insulative sleeve of claim 24, wherein the air gap means comprises a pattern formed on the portion of the sheet engaged with the outer surface of the cup.

26. The insulative sleeve of claim 25, wherein the formed pattern includes a plurality of ribs.

27. The insulative sleeve of claim 26, wherein the ribs are generally horizontal when the sleeve surrounds the cup.

28. The insulative sleeve of claim 26, wherein the ribs are generally vertical when the sleeve surrounds the cup.

29. The insulative sleeve of claim 26, wherein the sheet includes an inner surface arranged to face the outer surface of the cup and an opposite outer surface arranged to face away from the outer surface of the cup, and the plurality of ribs are attached to the inner surface extending from the insulative outer surface to the outer surface of the cup to engage the outer surface of the cup and define an air gap between the outer surface of the cup, the inner surface of the insulative sleeve, and two adjacent ribs.

30. The insulative sleeve of claim 25, wherein the formed pattern comprises a plurality of nubs.

31. The insulative sleeve of claim 30, wherein the nubs are arranged in rows.

32. The insulative sleeve of claim 31, wherein the rows are generally horizontal when the sleeve surrounds the cup.

33. The insulative sleeve of claim 25, wherein the pattern is formed by compressing portions of the sheet to plastically deform localized regions of the sheet to increase the density of the sheet in the localized regions of plastic deformation.

34. The insulative sleeve of claim 33, wherein undeformed regions of the sheet maintain a first density that is lower than a density of the sheet in the localized regions of plastic deformation, the regions having the first density defining the pattern.

35. The insulative sleeve of claim 34, wherein the formed pattern includes a plurality of ribs.

36. The insulative sleeve of claim 35, wherein the ribs are generally horizontal when the sleeve surrounds the cup.

37. The insulative sleeve of claim 35, wherein the ribs are generally vertical when the sleeve surrounds the cup.

38. The insulative sleeve of claim 35, wherein the ribs are helical when the sleeve surrounds the cup.

39. The insulative sleeve of claim 34, wherein the formed pattern comprises a plurality of nubs.

40. The insulative sleeve of claim 39, wherein the nubs are arranged in rows.

41. The insulative sleeve of claim 40, wherein the rows are generally horizontal when the sleeve surrounds a beverage container.

42. The insulative sleeve of claim 25, wherein the pattern is formed by compressing portions of the sheet to induce plastic deformation of localized areas of the sheet to reduce a thickness of the sheet in the localized areas of plastic deformation with undeformed areas having a thickness greater than the reduced thickness.

43. The insulative sleeve of claim 42, wherein the undeformed regions define features of the pattern.

44. The insulative sleeve of claim 43, wherein the formed pattern includes a plurality of ribs.

45. The insulative sleeve of claim 44, wherein the ribs are generally horizontal when the sleeve surrounds the cup.

46. The insulative sleeve of claim 44, wherein the ribs are generally vertical when the sleeve surrounds the cup.

47. The insulative sleeve of claim 44, wherein the ribs are helical when the sleeve surrounds the cup.

48. The insulative sleeve of claim 42, wherein the formed pattern comprises a plurality of nubs.

49. The insulative sleeve of claim 39, wherein the nubs are arranged in rows.

50. The insulative sleeve of claim 40, wherein the rows are generally horizontal when the sleeve surrounds the cup.

51. An insulating sleeve for surrounding the outer surface of a cup, the insulating sleeve comprising

Comprising a sheet of insulative cellular non-aromatic polymeric material comprising a sleeve wall, a floor platform, and retainer means for securing the floor platform to the sleeve wall to define a space for receiving a cup such that the floor platform of the insulative sleeve supports at least a portion of the cup when the insulative sleeve surrounds the cup.

52. The insulative sleeve of claim 51, wherein the retainer means comprises a single floor retaining tab.

53. The insulative sleeve of claim 52, wherein the floor retention tab, floor platform, and sleeve wall are formed in a single sheet of insulative cellular non-aromatic polymeric material.

54. The insulative sleeve of claim 53, wherein the floor platform and sleeve wall are coupled together along a fold line.

55. The insulative sleeve of claim 54, wherein the fold line is formed by compressing the sheet of insulative cellular non-aromatic polymeric material to form a localized plastic deformation region.

56. The insulative sleeve of claim 55, wherein the localized plastic deformation region has a density greater than a density of a remainder of the sheet of insulative cellular non-aromatic polymeric material.

57. The insulative sleeve of claim 56, wherein the insulative sleeve comprises a pattern formed on a portion of the sheet engaged with the outer surface of the cup.

58. The insulative sleeve of claim 57, wherein the formed pattern includes a plurality of ribs.

59. The insulative sleeve of claim 58, wherein the ribs are generally horizontal when the sleeve surrounds the cup.

60. The insulative sleeve of claim 58, wherein the ribs are generally vertical when the sleeve surrounds the cup.

61. The insulative sleeve of claim 58, wherein the ribs are helical when the sleeve surrounds the cup.

62. The insulative sleeve of claim 57, wherein the formed pattern includes a plurality of nubs.

63. The insulative sleeve of claim 62, wherein the nubs are arranged in rows.

64. The insulative sleeve of claim 63, wherein the rows are generally horizontal when the sleeve surrounds the cup.

65. The insulative sleeve of claim 57, wherein the pattern is formed by compressing portions of the sheet to form localized areas of plastic deformation in the sheet to increase a density of the sheet in the localized areas of plastic deformation.

66. The insulative sleeve of claim 65, wherein undeformed regions of the sheet maintain a first density that is lower than a density of the sheet in the plastically deformed localized regions, the regions having the first density defining the pattern.

67. The insulative sleeve of claim 51, wherein the retainer means comprises floor-retaining tabs.

68. The insulative sleeve of claim 67, wherein the floor retaining tabs and floor platforms are formed in a single sheet of insulative cellular non-aromatic polymeric material.

69. The insulative sleeve of claim 68, wherein the insulative sleeve comprises a pattern formed on a portion of the sheet engaged with an exterior surface of the beverage container.

70. The insulative sleeve of claim 69, wherein the formed pattern includes a plurality of ribs.

71. The insulative sleeve of claim 70, wherein the ribs are generally horizontal when the sleeve surrounds the cup.

72. The insulative sleeve of claim 70, wherein the ribs are generally vertical when the sleeve surrounds the cup.

73. The insulative sleeve of claim 70, wherein the ribs are helical when the sleeve surrounds the cup.

74. The insulative sleeve of claim 69, wherein the formed pattern includes a plurality of nubs.

75. The insulative sleeve of claim 74, wherein the nubs are arranged in rows.

76. The insulative sleeve of claim 75, wherein the rows are generally horizontal when the sleeve surrounds the beverage container.