Multilayer storage container

Abstract

A multiple layer reusable plastic container is disclosed. The multiple layer structure includes at least one layer of recycled or highly economic material and at least one outer layer made from either virgin resin or a more aesthetically appealing material to provide a multiple layer reusable container that is economical to manufacture in terms of material costs but yet has an acceptable outward appearance. The recycled or economical layer may be coated on both sides with virgin resin to provide an improved inner and outer appearance to the reusable container and also qualify the inner surface as an appropriate food contacting surface.

What is claimed:  
     
         1 . A reusable, three-dimensional storage container comprising: 
 a first layer comprising a post-consumer or post-industrial regrind resin selected from the group consisting linear low density polyethylene, high density polyethylene, polyvinylchloride, polyethyleneterephthalate, nylon and mixtures thereof,    a second layer comprising virgin resin tied to the first layer.    
     
     
         2 . The storage container of  claim 1  wherein the first layer serves as an inner layer and the second layer serves as an outer layer.  
     
     
         3 . The storage container of  claim 1  wherein the second layer further comprises a colorant.  
     
     
         4 . The storage container of  claim 1  further comprising a third layer comprising virgin resin material disposed adjacent the first layer opposite from the second layer, the third layer being tied to the first layer.  
     
     
         5 . The storage container of  claim 4  wherein the second layer further comprises a colorant.  
     
     
         6 . The storage container of  claim 4  wherein the third layer further comprises a colorant.  
     
     
         7 . The storage container of  claim 4  wherein the second and third layers each comprise a colorant.  
     
     
         8 . The storage container of  claim 1  wherein a ratio of thicknesses of the first to the second layer ranges from about 60:40 to about 80:20.  
     
     
         9 . The storage container of  claim 4  wherein a ratio of a thickness of the first layer to a combined thickness of the second and third layers ranges from about 50:50 to about 80:20.  
     
     
         10 . The storage container of  claim 1  wherein the first layer further comprises a foaming agent.  
     
     
         11 . The storage container of  claim 1  wherein the first layer further comprises calcium carbonate.  
     
     
         12 . The storage container of  claim 4  wherein the first layer further comprises a foaming agent.  
     
     
         13 . The storage container of  claim 4  wherein the first layer further comprises calcium carbonate.  
     
     
         14 . The storage container of  claim 1  wherein the container is formed using a co-extrusion blow molding process.  
     
     
         15 . A reusable, three-dimensional storage container comprising: 
 (a) a container portion comprising 
 a first layer comprising a post-consumer or post-industrial regrind resin selected from the group consisting linear low density polyethylene, high density polyethylene, polyvinylchloride, polyethyleneterephthalate, nylon and mixtures thereof,  
 a second layer comprising virgin resin tied to the first layer,  
 a third layer comprising virgin resin material disposed adjacent the first layer opposite from the second layer and tied to the first layer,  
 the first, second and third layers of the container portion being molded to form a bottom panel connected to and disposed between two opposing side panel and two opposing end panels, each side panel being disposed between and connected to the opposing end panels to form an open top box structure, and,  
   (b) a top portion comprising 
 a first layer comprising a post-consumer or post-industrial regrind resin selected from the group consisting linear low density polyethylene, high density polyethylene, polyvinylchloride, polyethyleneterephthalate, nylon and mixtures thereof,  
 a second layer comprising virgin resin tied to the first layer,  
 a third layer comprising virgin resin material disposed adjacent the first layer opposite from the second layer and tied to the first layer,  
 the first, second and third layers of the top portion being molded to form a top panel that engages top edges of the side and end panels of the container portion to provide a lid for the open box structure.  
   
     
     
         16 . The storage container of  claim 15  wherein the second and third layers further comprise a colorant.  
     
     
         17 . The storage container of  claim 15  wherein a ratio of a thickness of the first layer to a combined thickness of the second and third layers of the container portion ranges from about 50:50 to about 80:20 and a ratio of a thickness of the first layer to a combined thickness of the second and third layers of the top portion ranges from about 50:50 to about 80:20.  
     
     
         18 . The storage container of  claim 15  wherein the first layer further comprises a foaming agent.  
     
     
         19 . The storage container of  claim 15  wherein the first layer further comprises calcium carbonate.  
     
     
         20 . The storage container of  claim 15  wherein the second and third layers comprise a resin selected from the group consisting of polysulphone, polymethylpentene, polycarbonate, polyetherimide, nylon, polyarylate, polyphenylsulphide, polyphenylene oxide, polyethersulphone, polyethyleneterephtalate, aromatic polyketone, liquid crystal polymer and mixtures thereof.  
     
     
         21 . The storage container of  claim 15  wherein the container portion is formed using a co-extrusion blow molding process.  
     
     
         22 . The storage container of  claim 15  wherein the top portion is formed using a co-extrusion blow molding process.  
     
     
         23 . A lid for reusable, three-dimensional storage container, the lid comprising: 
 a first layer comprising a post-consumer or post-industrial regrind resin selected from the group consisting linear low density polyethylene, high density polyethylene, polyvinylchloride, polyethyleneterephthalate, nylon and mixtures thereof,    a second layer comprising virgin resin tied to the first layer.    
     
     
         24 . The lid of  claim 23  further comprising a third layer comprising virgin resin material disposed adjacent the first layer opposite from the second layer, the third layer being tied to the first layer.  
     
     
         25 . The lid of  claim 24  wherein the second and third layers each comprise a colorant.  
     
     
         26 . The lid of  claim 23  wherein a ratio of thicknesses of the first to the second layer ranges from about 60:40 to about 80:20.  
     
     
         27 . The lid of  claim 24  wherein a ratio of a thickness of the first layer to a combined thickness of the second and third layers ranges from about 60:40 to about 80:20.