Multilayer article and method for making a multilayer article, blank, and insulating cup

Abstract

Method of making a multilayer article including providing a first substrate and providing a second substrate. The method further includes disposing an expandable insulating material on an inner surface of at least one of the first substrate and the second substrate, wherein the expandable insulating material is in a first condition during disposing. The second substrate is adhered to the first substrate with the expandable insulating material therebetween to form a blank, wherein an insulating space is defined between the first substrate and the second substrate with the expandable insulating material therein and the insulating space includes a first volume. The method further includes forming the blank into the article and expanding the expandable insulating material to a second condition by application of energy, wherein the expandable insulating material in the second condition increases the insulating space to a second volume.

1 . A method of making a multilayer article, comprising:
 providing a first substrate having an inner surface and an outer surface;   providing a second substrate having an inner surface and an outer surface;   disposing an expandable insulating material on the inner surface of at least one of the first substrate and the second substrate, wherein the expandable insulating material is in a first condition during disposing;   adhering the second substrate to the first substrate with the expandable insulating material therebetween to form a blank, wherein an insulating space is defined between the first substrate and the second substrate with the expandable insulating material therein and the insulating space includes a first volume;   forming the blank into the article; and   expanding the expandable insulating material of the article to a second condition by application of energy, wherein the expandable insulating material in the second condition increases the insulating space to a second volume.   
     
     
         2 . The method of  claim 1 , wherein the disposing includes printing the expandable insulating material in a pattern on the inner surface of the first substrate. 
     
     
         3 . The method of  claim 1 , wherein the disposing includes printing the expandable insulating material on an interior region of the inner surface of the first substrate, wherein an outer margin of the inner surface of the first substrate remains free of the expandable insulating material. 
     
     
         4 . The method of  claim 1 , wherein the adhering includes adhering the second substrate along the inner surface of the first substrate with an adhesive. 
     
     
         5 . The method of  claim 1 , wherein the adhering includes coupling the first substrate to the second substrate with adhesive along surface areas of the first substrate and second substrate free of expandable insulating material. 
     
     
         6 . The method of  claim 1 , further comprising coating the outer surface of the first substrate with substance. 
     
     
         7 . The method of  claim 1 , further comprising coating the outer surface of the second substrate with a substance. 
     
     
         8 . The method of  claim 1 , wherein expanding the expandable insulating material of the article to a second condition with application of energy includes heating the article at approximately 400° F. to approximately 500° F. for a duration of at least approximately 30 seconds to approximately 60 seconds. 
     
     
         9 . The method of  claim 1 , wherein the disposing comprises at least one of printing, coating, spraying, laminating, and extruding. 
     
     
         10 . The method of  claim 1 , wherein the disposing the expandable insulating material includes disposing the expandable insulating material with a mesh screen ranging in dimension between approximately 60 Mesh and approximately 110 Mesh. 
     
     
         11 . The method of  claim 1 , wherein the disposing the expandable insulating material includes disposing the expandable insulating material in a ridge at an angle of approximately 45° F. with respect a center longitudinal axis of the article. 
     
     
         12 . A multilayer article, comprising:
 a first substrate having an inner surface and an outer surface;   a second substrate having an inner surface and an outer surface; and   an expandable insulating material applied to the inner surface of at least one of the first substrate and the second substrate, wherein the expandable insulating material includes a first condition at ambient temperature and a second condition upon application of energy, and   wherein the second substrate is adhered to the first substrate with the expandable insulating material therebetween to form a blank, wherein an insulating space is defined between the first substrate and the second substrate with the expandable insulating material therein, the insulating space having a first volume when the expandable insulating material is in the first condition and the insulating space having a second volume when the expandable insulating material is in the second condition.   
     
     
         13 . The article of  claim 12 , wherein the expandable insulating material includes an expandable material. 
     
     
         14 . The article of  claim 13 , wherein the expandable material includes microspheres. 
     
     
         15 . The article of  claim 13 , wherein the expandable insulating material further includes additives and is free of adhesive. 
     
     
         16 . The article of  claim 12 , wherein the expandable insulating material is in the second condition upon the application of energy between approximately 400° F. and approximately 500° F. and remains in the second condition thereafter. 
     
     
         17 . The article of  claim 12 , wherein the second substrate is adhered to the first substrate by adhesive. 
     
     
         18 . The structure of  claim 12 , wherein the article includes a total heat flux of approximately 1900 W/m 2 . 
     
     
         19 . The article of  claim 12 , wherein the article transfers approximately between approximately 70% and approximately 80% of heat energy. 
     
     
         20 . The article of  claim 12 , wherein the article has a stiffness deflection that ranges from approximately 0.35 lbs. force to 1.2 lbs. force. 
     
     
         21 . An insulating cup, comprising:
 a sidewall defining a top opening and a bottom portion, the sidewall including a multilayer article having:
 a first substrate having inner surface and an outer surface, 
 a second substrate having an inner surface and an outer surface, and 
 an expandable insulating material applied to the inner surface of at least one of the first substrate and the second substrate, wherein the expandable insulating material includes a first condition at ambient temperature and a second condition upon application of energy, and 
 wherein the second substrate is adhered to the first substrate with the expandable insulating material therebetween, wherein an insulating space is defined between the first substrate and the second substrate with the expandable insulating material therein; and 
   a base coupled to the bottom portion of the sidewall when the expandable insulating material is in the first condition.   
     
     
         22 . The insulating cup of  claim 21 , wherein the insulating space has a first volume when the expandable insulating material is in the first condition and the insulating space has a second volume when the expandable insulating material is in the second condition, the expandable insulating material being expanded to the second condition after forming the cup. 
     
     
         23 . The insulating cup of  claim 21 , wherein the sidewall further comprises a rolled top portion to define a rim about the top opening. 
     
     
         24 . The insulating cup of  claim 23 , wherein the rim is disposed above a top edge of the second substrate of the structure. 
     
     
         25 . The insulating cup of  claim 21 , wherein the base comprises a skirt to define a surface-engaging edge with the sidewall. 
     
     
         26 . The insulating cup of  claim 21 , wherein the expandable insulating material is applied to the inner surface of at least one of the first substrate and the second substrate in a ridge at an angle of approximately 45° F. with respect a center longitudinal axis of the cup. 
     
     
         27 . The insulating cup of  claim 21 , wherein the expandable insulating material is applied to the inner surface of at least one of the first substrate and the second substrate at a density corresponding to a mesh screen size dimension ranging between approximately 60 Mesh and approximately 110 Mesh.