EMBOSSED DOUBLE WALL CUP

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

None.

FIELD OF THE INVENTION

The present invention is generally directed to a multi-walled container which includes an inner receptacle having outwardly projecting embossments, an outer sleeve having inwardly projecting debossments, and an intermediate insulating layer defined between the receptacle and outer sleeve for insulating the container.

BACKGROUND

Multi-walled containers suitable for holding hot and cold liquids are well known in the food and beverage packaging industry. Various solutions have been developed to enhance user comfort, improve thermal insulation and prevent spills. Historically, single-wall cups have been a widespread choice for their simplicity; however, they tend to be poor insulators and often require additional sleeves or layers to protect the user from extreme temperatures. The development of multi-walled containers with inner cups and outer cups, sleeves, or sidewalls marked a significant improvement in thermal insulation capabilities, providing an air gap between the walls that reduced heat transfer and the need for additional hand protection.

Despite their advantages, conventional multi-walled containers possess inherent limitations. Currently known containers in the industry typically only have embossments on the outer sleeve of the container. The embossments on the outer sleeve require significantly more surface area contact between the outer sleeve and inner cup in order to secure the outer sleeve to the inner cup, only allow for a narrow insulation layer, and demand a significantly higher quantity of adhesive to secure the outer sleeve to the inner cup. Accordingly, the need exists for a compostable, insulated container which utilizes embossments on the exterior surface of the inner cup and debossments on the interior surface of the outer sleeve to minimize the quantity of contact points, thereby decreasing the surface area contact, maximizing the depth of the insulated layer between the inner cup and outer sleeve, and reducing the amount of adhesive required to secure the outer sleeve to the inner cup.

SUMMARY OF THE INVENTION

The present invention introduces a novel enhancement in the form of a compostable container comprised of a receptacle and outer sleeve, the container having outwardly projecting embossments on the receptacle and inwardly projecting debossments on the outer sleeve, which addresses the aforementioned deficiencies. The embossments on the receptacle engage and contact the embossments on the outer sleeve at contact points to define an intermediate insulating layer between portions of the receptacle and outer sleeve. The outer sleeve can be secured to the receptacle by way of friction fit, one or more locking or interlocking features, lining or coating material, adhesive such as a compostable biopolymer-based adhesive, or any other suitable method now known or hereafter developed. This embossed double-walled container minimizes or entirely eliminates the reliance on adhesives or hot glue bands, which in known containers are used to create an insulating space between a receptable and outer sleeve. Embodiments of the present invention may also reduce the number of contact points necessary to join the receptacle with the outer sleeve, through which heat can transfer, while also creating an intermediate insulating layer. Such a design enhances the insulation qualities of the container while also simplifying assembly, which is advantageous for the cup's performance and recyclable qualities. These innovations present a clear departure from traditional approaches and signify a meaningful contribution to the field of beverage containers.

One embodiment of the present invention is generally directed to a multi-walled container comprising a receptacle, an outer sleeve, and an intermediate insulating layer defined therebetween. The receptacle is constructed of paperboard material and comprises a circumferential sidewall and a bottom wall, wherein the exterior receptacle sidewall includes at least one vertically-extending, outwardly projecting embossment spaced below an upper edge of the receptacle sidewall. The at least one vertically-extending, outwardly projecting embossment may be a plurality of spaced apart embossments formed around the entire perimeter of the exterior receptacle sidewall, or the plurality of embossments may be formed generally intermittently around at least a portion of the perimeter of the receptacle sidewall. The receptacle sidewall may also include an outwardly projecting upper lip at the top end thereof. The outer sleeve includes a circumferential sidewall, wherein a portion of the outer sleeve is positioned against the outwardly projecting embossments of the receptacle. The intermediate insulating layer may be defined between exterior receptacle sidewall and the interior outer sleeve sidewall and is a plurality of spaces.

In another embodiment, the outer sleeve further includes at least one inwardly projecting debossment positioned below the top edge of the sleeve sidewall. The at least one inwardly projecting debossment may be a continuous debossment extending circumferentially around substantially an entire perimeter of the sleeve sidewall, or it may be multiple debossments formed generally intermittently around the perimeter of the sleeve sidewall. The at least one inwardly projecting debossment is positioned against the at least one outwardly projecting embossment of the receptacle. The intermediate insulating layer may be at least one void space defined between the receptacle sidewall and the outer sleeve sidewall.

In a further embodiment, the receptacle further includes a plurality of inwardly projecting debossments positioned below the top edge of the sleeve sidewall. The debossments may extend circumferentially and are formed continuously around substantially an entire perimeter of the sleeve sidewall. The debossments may be spaced apart along the height of the sleeve side wall and arranged generally parallel to one another. A portion of the at least one inwardly projecting debossment is positioned against at least one of the plurality of outwardly projecting embossments. The intermediate insulating layer may be a plurality of air gaps defined between the receptacle sidewall and the outer sleeve sidewall.

Other and further objects of the invention, together with the features of novelty appurtenant thereto, will appear in the course of the following description.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views:

FIG. 1 is a side perspective view of a container in accordance with one embodiment of the present invention;

FIG. 2 is an exploded side perspective view of the container of FIG. 1;

FIG. 3 is a side sectional view of the container of FIG. 1 taken generally along line 3-3 in the direction of the arrows;

FIG. 4A is an enlarged side sectional view of a portion of the container in balloon 4A of FIG. 3 in accordance with one embodiment of the present invention;

FIG. 4B is an enlarged side sectional view of a portion of the container in balloon 4B of FIG. 3 in accordance with one embodiment of the present invention;

FIG. 5 is a plan view of a deconstructed container in accordance with one embodiment of the present invention;

FIG. 6 is a plan view of an embossed blank for a receptacle sidewall and a debossed blank for an outer sleeve in accordance with a second embodiment of the present invention;

FIG. 7 is a plan view of an embossed blank for a receptacle sidewall and a debossed blank for an outer sleeve in accordance with a third embodiment of the present invention;

FIG. 8 is a plan view of an embossed blank for a receptacle sidewall and a debossed blank for an outer sleeve in accordance with a fourth embodiment of the present invention;

DESCRIPTION OF THE INVENTION

The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures. It will be appreciated that any dimensions included in the drawing figures are simply provided as examples and dimensions other than those provided therein are also within the scope of the invention.

The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled.

Referring generally to FIGS. 1-5, one embodiment of the present invention is directed to a container 10 which includes a receptacle 12, an outer sleeve 50, and an plurality of spaces 14 defined between the receptacle 12 and outer sleeve 50. While the container 10 may be adapted for holding hot and cold liquids, it will be appreciated that it can also be used in connection with the storage and transportation of other items. Further, it will be appreciated that the outer sleeve 50 may be manufactured independently from the receptacle 12 and later applied to the receptacle 12.

As illustrated in FIG. 2, the receptacle 12 may be formed of a bottom wall 16 and a circumferential sidewall 18, with the exterior receptacle sidewall 18a including at least one vertically-extending, outwardly projecting embossment 22. The at least one vertically-extending, outwardly projecting embossment 22 may be in the form of a protuberance, deformation, distortion, bend, bulge, bump, lump, hump, knob, swelling, protrusion, rib, or the like extending outwardly from a sidewall forming the receptacle sidewall 18. The at least one embossment 22 may extend at least a majority of the height of the receptacle.

The at least one embossment 22 may be formed by an embossing roller, die plate, press plate, pins, or other suitable machinery or methods, and may be embossed while the receptacle sidewall 18 is still in flat form prior to being formed into a circumferential receptacle 12. In one embodiment, the embossment(s) 22 may be formed while the receptacle sidewall 18 is on a press or die cutter. The embossments 22 may be pressed, stamped, or rolled into the receptacle sidewall 18 simultaneously, or in close temporal and spatial proximity with, with the die cutting or printing of the receptacle sidewall 18. In another embodiment, the embossments 22 are formed by applying, adding, or forming additional material along the outer surface of the receptacle sidewall 18. The embossments 22 may also be formed by swelling or expanding the material forming the sleeve receptacle sidewall 18 in the area of the embossments 22 through, for example, causing moisture to be absorbed or adsorbed, in the paperboard or other material forming the receptacle sidewall 18.

The at least one vertically-extending, outwardly projecting embossment 22 may have a height and a width, wherein the height of at least one of the embossment(s) 22 is at least four (4) times greater than the width of such embossment in one embodiment, at least ten (10) times greater than the width in another embodiment, at least twenty (20) times greater than the width in yet another embodiment, and at least thirty (30) times greater than the width in a further embodiment, although other height to width ratios of the embossment(s) 22 are possible and within the scope of the present invention. The embossment 22 has a depth D_E, which may protrude outward from the exterior receptacle sidewall 18a a distance of between about 0.02 inches and about 0.3 inches in one embodiment, a distance of between about 0.04 inches and about 0.2 inches in another embodiment, and a distance of between about 0.06 inches and about 0.1 inches in a further embodiment, although other depths D_E are possible and within the scope of the present invention.

The at least one vertically-extending, outwardly projecting embossment 22 may be a plurality of spaced apart embossments 22 formed around the entire perimeter of the receptacle sidewall 18a, or the plurality of embossments 22 may be formed generally intermittently for example, around at least a portion of the perimeter of the receptacle sidewall 18. The plurality of embossments 22 may be arranged in a parallel fashion, although other constructions are possible. For example, in a different embodiment, as illustrated in FIG. 7, the exterior receptacle sidewall 18a may include a plurality of outwardly projecting embossments 22 spaced apart and arranged generally parallel to one another at a diagonal angle. Such angle can be quantified in degrees relative to a defined reference axis, where such angle may range from zero (0) degrees to ninety (90) degrees. In further embodiments, the outwardly projecting embossments 22 may be other suitable shapes, spacings, patterns, or configurations.

The receptacle 12 can be constructed of a paperboard material, and may optionally be a coated paperboard in order to resist the migration of liquids contained within the storage chamber 24. However, it will be appreciated that the receptacle 12 may be constructed of other materials, including but not limited to, uncoated paperboard, polyethylene, polypropylene, polyethylene terephthalate (PET), or other materials suitable for use as a receptacle 12. The bottom wall 16 and receptacle sidewall 18 may be die cut from a larger sheet or roll (not shown) of material. As shown in FIG. 3, the bottom wall 16 includes a depending skirt 26 secured to the receptacle sidewall 18 by a reverse bend 28 portion of the receptacle sidewall 18. Securement of the bottom wall 16 to the receptacle sidewall 18 may be achieved by use of a compostable, biopolymer-based adhesive such as, but not limited to, cellulose-based, starch-based, lignin-based, protein-based, and vegetable oil-based adhesives. Securement may also be achieved by other methods, including but not limited to, adhesive, hot melt, sonic welding, sealants, or the like. The reverse bend 28 forms a footing upon which the container 10 may sit when in use. Construction of the receptacle 12 as just described is well known in the art.

The receptacle 12 preferably has a generally frustoconical shape with a generally circular transverse cross sectional shape of varying diameter that increases in size from a bottom end of the receptacle 12 to the top edge of the receptacle 12. In one embodiment, the top edge of the receptacle includes an outwardly rolled upper lip 20 at the top edge thereof, which allows for nesting in storage and shipping. The receptacle sidewall 18 may be formed from a blank and wrapped around a mandrel. The receptacle sidewall 18 may include an overlapping seam (not shown) extending generally longitudinally between the top and bottom ends of the receptacle 12.

The seam (not shown) can be formed by adhering the overlapping margin portions of the receptacle sidewall 18 together with a compostable, biopolymer-based adhesive such as, but not limited to, cellulose-based, starch-based, lignin-based, protein-based, and vegetable oil-based adhesives, so that all features of the container 10 remain completely compostable. The seam may also be formed by other methods, including but not limited to, adhesive, hot melt, sonic welding, or the like. The exposed edges at the seam of the receptacle sidewall 18 may be sealed to prevent the migration of liquids into the material comprising the receptacle sidewall 18. The container 10 of the present invention may have a storage chamber 24 volume on the order of, for example, about four (4) fluid ounces to about thirty-two (32) fluid ounces, although larger or smaller containers 10 may be made and are within the scope of the present invention.

As illustrated in FIG. 1, an outer sleeve 50 surrounds and overlies a substantial portion of the receptacle sidewall 18. The outer sleeve 50 may be constructed from a suitable flat blank material and includes a circumferential sleeve sidewall 52, with the interior sleeve sidewall 52a including at least one inwardly projecting debossment 54. The exterior of sleeve sidewall 52 may be suitable for having advertising, logos, and other graphics printed thereon.

In one embodiment, the interior sleeve sidewall 52a may include at least one inwardly projecting debossment 54 positioned below the top edge of the sleeve sidewall 52. The at least one debossment 54 may be in the form of a protuberance, deformation, distortion, bend, bulge, bump, lump, hump, knob, swelling, protrusion, rib, or the like extending inwardly from a sidewall forming the outer sleeve 50. In one embodiment, the debossment 54 is a continuous debossment extending circumferentially around substantially an entire perimeter of the sleeve sidewall 52, while another embodiment comprises multiple debossments 54 formed generally intermittently around the perimeter of the sleeve sidewall 52.

In another embodiment, as illustrated in FIGS. 2, 5, and 7, the interior sleeve sidewall 52a may include a plurality of debossments 54 extending circumferentially and are formed continuously around substantially an entire perimeter of the sleeve sidewall 52. The debossments 54 may be spaced apart along the height of the sleeve sidewall 52 and arranged generally parallel to one another, although other constructions are possible. In another embodiment, as illustrated in FIG. 8, the sleeve sidewall 52 may include a plurality of inwardly projecting debossments 54 spaced apart and arranged generally parallel to one another at a diagonal angle. Such angle can be quantified in degrees relative to a defined reference axis, where such angle may range from zero (0) degrees to ninety (90) degrees. However, it will be appreciated that the inwardly projecting debossments 54 may be other suitable shapes, spacings, patterns, or configurations. In other embodiments, as illustrated in FIG. 6, the outer sleeve 50 may contain no embossments.

The at least one debossment 54 may be formed by an embossing roller, die plate, press plate, pins, or other suitable machinery or methods, and may be embossed while the sleeve is still in flat form prior to being formed into a circumferential outer sleeve 50. In one embodiment, the debossment(s) 54 may be formed while the outer sleeve 50 is on a printing press or die cutter. The debossments 54 may be pressed, stamped, or rolled into the sleeve simultaneously, or in close temporal and spatial proximity with, with the die cutting or printing of the outer sleeve 50. In another embodiment, the debossments 54 are formed by applying, adding, or forming additional material along the inner surface 52a of the sleeve sidewall 52. The debossments 54 may also be formed by swelling or expanding the material forming the sleeve sidewall 52 in the area of the debossments 54 through, for example, causing moisture to be absorbed or adsorbed, in the paperboard or other material forming the outer sleeve 50. The debossments 54 protrudes inwardly from the sleeve sidewall 52 at a depth D_D, which may between about 0.02 inches and about 0.3 inches in one embodiment, a distance of between about 0.04 inches and about 0.2 inches in another embodiment, and a distance of between about 0.06 inches and about 0.1 inches in a further embodiment, although other depths D_D are possible and within the scope of the present invention.

In one embodiment, the outer sleeve 50 is preferably constructed of paperboard material; however, other materials including, but not limited to, polyethylene, polypropylene, PET, or other materials suitable for use as a receptacle 12 are within the scope of the invention. The outer sleeve 50 preferably has a generally frustoconical shape with a generally circular transverse cross sectional shape of varying diameter that increases in size generally in accordance with a corresponding receptacle 12. The sleeve sidewall 52 may be formed from a blank and wrapped around a mandrel. The sleeve sidewall 52 may include an overlapping seam (not shown) extending generally longitudinally between the top and bottom ends of the outer sleeve 50. The outer sleeve seam (not shown) can be formed by adhering the overlapping margin portions of the sleeve sidewall 52 together with a compostable, biopolymer based adhesive such as, but not limited to, cellulose-based, starch-based, lignin-based, protein-based, and vegetable oil-based adhesives. The seam may also be formed by other methods, including but not limited to, adhesive, hot melt, sonic welding, or the like.

An intermediate insulating layer 14 may be defined between the exterior receptacle sidewall 18a and the outer sleeve 50 in order to protect a user's fingers and palm from the discomfort usually associated with holding a hot or cold beverage. In one embodiment, the intermediate insulating layer 14 may be at least one void space defined between the exterior receptacle sidewall 18a and the outer sleeve 50, or the intermediate insulating layer 14 may be a plurality of spaces 14 defined between the receptacle sidewall 18a and the interior sleeve sidewall 52a. In another embodiment, the void space(s) 14 may be an air gap defined between the exterior receptacle sidewall 18a and the interior sleeve sidewall 52a. As illustrated in FIGS. 3, 4A, and 4B, the intermediate insulating layer 14 can be formed, for example, by a standoff between the exterior receptacle sidewall 18a and the interior sleeve sidewall 52a created by the outwardly projecting embossment(s) 22 of the receptacle sidewall 18 engaging with and contacting the inwardly projecting debossments 54 at contact point(s) 56. In another embodiment, as illustrated in FIG. 6, the intermediate insulating layer 14 may be formed by a standoff between the exterior receptacle sidewall 18a and the interior sleeve sidewall 52a created by the outwardly projecting embossment(s) 22 of the receptacle sidewall 18 engaging with and contacting the interior sleeve sidewall 52a at contact point(s) 56. The contact point(s) 56 aid in decreasing the amount of adhesive necessary to secure the outer sleeve 50 to the receptacle 12 and enhance the insulation qualities of the container 10.

In another embodiment, the intermediate layer 14 may also be composed from a paper material of various forms, including corrugated paper, paper with dimpled surfaces, low density paper, recycled paper, deformed paper, or the like. It may also be within the scope of the invention that the intermediate layer 14 may be composed of a thermoplastic resin, including but not limited to, polyethylene, polyolefin, polyvinylchloride, polystyrene, polyester, nylon, or materials suitable for use as an insulating layer.

As illustrated in the embodiment shown in FIGS. 4A and 4B, the total distance between the exterior receptacle sidewall 18a and the outer sleeve 50 may vary at different locations within the intermediate layer 14. When the optional inwardly projecting debossment(s) 54 of the outer sleeve 50 contact and engage the outwardly projecting embossment(s) 22 of the receptable 12 at contact point(s) 56, the embossment(s) 22 project outward a distance D_E from the exterior sidewall 18a, wherein the depth of the insulating layer 14 is substantially similar to depth D_D of the debossment(s) 54. When the debossment(s) 54 do not contact the receptacle 12, the insulating layer depth increases to a depth D_T. Depths D_T and D_D may vary between about 0.02 inches and 0.6 inches in some embodiments, although other sized spacing gaps are also within the scope of the present invention.

The outer sleeve 50 can be secured to the receptacle 12 by way of friction fit, one or more locking or interlocking features, lining or coating material, adhesive such as a compostable biopolymer-based adhesive, or any other suitable method now known or hereafter developed. In one embodiment, the outer sleeve 50 is secured to the receptacle 12 by way of an adhesive positioned on either the outwardly projecting embossment(s) 22 of the sidewall 18, the inwardly projecting debossment(s) 54 of the sleeve sidewall 52, or both. Securement of the outer sleeve 50 to the receptacle 12 may be achieved by use of a compostable, biopolymer-based adhesive such as, but not limited to, cellulose-based, starch-based, lignin-based, protein-based, and vegetable oil-based adhesives. Securement may also be achieved by other methods, including but not limited to, hot melt, sonic welding, sealants, or the like.

From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are inherent to the structure and method. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.