SPILL RESISTANT CUP WITH INTEGRATED FOLDING LID

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 63/726,206, filed Nov. 27, 2024, and titled “SPILL RESISTANT CUP WITH INTEGRATED FOLDING LID”, which is hereby incorporated by reference herein in its entirety and for all purposes.

INCORPORATION BY REFERENCE

U.S. patent application Ser. No. 17/815,069 filed Jul. 26, 2022, and titled “CUP WITH INTEGRATED FOLDING LID”, U.S. patent application Ser. No. 17/026,843 filed Sep. 21, 2020, and titled “CUP WITH INTEGRATED FOLDING LID” (now U.S. Pat. No. 11,434,042) and U.S. patent application Ser. No. 18/621,615 filed Mar. 29, 2024, and titled “CUP WITH INTEGRATED FOLDING LID”, are hereby incorporated by reference herein in their respective entireties and for all purposes.

TECHNICAL FIELD

The subject disclosure relates generally to foldable containers; for example, spill resistant liquid containers with a foldable lid are disclosed.

BACKGROUND

Disposable cups are widely used throughout the food service industry. Fast food service restaurants, sit-down restaurants, school cafeterias and lunch counters, bistros, diners and drive through take-out shops are a few examples of food services that often use disposable cups. Such cups are made of paper or plastic material and are configured to contain liquid, including hot or cold liquids, as well as room temperature liquids.

Traditional disposable cups are configured to accept separate plastic lids that conform to the top of the cup by snapping in place over a rolled upper edge of the cup. The lid may have a hole from which to pour or drink a beverage directly, such as a coffee cup lid. Other lids contain a hole to accept a separate straw for sipping the beverage, such as with a soda fountain cup lid.

Disposable cups and associated lids generally do not stack compactly when combined, and thus the two components are often stored, shipped and even sold separately. Food service facilities that utilize disposable cups and lids are often equipped with individual fixtures to separately house a stack of disposable cups, a stack of lids, and groups of straws. Employees or customers retrieve individual components from the respective fixtures to assemble a cup and fill the cup with a beverage. Additionally, food service facilities separately utilize conventional non-watertight paper containers for food products. Conventional plastic containers, or plastic lids with paper containers, are utilized for food products having a liquid component that may leak through a non-watertight container.

SUMMARY

The following presents a simplified summary of the specification in order to provide a basic understanding of some aspects of the specification. This summary is not an extensive overview of the specification. It is intended to neither identify key or critical elements of the specification nor delineate the scope of any particular embodiments of the specification, or any scope of the claims. Its purpose is to present some concepts of the specification in a simplified form as a prelude to the more detailed description that is presented in this disclosure.

Embodiments of the present disclosure are directed to a cup with an integrated folding lid. The inventors have identified problems associated with traditional disposable cups and propose an integrated lid and cup to overcome these identified problems. Traditional disposable cups require at least a separate plastic lid which snaps over the opening of the traditional cup by holding onto a rolled edge of the cup with tabs configured around a mating surface on the lid. If the tabs do not fit the cup properly, however, a loose lid to cup interface results which can lead to leaking or spillage. Another issue associated with traditional disposable cup lids is that they can split or break if a user attempts to remove the lid. For example, if a user removes a lid to refill the cup, or add ice, then the lid can tear, bend, or otherwise break requiring a new lid. It will be appreciated, in light of the present disclosure, that such traditional plastic disposable lids unnecessarily add to increased garbage production and waste. Moreover, in instances that a disposable cup contains a hot beverage a loose or broken lid can lead to injury, for example, burns on the skin, when a user attempts to drink from the lid. Traditional disposable cups, lids, and straws also place additional logistical burdens on the food service industry and suppliers thereof. For example, traditional disposable cups, lids, and straws are often produced in separate facilities and are required to ship individually to a supply distributor or a restaurant directly. Additionally, the restaurants must allocate additional employee hours to inventory and track cup, lid, and straw quantities individually for each cup size offered.

The aforementioned characteristics can also be associated with conventional take-out food containers, for which the inventors have identified further drawbacks. For example, conventional take-out food containers are either of a folding paper type, which are not watertight due to a folded bottom, or of a cup and lid combination (e.g., paper and/or plastic soup or beverage cup and lid combinations). Further, conventional take-out food containers of the folding paper type (e.g., Chinese food takeout containers, etc.) are often restricted to square or rectangular cross-sectional geometries only and are not suited for cup holders, or the like (e.g., insulation sleeves, koozies, etc.). Additionally, such conventional folding paper type containers cannot be assembled and stacked for easy accessibility by a consumer. For example, traditional soda fountain cups are often stacked (e.g., a series of cups are inserted over each other) next to a soda fountain for a consumer, or food service employee, to easily access a cup and fill it at the soda fountain. Conventional folding paper type containers are prone to folding in on themselves when unfilled and therefore cannot be easily stacked over each other without binding and tearing when a consumer, or food service employee, goes to separate the conventional folding paper type containers. Moreover, conventional folding paper type containers have to be assembled on a per order basis and therefore place an additional time and manpower burden on food service facilities. Further, in instances where a food order contains multiple food types a combination of conventional folding paper type and conventional cup and lid containers must be used (e.g., an order containing rice and soup). It will be appreciated, in light of the present disclosure, that a food service facility must commit additional resources to store, assemble, track, and reorder a plurality of conventional container types.

The present disclosure proposes to solve at least the aforementioned problems associated with conventional folding paper type containers, and conventional cup and lid containers, through the provision of a cup with an integrated lid. The integrated lid can be configured with a portion of the lid configured to consume liquid therethrough further removing the need for a separate straw in some embodiments.

An example embodiment comprises an enhanced integrated cup with an integrated lid that is assembled by folding a continuous piece of material, such as paper, cut into a pre-configured shape (e.g., a blank, a die, or other suitable nomenclature). In such embodiments, the enhanced integrated cup comprises one or more of a base, a sidewall, an integrated lid section, a tab and slit, a fold line, or an adhesive. In some embodiments, the base can be a separate piece of material attached to a bottom portion of the sidewall, for example, by way of an adhesive (e.g., epoxy, etc.). In some embodiments, the base can comprise the same material as the sidewall and integrated lid components of the enhanced integrated cup. In some embodiments, the cup with the integrated lid can be at least partially assembled before reaching an end user (i.e., a consumer). For example, the cup can be shipped to a restaurant with a base and sidewall folded together and attached by way of an adhesive in order to maintain a substantially recognizable cup shape with an open top. In such embodiments, integrated lid sections can extend upward from at least an upper portion of the sidewall and at the transition region between the sidewall and the integrated lid sections one or more fold lines are configured. The one or more fold lines are configured to provide for the folding of the integrated lid sections over the opening of the cup to substantially form a covering (i.e., lid) over the opening of the cup without the need for a separate lid component. In some embodiments, at least a portion of the integrated lid can form a hole configured for drinking. In such embodiments, at least a portion of the integrated lid can protrude to define a spout configured to receive a straw, to drink from directly, or to pour out contents of the cup.

In some embodiments, the continuous piece of material used to make the enhanced integrated cup blank can comprise one or more materials including, without limitations, paper, plastic, foams, fabrics, the like, or combinations thereof. In some embodiments, the one or more materials can be at least partially treated with sealants to block the absorption of fluid into the material and thereby prevent leakage from the enhanced integrated cup. In some embodiments, only the interior of the cup's side wall and base can be treated with sealant. In other embodiments, all exposed surfaces of the enhanced integrated cup can be treated with sealant. In yet other embodiments, no sealant can be utilized. Sealants can include, without limitation, one or more of a natural coating, a synthetic coating, a plastic-free coating, polylactic acid (PLA), wax (e.g., paraffin wax, beeswax, etc.), resin, epoxy, petroleum-based coating (e.g., polyethylene, etc.), the like, or combinations thereof. In some embodiments, it will be appreciated that a plastic free coating can be applied such that the drink can be fully contained without seepage for up to 6 hours. In some embodiments, a paper material used to produce the enhanced integrated cup blanks can comprise a single sheet of paper, multiple sheets of paper overlaid and attached to each other (e.g., by way of adhesives, a lamination process, etc.), one or more sheets of cardboard, the like, or combinations thereof. For example, in at least one example embodiment, the enhanced integrated cup can be employed for cold drink products (e.g., iced tea) for which the material can comprise a single sheet of paper coated with PLA to prevent liquid absorption into the paper material. In still another example embodiment, the enhanced integrated cup can be employed for hot drink products (e.g., coffee), for which the material can comprise cardboard treated with a wax coating. In some embodiments, cardboard materials can be configured with one or more channels between at least two surfaces and the space within the channels can be configured to insulate the sidewalls of the enhanced integrated cup. It will be appreciated, in light of the present disclosure, that wax and PLA based sealants can be utilized to improve the biodegradability of the enhanced integrated cup.

In other embodiments, a plastic material used to produce the enhanced integrated cup blanks can comprise one or more sheets of a thermoplastic, a thermoset, polyethylene terephthalate (PETE), high-density polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene (PP), polycarbonate (PC), silicone, polylactic acid (PLA), the like, or combinations thereof. In further embodiments, the enhanced integrated cup can be repeatedly washed and reused by a consumer. For example, the enhanced integrated cup can be produced by means of injection molding utilizing a silicone material, or the like. In such example embodiments, the integrated lid of the enhanced integrated cup can be repeatedly opened and closed without substantial deterioration accumulating along one or more fold lines. It will be appreciated, in light of the present disclosure, that in at least such plastic embodiments the one or more fold lines can be configured to function as embedded or integrated hinges (e.g., living hinges, or other suitable nomenclature) configured for multiple reuses. In some embodiments, plastic materials can be configured with one or more channels between at least two surfaces and the space within the channels can be configured to insulate the sidewalls of the enhanced integrated cup.

It will be appreciated, in light of the present dis-closure, that materials may be selected and/or configured based on one or more of their physical characteristics including, without limitation, color, thermal properties, chemical resistance, the like, or combinations thereof. In some embodiments, the thickness of a material may be increased or decreased to proportionally increase or decrease heat transfer therethrough. For example, a material thickness may be increased to insulate the enhanced integrated cup from heat transfer therethrough. In some embodiments, the enhanced integrated cup blank may comprise one or more thicknesses. For example, a sidewall portion of the blank may be configured with a first thickness while an integrated lid section may comprise a second thickness and a base section may comprise a third thickness.

According to an aspect of the present disclosure, there is provided a cup with an integrated folding lid. In some aspects of the disclosed embodiments, the cup with the integrated folding lid can comprise a body comprising one or more materials. The body can comprise one or more fold lines that when the body, or a portion thereof, is bent along the one or more fold lines the body may comprise, or define, one or more of a center portion, a circular bottom portion, a top portion or a plurality of integrated lid sections. In further aspects of the disclosed embodiments, the center portion can define a sidewall. The sidewall can be configured as a single continuous surface looped over on itself to define, for example, one or more circular cross-sections. The sidewall can be configured to extend between a first end and a second end, the first end of the sidewall can be attached to the second end of the sidewall, for example, by mechanical or chemical means, or both. In still further aspects of the disclosed embodiments, the circular bottom portion can extend from the center portion defining a base.

In one or more alternative or additional aspects of the disclosure, the circular bottom portion can be configured to extend from the sidewall in a first direction and can attach to a bottom edge. In one or more embodiments, the top portion can define an opening configured to allow access into one or more cavities defined by at least the center portion. In additional embodiments, the plurality of integrated lid sections can extend from the top portion (e.g., a top edge of the sidewall) of the cup. The individual sections of the plurality of integrated lid sections can be coupled to the top portion at respective fold lines, where respective fold lines are situated between respective integrated lid sections and the top portion. The plurality of integrated lid sections can comprise at least one integrated lid section that can define at least a tab and can comprise at least an additional integrated lid section that can define at least a slit.

In one or more embodiments, the slit can be configured to receive, therethrough, the tab. In embodiments, the plurality of integrated lid sections may be configured to interlock at least by way of the tab being received within the slit. The interlocked plurality of integrated lid sections may define a lid cover that may be configured to at least partially cover the opening.

In some embodiments, the tab can define a locking edge and the slit can define one or more lock receiving edges. In such embodiments, the locking edge of the tab can hook, latch, clasp, or otherwise attach to the lock receiving edge(s) to more reliably secure the tab within the slit, and resist releasing of the tab from the slit to maintain closure of the lid cover. For instance, the locking edge and lock receiving edge(s) can keep the lid cover closed in response to movement of the cup, in response to inversion of the cup and force of gravity on contents therein, in response to inadvertent friction or movement against the one integrated lid section and the additional integrated lid section that define the lid cover, or the like.

In yet another embodiment, the folded lid portions can define a lid cover. The lid cover can define a front lid cover portion, a midsection and a rear lid cover portion. The lid cover can be configured to slope upward from the midsection to the front lid cover portion. In an embodiment, the front lid cover portion can define a pour spout. In another embodiment, the front lid cover portion can define a detachable (e.g., serrated, or the like) covering over the pour spout, whereas in other embodiments the front lid cover portion can be devoid of the detachable covering. Still further, the front lid cover portion can define a flat or substantially flat surface, whereas in other embodiments the front lid cover portion can define a concave or substantially concave surface, sloping upward from the midsection to the pour spout. In additional embodiments, the rear lid cover portion can slope upward from the midsection to a rear lid edge. The rear lid cover portion can define a convex or substantially convex surface from the midsection or near the midsection sloping upward toward the rear lid edge. In still further embodiments, the rear lid edge can define a convex curve with a highpoint near a center of the rear lid edge and sloping downward along the convex curve to the edge-points of the rear lid edge.

In further embodiments, when the plurality of integrated lid sections of the integrated folding lid of a disclosed integrated cup are interlocked, the integrated cup can define the bottom portion, the sidewall and the lid cover. The sidewall can include a back surface opposite a pour spout of the lid cover. Moreover, the back surface can define a concave curvature extending from below the rear lid edge of the lid cover. In at least some embodiments, the concave curvature of the back surface can extend from (or approximately from) the rear lid edge at an upper extent thereof and to (or approximately to) a max fill line defined in the sidewall of the integrated cup at a lower extent thereof.

The following description and the drawings set forth certain illustrative aspects of the specification. These aspects are indicative, however, of but a few of the various ways in which the principles of the specification can be employed. Other advantages and novel features of the specification will become apparent from the following detailed description of the specification when considered in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects or features of this disclosure are described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In this specification, numerous specific details are set forth in order to provide a thorough understanding of this disclosure. It should be understood, however, that certain aspects of the subject disclosure may be practiced without these specific details, or with other methods, components, materials, etc. In other instances, well-known structures and devices are shown in block diagram form to facilitate describing the subject disclosure.

FIG. 1 depicts a rear perspective view of a spill resistant integrated cup according to aspects of the present disclosure;

FIG. 2 depicts a top slot-side perspective view of the spill resistant integrated cup in an aspect(s);

FIG. 3 depicts a top tab-side perspective view of the spill resistant integrated cup in additional aspects;

FIGS. 4A, 4B and 4C illustrate perspective views of the spill resistant cup with integrated lid portions in folded and locked positions in further aspects;

FIGS. 5A, 5B, 5C and 5D depict example steps in closing the integrated lid portions and associated order and direction instructions on respective lid portions;

FIG. 6 illustrates a diagram of an example blank, unfolded and unsecured version of a spill resistant integrated cup in still further aspects;

FIG. 6A depicts a diagram of an example blank and dimensions thereof,

FIG. 7 shows an image of a top rear perspective view of a spill resistant integrated cup according to alternative or additional aspects of the present disclosure;

FIG. 8 shows an image of the spill resistant integrated cup inverted with liquid being poured from an integrated pour spout, in still other aspects of the disclosure.

FIG. 9 depicts a side-view drawing of dimensions of an example cup of various aspects of the disclosed embodiments;

FIG. 10 illustrates an overhead view of a locked lid of a spill resistance cup with integrated folding lid in still further aspects of the disclosed embodiments.

DETAILED DESCRIPTION

Introduction

One or more embodiments of the present disclosure provide a spill resistant cup with integrated folding lid cover. The spill resistant cup can be configured for hot liquids, in some embodiments, and can be formed of a material configured to provide thermal insulation to the hot liquid contained within the spill resistant cup. The material can be a biodegradable material, in further embodiments. In still additional embodiments, the spill resistant cup can retain liquid therein while partially (or mostly) inverted at a rear lid edge of the integrated folding lid cover. Moreover, the spill resistant cup can resist seepage of liquid from the rear lid edge in response to tilting the spill resistant cup toward a front top edge to pour liquid out from a pour spout of the spill resistant cup located at the front top edge of the lid cover. Disclosed embodiments provide a spill resistant cup configured to avoid absorption of liquid at a rear portion of the integrated folding lid cover, configured to avoid seepage or leaking of liquid at the rear portion while drinking from the spill resistant cup, and the like. Accordingly, the disclosed spill resistant cup can improve the drinking experience for a biodegradable disposable cup compared with conventional disposable cups.

As utilized herein, the term “substantially” and other relative terms or terms of degree (e.g., about, approximately, substantially, and so forth) are intended to have the meaning specified explicitly in conjunction with their use herein, or a meaning which can be reasonably inferred by one of ordinary skill in the art, or a reasonable variation of a specified quality(ies) or quantity(ies) that would be understood by one of ordinary skill in the art by reference to this entire specification (including the knowledge of one of ordinary skill in the art as well as material incorporated by reference herein). As an example, a term of degree could refer to reasonable manufacturing tolerances about which a specified quality or quantity could be realized with fabrication equipment. Thus, as a specific illustration, though non-limiting, for an element of a resistive switching device expressly identified as having a dimension of about 5 millimeters (mm), the relative term “about” can mean reasonable variances about 5 mm that one of ordinary skill in the art would anticipate the specified dimension of the element could be realized with commercial fabrication equipment, industrial fabrication equipment, laboratory fabrication equipment, or the like, and is not limited to a mathematically precise quantity (or quality). In other examples, a term of degree could mean a variance of +/−0-3%, +/−0-5%, or +/−0-10% of an expressly stated value, where suitable to one of ordinary skill in the art to achieve a stated function or feature of an element disclosed herein. In still other examples, a term of degree could mean any suitable variance in quality(ies) or quantity(ies) that would be suitable to accomplish an explicitly disclosed function(s) or feature(s) of a disclosed element. Accordingly, the subject specification is by no means limited only to specific qualities and quantities disclosed herein, but includes all variations of a specified quality(ies) or quantity(ies) reasonably conveyed to one of ordinary skill in the art by way of the context disclosed herein.

Relative positioning description throughout the present disclosure should not be construed to limit the spirit and scope of the disclosed embodiments. For instance, features shown on a “left” side relative to another feature can be inverted to a “right” side where suitable. Likewise, features shown “below” another feature can be constructed “above” that feature in yet other examples, where suitable. Accordingly, relative positioning is intended to describe current embodiments, but not to limit the scope of the disclosed embodiments as would be understood by one of ordinary skill in the art or as reasonably conveyed to one of ordinary skill by way of the context provided herein.

Some embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. The several embodiments of the invention expressly depicted herein can be constructed in different forms and should not be construed as limiting the full scope of the disclosure. Rather, the explicitly described embodiments are provided to give a general understanding of some embodiments of the invention that one of ordinary skill in the art might envision modifications thereto based on reasonable inferences drawn from the general context provided herein. Such modifications are considered within the scope of this disclosure. As used herein, the terms “along,” “near,” “adjacent,” and similar terms mean near or on, but not necessarily requiring directly on, an edge or other referenced location. Additionally, the term “attachment surface,” and similar refer to the part of a first component body to which at least one second component is attached, connected, or integrated. As used herein, the term “expandable,” and similarly utilized terms, refers to one or more components capable of transitioning between two or more configurations and does not suggest a directionality (e.g., “expandable” may comprise contraction, expansion, or other movement). Further, the terms “angle,” “angled,” “bend angle,” and similarly utilized terms, refer to an angle between zero and 180 degrees. Use of such terms should not be taken to limit the spirit and scope of embodiments of the present invention.

Overview

FIG. 1 illustrates an example perspective view in accordance with some example embodiment of a spill resistant integrated cup 100. As depicted, by FIG. 1, the example spill resistant integrated cup 100 is shown with a fully open plurality of integrated lid sections 102 extending from a top edge of the sidewall 110. The plurality of integrated lid sections 102 comprises a first integrated lid section 102A configured with a slit 104, a second integrated lid section 102B configured with a tab 106, a third integrated lid section 102C, and a fourth integrated lid section 102D. Slit 104 is configured to receive tab 106 during the folding and interlocking of the plurality of integrated lid sections 102. The third integrated lid section 102C and the fourth integrated lid section 102D can be attached, secured, fastened or the like (e.g., by adhesive) along seam 103. Seam 103 is defined by the union of a first end 110A of sidewall 110 and a second end 110B of a sidewall 110 (e.g., see FIG. 6, infra) and extends down the length of sidewall 110 and integrated lid sections 102C and 102D.

The sidewall 110 and the plurality of integrated lid sections 102 are configured with fold lines 108 there between. Fold lines 108 are configured to facilitate the folding over of the plurality of integrated lid sections 102 during the folding and interlocking of the plurality of integrated lid sections 102. The placement of fold lines 108 is configured to ensure that the interlocking features (e.g., slit 104 and tab 106) of the plurality of integrated lid sections 102 align properly when folded together. The example spill resistant integrated cup 100 is shown with a circular bottom edge 110C defined at least partially by a bottom portion of sidewall 110. The example spill resistant integrated cup 100, as shown in FIG. 1, defines a frustoconical shape with an expanding diameter defined by a circular cross-section increasing from the circular bottom edge 110C along the length of sidewall 110 up until at least fold lines 108. The fully open plurality of integrated lid sections 102 define an opening that provides accessibility to a water tight retention cavity at least partially enclosed by the body of the cup defined by at least sidewall 110. While the illustrated embodiment of FIG. 1 depicts integrated lid section 102B defining a tab 106 as a tab extending from the integrated lid section 102B, according to some embodiments an integrated lid section may itself define the tab, whereby the integrated lid section extends sufficiently to engage a slit in another integrated lid section configured to receive the integrated lid section defining the tab.

The example spill resistant integrated cup is shown with a fully open plurality of integrated lid sections 102 extending from the top portion of the sidewall 110. As illustrated, the frustoconical profile of the spill resistant integrated cup body is shown to taper continuously from the top portion comprising the plurality of open integrated lid sections 102 downwards through sidewall 110 until a minimum circular diameter is reached at the circular bottom edge 110C of the sidewall.

Fold lines 108 can be formed with a creasing process (e.g., such as a creasing knife with dull, blunted or rounded knife edge) to form a crease depth within a selected range and tolerance. The crease depth can be within a range of about 0.2 and about 0.4 mm, in various aspects of the disclosed embodiments, or any suitable value or range there between (e.g., 0.2 mm, 0.24 mm, 0.26 mm, 0.29 mm, 0.32 mm, 0.35 mm, 0.37 mm, 0.39 mm, 0.40 mm, or 0.24-0.28 mm, 0.27-0.31 mm, 0.30 and 0.35 mm, and so on). In some aspects of the disclosed embodiments, the fold lines 108 can be formed by a deboss process, or emboss process to similar depth(s) or range(s) of depth.

FIG. 2 depicts a slit-side elevation view of the spill resistant integrated cup 100 according to additional aspects of the disclosure. FIG. 2 illustrates a cutout 202 located between the first integrated lid section 102A, configured with a slit 104, and the second integrated lid section 102B, configured with a tab 106. The plurality of integrated lid sections 102 are depicted in the full open configuration, however, when the plurality of integrated lid sections 102 are in the fully interlocked, or at least partially closed, position then cutout 202 is configured to define an opening or spout (e.g., see FIGS. 4, 7 and 8, infra) within the integrated lid formed by interlocking the integrated lid sections 102. In some embodiments, cutout 202 may be configured with a straw (not shown) at least attached, therethrough, to a portion of the body of spill resistant integrated cup 100. In some embodiments, cutout 202 can be configured with a piece of material (not shown) (e.g., an extension of sidewall 110, integrated lid section 102A, or the like) configured to cover, at least partially, cutout 202. In such embodiments, cutout 202 can be defined, at least partially, by one or more fold lines (not shown) (e.g., a perforated line, a serrated line, etc.) configured around one or more edges of cutout 202. In such embodiments, a user may tear, and/or fold, the piece of material (not shown) along the one or more fold lines (not shown) (e.g., a perforated line, etc.) configured around one or more edges of cutout 202. In an alternative (or additional embodiment), the piece of material (not shown) can be formed to receive and to constrain a straw within a perimeter of cutout 202 or a spout formed by cutout 202 and one or more integrated lid sections 102A-102D in which cutout 202 is formed. In such embodiment(s), the piece of material can be partially serrated, pre-cut, etc., to tear away from a segment(s) of cutout 202, and partially non-serrated (or non pre-cut, etc.) to remain secured to cutout 202. The partially torn away portion can be configured to receive a straw provided thereto and retain the straw in relative position within the spout by the portion of the piece of material that remains secured to cutout 202. In at least some embodiments, the straw (e.g., a straight straw, a flexible straw, a telescoping straw, etc.) can be connected to the blank (not depicted) and removed from the connection to be inserted into the spout by the partially torn away and partially secured piece of material (not depicted).

FIG. 2 depicts cutout 202 located on a right side of first integrated lid section 102A in the orientation provided by the slid-side elevation view. From a different orientation, FIG. 3 shows a tab-side elevation view of spill resistant integrated cup 100 in additional aspects. Tab-side elevation view shows cutout 202 located on a left side of second integrated lid section 102B configured with a tab 106. Referring again to FIG. 2, first integrated lid section 102A is shown with slit 104 depicted in detail. Slit 104 defines an opening configured to receive some or all of tab 106 therein. Moreover, slit 104 can define one or more lock receiving edges 204 at respective edges of slit 104. A lock receiving edge 204 can define cutouts into a sidewall of slit 104, as shown. The cutouts can be substantially thin (e.g., approximately one-dimensional line-cuts) that allow the sidewall of slit 104 to receive a corresponding locking edge 206 of tab 106. Mating of locking edge 206 with a lock receiving edge of slit 104 can mitigate or avoid tab 106 from inadvertently slipping out from slit 104. For instance, lock receiving edge and locking edge 206 can mitigate or avoid casual contact, slowing of liquid within spill resistant integrated cup 100, or even inversion of spill resistant integrated cup 100 when pouring out liquid (e.g., see FIG. 8, infra) from inadvertently loosening tab 106 from slit 104 and accidentally opening a lid cover of the spill resistant integrated cup 100. Accordingly, slit 104 defined with one or more lock receiving edges 204 or tab 106 defined with locking edge 206, or both, can significantly improve retention of liquid within spill resistant integrated cup 100 and avoid accidental spills.

In additional embodiments, an interior surface of sidewall 110 can define a single continuous surface extending from a circular base defined by bottom portion 110C within the interior surface of spill resistant integrated cup 100. The circular base of bottom portion 110C can be attached to sidewall 110 around a base seam (not depicted). The base seam can define a circumference around the circular base. Moreover, the base seam can attack bottom portion 110C to sidewall 110 by way of mechanical or chemical means. For instance, an exterior edge of the base seam can be defined by an edge of bottom portion 110C being bonded to a bottom edge of sidewall 110 by way of an epoxy, a mechanical crimping of the edges, or a combination of both (e.g., the mechanical crimping can be implemented following application of epoxy to cause the epoxy to at least partially penetrate each respective edge material).

In further embodiments, the interior of spill resistant integrated cup 100 can define a retention cavity. In some aspects, interior surfaces of sidewall 110 and bottom portion 110C can be treated with a sealant to define a watertight retention cavity within the interior of the cup. In some embodiments, the base seam around the circular base portion of bottom portion 110C can be treated with at least the sealant used to treat sidewall 110 and bottom portion 110C to produce a watertight seam around a circular based defined by the bottom edge of sidewall 110 and an edge of bottom portion 110C.

FIGS. 4A, 4B and 4C depict respective elevation views of a closed lid 405 formed by closed and secured integrated lid sections 102 of spill resistant integrated cup 100 in still further embodiments of the present disclosure. A tab side perspective view 400A shows closed lid 405 defining a pour spout 450 at a front of closed lid 405. Also depicted are instruction segments 410 for order and direction of properly closing the integrated lid sections 102 to achieve closed lid 405. Instruction segments 405 can be embossed, debossed, painted, sputtered, or the like, or suitable combinations of the foregoing, into a material of integrated lid sections 102.

In one or more aspects of the present disclosure, instruction segments 410 can be formed by a deboss process to form an impression in a material of integrated lid sections 102 to a selected impression depth (e.g., see FIG. 10, infra). The impression depth can be chosen for the given thickness (e.g., about 0.40 to about 0.50 mm, or any suitable value or range there between) and material of spill resistant integrated cup 100 to leave an enduring (e.g., permanent or at least quasi-permanent) tactile impression or visual impression, or both, within the material of integrated lid sections 102 without causing leaking of liquid through the debossed features. In at least one embodiment, instruction segments 410 can form tactile impressions (or visual impressions, or both) in a location matching a recommended position for a person's fingers to quickly and efficiently fold all of integrated lid sections 102. For example, instruction segments 410 on integrated lid sections 102C, 102D can provide tactile location information of preferred/recommended thumb positions (on integrated lid sections 102C and 102D) of a preferred/recommended orientation of a user's hands when grasping the spill resistant integrated cup 100 to fold the integrated lid sections 102. An instruction segment 410 on integrated lid section 102A can provide tactile location information of a preferred/recommended right-hand finger position for folding integrated lid section 102A according to the preferred/recommended orientation of the user's hands. Similarly, an instruction segment 410 on integrated lid section 102B can provide tactile location information of a preferred/recommended left-hand finger position for folding integrated lid section 102B according to the preferred/recommended orientation of the user's hands. In various aspects, the impression depth of the deboss process can be in a range from about 0.25 and about 0.45 mm, or any suitable value or range there between (e.g., 0.27 mm, 0.30 mm, 0.33 mm, 0.36 mm, 0.39 mm, 0.42 mm; 0.25 to 0.29 mm, 0.28 to 0.32 mm, 0.31 to 0.34 mm, 0.35 to 0.39 mm, and so on). In an aspect, the impression depth of the deboss process can be in a range of about 50 percent to one-hundred fifty percent of a thickness of the material of folding integrated lid sections 102A, 102B, 102C, 102D, or any suitable value or range there between (e.g., 55 percent, 65 percent, 70 percent, 80 percent, 95 percent, 100 percent, . . . ; 60 to 140 percent, 70 to 125 percent, 80 to 110 percent, etc.). In further aspects, a combined deboss plate thickness (e.g., of male and female deboss plates) can be in a range from about 4.5 mm to about 5.5 mm, or any suitable value or range there between (e.g., 4.57 mm, 4.63 mm, 4.77 mm, 4.81 mm, 4.96 mm, 5.05 mm, 5.12 mm, 5.24 mm, 5.38 mm, 5.49 mm; or 4.50 to 4.70 mm, 4.70 to 4.90 mm, 4.90 to 5.10 mm, 5.10 to 5.30 mm, 5.30 to 5.40 mm, 5.40 to 5.50 mm, or other suitable value(s) or range(s) there between). In still further embodiments, a debossing plate pressure of the deboss process can be selected from a range of about 0.5 Mpa and about 2.0 Mpa, or any suitable value or range there between (e.g., 0.8 Mpa, 1.0 Mpa, 1.1 Mpa, 1.2 Mpa, 1.4 Mpa; or 0.5 to 0.7 Mpa, 0.8 to 1.2 Mpa, 1.1 to 1.5 Mpa, and so forth).

Tab side perspective view 400A shows instruction segments 3 and 4 associated with folding down second integrated lid section 102B over first integrated lid section 102A, and inserting tab 106 into slit 104, respectively, to complete forming closed lid 405. Slot side perspective view 400B shows a second instruction step 410 for folding down first integrated lid portion 102A over third integrated lid portion 102C and fourth integrated lid portion 102D (not shown, but see FIG. 5, infra).

Top rear perspective view 400C shows tab 106 removed from slit 104 for perspective. Also depicted, are a rear convex edge 420C of a top rear edge of closed lid 405 and a back concave surface 410C of a back surface of spill resistant integrated cup 100. Rear convex edge 420C and back concave surface 410C can enhance the leak mitigation of spill resistant integrated cup 100 as described in more detail at FIGS. 7 and 8, infra.

Figures SA, 5B, 5C and 5D depict an example lid folding process 500 for spill resistant integrated cup 100 according to still further aspects of the present disclosure. Figure SA shows a rear elevation view of spill resistant integrated cup 100 showing third integrated lid portion 102C and fourth integrated lid portion 102D with respective instruction segments 410 showing order and direction of folding. Third integrated lid portion 102C and fourth integrated lid portion 102D can be folded downward along respective seams 108 to produce a folded rear portion of closed lid 405. FIG. 5B shows a slit-side perspective view of spill resistant integrated cup 100 with associated instruction segments 410 showing inward folding of first integrated lid segment 102A on top of the folded rear portion as shown in FIG. 5C. Second integrated lid segment 102B can then be folded inward on top of first integrated lid segment 102A and the folded rear portion and tab 106 can be inserted into slit 104 as shown in FIG. 5D. Particularly, tab 106 can be pushed forward toward pour spout 450 to engage locking edge 206 of tab 106 with lock receiving edge 204 of slit 104, to lock tab 106 into slit 104.

FIG. 6 depicts an example cup blank diagram 600 for a spill resistant integrated cup according to one or more additional embodiments of the present disclosure. Cup blank diagram 600 can define a sidewall 610 having a first sidewall edge 610A and second sidewall edge 610B. In some embodiments, sidewall, first sidewall edge 610A and second sidewall edge 610B can be substantially the same as sidewall 100, first end 110A and second end 110B of sidewall of FIG. 1, supra. Sidewall 610 can have an upper edge terminating in folding portions 605. Folding portions 605 can be embossed, debossed, crimped, serrated, perforated, or the like, or a suitable combination of the foregoing, to facilitate ease of folding of attached lid portions 610 connected to sidewall 610 at respective folding portions 605. In some embodiments, sidewall 610 can be connected to a bottom portion (not depicted) integrated with a bottom edge 607 of sidewall 610, opposite the upper edge terminating in folding portions 605. In other embodiments, the bottom portion can be secured to bottom edge 607 when example cup blank 600 is formed into a revolved exterior surface such that first sidewall edge 610A meets or overlaps second sidewall edge 610B and are secured together (e.g., by mechanical or chemical means, or the like, or a suitable combination of the foregoing). The revolved exterior surface with bottom portion attached can form spill resistant integrated cup 100 of FIG. 1, in one or more embodiments.

Lid portions 610 include a first lid portion 630 defining a slit 632 having width dimension C and thickness dimension D. Width dimension C can be from 20 to 35 millimeters in various embodiments, or any suitable value or range therebetween (e.g., 24, 25, 26, 27, 28, 29, 30 millimeters, etc., suitable sub-millimeter values therebetween, and so on). Thickness dimension D can be from 1 to 10 millimeters in further embodiments, or any suitable value or range therebetween (e.g., 3, 4, 5, 6 millimeters, etc., suitable sub-millimeter values therebetween, and so forth). Slit 632 can have one or more lock receiving edges as described herein.

Lid portions 610 further include a second lid portion 620 defining a tab 622 having a locking edge 624. Locking edge 624 can have a length dimension B and a height dimension A. Length dimension B can be from 0.1 to 5 millimeters or any suitable value or range therebetween (e.g., 0.2, 0.4, 0.6, . . . 1.0, 1.5, 2.0, . . . 3.0, 3.3, 3.7, etc., and others). Height dimension A can be from 0.1 to 5 millimeters or any suitable value or range therebetween (e.g., 0.2, 0.4, 0.6, . . . 1.0, 1.5, 2.0, . . . 3.0, 3.3, 3.7, etc., and others). In at least some embodiments, height dimension A can be larger than width dimension B.

Between first lid portion 630 and second lid portion 620 is a gap spacing 650 configured to form a pour spout (e.g., front pour spout 750 of FIGS. 7 and 8, infra) when lid portions 610 are folded along folding portions 605 to form a lid. Still further, respective gaps 616 and 618 are defined between first lid portion 630 and a third lid portion 614, and between second lid portion 620 and a fourth lid portion 616, as shown. Moreover, gaps 616 and 618 can taper down to a near point 619 at an intersection of an edge 634 of first lid portion 630, a second edge 615 of third lid portion 614 and folding portions 605. Edge 634 of first lid portion 630 can be substantially straight into the near point 619, whereas an associated edge 615 of third lid portion 614 can have a small radius convex curvature at an end of the associated edge that joins near point 619. Though not depicted, a similar geometry can be provided for gap 618 between fourth lid portion 612 and second lid portion 620.

FIG. 6A depicts example dimensions for one or more aspects of the disclosed embodiments of an example cup blank diagram 600A for a spill resistant integrated cup in further aspects of the disclosed embodiments. Various dimensions are measured with respect to fold lines 605B of cup blank diagram 600A, a max fill line level 602B and a tangent line curvature 604B that intersects (or approximately at) a highest edge of lid section 630 or lid section 620, or both. A first dimension 625B is a distance from max fill line level 602B and an intersection of a spout opening (e.g., spout 650 of FIG. 6, supra) with a fold line 605B of cup blank diagram 600A (see also FIG. 9, infra showing max fill 740 and spout 750 of spill resistant integrated cup 700 in a completed form with closed integrated lid). A second dimension 626B is a distance from the max fill line level 602B to a bottom edge of lid section 630 coincident with fold line 605B (see also FIG. 9), and a third dimension 627B from the max fill line level 602B to a bottom edge of lid section 614 coincident with fold line 605B (see also FIG. 9). Still further, a fourth dimension 628B is a distance from the intersection of the spout opening and fold line 605B to the tangent line curvature 604B; a fifth dimension 629B is a distance from the bottom edge of lid section 630 coincident with fold line 605B to the tangent line curvature 604B (within lid section 630), and a sixth dimension 630B is a distance from fold line 605B and the tangent line curvature 604B within lid section 614. The distances can have the values presented in table 1 below, in some aspects of the disclosed embodiments, or can be within a range from 3 percent (for a small cup) to 10 percent (for the largest cup) variation about the stated numbers in alternative aspects of the disclosed embodiments.

FIG. 7 shows an image of a spill resistant integrated cup 700 formed from example cup blank 600 of FIG. 6. Spill resistant integrated cup 700 includes a folded top surface 730 defining a front pour spout 750 at a front portion thereof, and a rear convex edge 710 at a back portion thereof. Folded top surface 730 can define a low point near top-center lowpoint 732, as shown, which rises along a curvature 738 from top-center lowpoint 732 to front pour spout 750 to form the front portion of folded top surface 730. Likewise, folded top surface 730 defines a rising curvature to rear 736 from top-center lowpoint 732 to rear convex edge 710. Rear convex edge 710 has a convex curvature as shown, with a high point at or near a center of rear convex edge 710 and low points at edges (or ends) of rear convex edge 710. Moreover, a rear portion of folded top surface 730 defines a rear-top convex surface 734 that, in conjunction with rear convex edge 710 and back concave surface 722 provide substantial spill resistance at rear convex edge 710 and throughout the rear portion of folded top surface 730 (e.g., see FIG. 8, infra). Whereas conventional folding cups suffer from significant liquid leakage along a rear edge, particularly at the edges of the rear edge, spill resistant integrated cup 700 has little to no liquid leakage even when partially or mostly inverted.

In some embodiments, folded top surface 730 at a front portion thereof between top-center lowpoint 732 and front pour spout 750 can define a flat or substantially flat surface (in contrast to rear-top convex surface 734 of the rear portion of folded top surface 730), or can define a mildly concave surface. Back concave surface 722 can have concave curvature from a left side (relative to a rear perspective view of back surface 720) to a right side of back surface 720. Back concave surface can extend from rear convex edge 710 at an upper edge thereof, approximately to a max fill line 740 at a lower edge thereof. Max fill 740 can be a tactile or visual marker, such as an embossed, debossed, marked, painted, or the like, or a suitable combination thereof, marker to convey a recommended maximum liquid level. The tactile marker of max file 740 can be visible (and determinable in a tactile manner) both at an interior surface of sidewall 710 and an exterior surface thereof. In some embodiments, back concave surface 722 can have a lower edge that stops short of max fill 740.

FIG. 8 shows spill resistant integrated cup 700 mostly inverted for pouring liquid out front pour spout 750. As shown, no liquid is escaping at or near rear convex edge 710 even with spill resistant integrated cup 700 in a near vertical orientation. This is a substantial improvement over the conventional art. Moreover, folded top surface 730 remains closed despite the weight of liquid contained within spill resistant integrated cup 700 when inverted. The locking tab and slit geometries disclosed herein provide significant advancements over the conventional art in maintaining folded top surface 730 in a closed and sealed or substantially sealed manner (excepting front pour spout 750) even when spill resistant integrated cup 700 is inverted. Thus, while poured liquid 840 falls from front pour spout 750 (e.g., when the liquid is being consumed by a user) a drip-free edge 850 can be maintained at rear convex edge 710 for a significant time period. The combination of rear convex edge 710, back concave surface 722 and rear-top convex surface 734 operate to yield drip-free edge 850, in various embodiments.

FIG. 10 shows an example overhead view 1000 of a spill resistant integrated cup according to one or more aspects of the disclosed embodiments. Overhead view 1000 shows a folded top surface 1005 with integrated lid sections in a folded position. Also shown are debossed impressions 1010, 1020, 1030 providing tactile information and visual information of folding instructions of the integrated lid sections. Visible in overhead view 1000 are a second fold order and arrow of fold direction of a second flap of the integrated lid sections, as well as a third fold order and arrow of fold direction of a third flap of the integrated lid sections. Also visible is a deboss impression 1030 shaped in a partial semi-circle (or partial approximation of a semi-circle) or a partial semi-ovaloid (or partial approximation of a semi-ovaloid). Deboss impression 1030 can define a preferred finger or thumb locations for locking a tab of the third flap into a slot of the second flap, as described herein. Deboss impression depth(s), debossing plate thicknesses and debossing plate pressures described herein can be implemented for debossed impressions 1010, 1020, 1030 to achieve a permanent (or semi-permanent) physical impression, indentation or the like, in a material of the spill resistant integrated cup that provides both visual information and tactile information as to a fold order, fold direction and optionally preferred finger location(s) for one or more of the integrated lid sections of the spill resistance integrated folding lid.

In regard to the various functions performed by the above described components, integrated lid portion(s), sidewall portion(s), bottom portion(s), and described novel characteristics thereof (alone and in combination), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function or characteristic of the described component (e.g., a functional equivalent), even though not structurally equivalent to the disclosed structure, which performs the function in the herein illustrated exemplary aspects of the embodiments. In this regard, it will also be recognized that the embodiments include alternate materials known to one of ordinary skill in the art for achieving a disclosed function(s), alternate dimensions of disclosed components known to one of ordinary skill for achieving a disclosed function(s), additional components not disclosed but understood as suitable alternatives to one of ordinary skill, or equivalents not explicitly disclosed but reasonably conveyed to one of ordinary skill in the art by way of the context disclosed herein.

In addition, while a particular feature may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. For instance, a feature in one drawing, illustration or embodiment can be applied to other drawings, illustrations or embodiments without limitation except where unsuitable to achieve described characteristics or functions of these other drawings, illustrations or embodiments. Furthermore, to the extent that the terms “includes,” and “including” and variants thereof are used in either the detailed description or the claims, these terms are intended to be inclusive in a manner similar to the term “comprising”.

As used in this application, the term “of” is intended to mean an inclusive “or” rather than an exclusive “of”. That is, unless specified otherwise, or clear from context, “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, if X employs A; X employs B; or X employs both A and B, then “X employs A or B” is satisfied under any of the foregoing instances. In addition, the articles “a” and “an” as used in this application and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from context to be directed to a singular form.

In other embodiments, combinations or sub-combinations of the above disclosed embodiments can be advantageously made. The drawings, illustrations and images of the subject disclosure are grouped for ease of understanding. However, it should be understood that combinations of drawings, illustrations, images or components (and sub-components) contained therein can be re-arranged in alternative embodiments of the present disclosure. It is also understood that the examples and embodiments described herein are for illustrative purposes only and that various modifications or changes in light thereof will be suggested to persons skilled in the art and are to be included within the spirit and purview of this application and scope of the appended claims.