METHOD OF MANUFACTURING AND AN ARTICLE FOR A DISPOSABLE LID WITH A WINDOW

Description

CROSS REFERENCE TO OTHER APPLICATIONS

The present application is a Continuation in Part of U.S. application Ser. No. 19/065,785 filed on Feb. 27, 2025, which is a Continuation in Part of the following US Design Applications: (a) Ser. No. 29/977,681 filed Dec. 10, 2024 for a Rectangular Lid with a Circular Window; (b) Ser. No. 29/977,682 filed Dec. 10, 2024 for a Rectangular Lid with a Heart Shaped Window; (c) Ser. No. 29/977,689 filed Dec. 10, 2024 for a Rectangular Lid with a Hexagon Shaped Window; (d) Ser. No. 29/977,691 filed Dec. 10, 2024 for a Rectangular Lid with a Triangular Shaped Window; (e) Ser. No. 29/977,692 filed Dec. 10, 2024 for a Rectangular Lid with a Square Shaped Window; (f) Ser. No. 29/977,693 filed Dec. 10, 2024 for a Rectangular Lid with a Diamond Shaped Window; (h) Ser. No. 29/977,701 filed Dec. 10, 2024 for a Rectangular Lid with a Star Shaped Window; (i) Ser. No. 29/977,705 filed Dec. 10, 2024 for a Rectangular Lid with a Rectangular Window; (j) Ser. No. 29/980,338 filed Dec. 24, 2024 for a Circular Lid with a Circular Shaped Window; (k) Ser. No. 29/980,340 filed Dec. 24, 2024 for a Circular Lid with a Heart Shaped Window; (l) Ser. No. 29/980,344 filed Dec. 24, 2024 for a Circular Lid with a Hexagon Shaped Window; (m) Ser. No. 29/980,345 filed Dec. 24, 2024 for a Circular Lid with a Triangular Shaped Window; (n) Ser. No. 29/980,349 filed Dec. 24, 2024 for a Circular Lid with a Square Shaped Window; (o) Ser. No. 29/980,354 filed Dec. 24, 2024 for a Circular Lid with a Diamond Shaped Window; (p) Ser. No. 29/980,355 filed Dec. 24, 2024 for a Circular Lid with a Star Shaped Window; and (q) Ser. No. 29/980,361 filed Dec. 24, 2024 for a Circular Lid with a Rectangular Shaped Window, all of which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to the art of pan lids manufactured from aluminum or cardboard such that the lids are disposable, and more particularly, the present invention is directed to a method of manufacturing and an article for a disposable lid with transparent windows.

BACKGROUND OF THE INVENTION

Disposable aluminum pans and their corresponding lids are often referred to as foil pans/lids widely used by consumers to cook and keep food warm. The lids have been manufactured by well know methods. When the lids are disposable aluminum, a die is used to stamp a sheet of aluminum into a lid. During the stamping process upper and lower dies are pressed together with the sheet of aluminum feed between the dies. After pressing, the lid is formed. In the case of disposable cardboard lids, typically multiple layers are secured/glued together Oftentimes, one side is a cardboard material and the other side is aluminum, aluminum film, sprayed aluminum particles or metalized polyester (generally referred to as a metallic side).

The lids are always a solid form of material that the consumer uses to completely cover the pan and the contents within the pan are kept warm. The problem is that for the user to look inside the pan, the user must remove either a portion of the lid or the entire lid. This immediately releases heat from the inside of the pan. Other lids which can be made of glass or made from a stainless steel or other material are known to exist with windows. However, there is no known (either now or in the prior art) aluminum disposable lid made from aluminum or cardboard to define a flexible/bendable pan lid with a transparent window.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the present invention, there is provided a method of manufacturing and an article for a disposable aluminum lid with a transparent window and the same for a disposable cardboard lid. Both lids are designed/configured for use with a disposable pan.

In a first embodiment there is a disposable aluminum lid. The lid is stamped from a bendable formed aluminum where the lid is configured to include a base defining a top section and a bottom section. The base terminating at an outside edge. A window is formed through the base and is positioned within the outside edge of the base. The lid further includes a skirt extending downwardly from an outside edge of the base and extending continuously around the base to form a well around the bottom section. The skirt further having a terminal lower edge. The lid further includes a transparent film material secured over the window on the bottom section of the base.

In a second embodiment this is provided a disposable aluminum lid. The lid is stamped from aluminum. The lid is configured to include a base terminating around a periphery at an edge and the base has a top section and bottom section. A continuous skirt wall extends downwardly from the edge of the base to form a well around the bottom section. The continuous skirt being configured to bend. A window is formed through the base and further formed within the periphery of the base. A transparent film material is secured over the window on the bottom section of the base.

In a third embodiment there is provided a method of manufacturing a disposable aluminum lid comprising the steps of: (a) placing a sheet of aluminum between a pair of die shoes; (b) stamping the pair of die shoes together to form, from the sheet of an aluminum, a disposable aluminum lid, and wherein the disposable aluminum lid is defined to include a base with a top section and a bottom section, the base terminating around a periphery at an edge and a skirt downwardly extending from the edge of the base; (c) cutting a window through the disposable aluminum lid; and (d) securing a transparent film material over the window on the bottom section of the lid.

In a fourth embodiment of the invention, there is provided a disposable cardboard lid for a disposable pan. The lid includes a base having a cardboard material side and a metallic material side secured to each other. The base has an outside terminal edge. A window is formed through the base. A transparent film material is secured to one side of either the carboard material side or metallic material side.

In a fifth embodiment of the invention, there is provided a method of forming a disposable cardboard lid for a disposable pan. The method includes the steps of (a) providing a cardboard material; (b) providing an metallic material (such as aluminum or metalized polyester); (c) laminating the cardboard material to the metallic material to form a base; (d) cutting the base to a predefined shape with an outside terminal edge; (e) cutting a window through the base; and (f) securing a transparent film material to one side of either the cardboard material or the metallic material.

In a sixth embodiment of the invention, the laminated material is received from a supplier and then the steps are as follows (a) cutting the laminated material to a predefined shape with an outside terminal edge; (b) cutting a window through the base; and (c) securing a transparent film material to one side of either the cardboard material or the metallic material.

In one or more of these embodiments, there may also be an adhesive secured around a boarder of the window on the bottom section to secure the transparent film material to the bottom section. It is also possible that the transparent film material is secured to the side of the lid by heat.

In addition, the window may have a profile shape from one of the following shapes: rectangle, square, circle, heart, hexagon, triangle, diamond, and star. And yet, in addition, the disposable lid has a defined shape of one of the following shapes, rectangle, square, circle, and oval.

Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims, and from the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

A fuller understanding of the foregoing may be had by reference to the accompanying drawings, wherein:

FIGS. 1A-1D are prior art perspective views of disposable aluminum lids and disposable cardboard lids;

FIG. 2 is a representation of a stamp machine used in manufacturing disposable aluminum lids;

FIG. 3 is a representation of the press stamping showing the upper and lower dies;

FIG. 4 is a representation of an aluminum roll used in manufacturing disposable aluminum lids;

FIG. 5 is a representation of the aluminum feed between the upper and lower dies of the stamping machine;

FIG. 6 is a representation of the disposable aluminum lid being stamped;

FIG. 7 is a representation of the disposable aluminum lid after being stamped in the stamp machine;

FIG. 8 is a representation of the upper die having a cutting outline to cut a window in the disposable aluminum lid;

FIG. 9 is a representation of the disposable aluminum lid with a transparent window secured thereto;

FIG. 10 is an exploded view of the disposable aluminum lid with a transparent window;

FIG. 11 is a representation of the disposable aluminum lid moving off of a conveyor belt;

FIG. 12 is a perspective top view of the disposable aluminum lid with a transparent window;

FIG. 13A is a perspective bottom view of the disposable aluminum lid with a transparent window;

FIG. 13B shows the disposable aluminum lid with a transparent window positioned on a disposable aluminum pan;

FIG. 14 is a perspective top view of the disposable cardboard lid with a transparent window;

FIG. 15A is a perspective bottom view of the disposable cardboard lid with a transparent window;

FIG. 15B illustrates a rectangular disposable cardboard lid positioned over a disposable pan;

FIG. 15C illustrates a circular disposable cardboard lid positioned over a disposable pan;

FIGS. 16A-16D are illustrated rectangular disposable lids with circular shaped windows;

FIGS. 17A-17D are illustrated rectangular disposable lids with heart shaped windows;

FIGS. 18A-18D are illustrated rectangular disposable lids with hexagonal shaped windows;

FIGS. 19A-19D are illustrated rectangular disposable lids with triangular shaped windows;

FIGS. 20A-20D are illustrated rectangular disposable lids with square shaped windows;

FIGS. 21A-21D are illustrated rectangular disposable lids with diamond shaped windows;

FIGS. 22A-22D are illustrated rectangular disposable lids with star shaped windows;

FIGS. 23A-23D are illustrated circular disposable lids with circular shaped windows;

FIGS. 24A-24D are illustrated circular disposable lids with heart shaped windows;

FIGS. 25A-25D are illustrated circular disposable lids with hexagonal shaped windows;

FIGS. 26A-26D are illustrated circular disposable lids with triangular shaped windows;

FIGS. 27A-27D are illustrated circular disposable lids with square shaped windows;

FIGS. 28A-28D are illustrated circular disposable lids with diamond shaped windows;

FIGS. 29A-29D are illustrated circular disposable lids with star shaped windows; and

FIGS. 30A-30D are illustrated circular disposable lids with rectangular shaped windows.

DETAILED DESCRIPTION OF THE EMBODIMENTS

While the invention is susceptible to embodiments in many different forms, there are shown in the drawings and will be described herein, in detail, the preferred embodiments of the present invention. It should be understood, however, that the present disclosure is to be considered an exemplification of the principles of the invention and is not intended to limit the spirit or scope of the invention and/or claims of the embodiments illustrated.

With reference to Prior Art FIGS. 1A through 1d there is provided a disposable lid formed from stamping aluminum, generally referenced as a disposable aluminum lid 10. The disposable aluminum lid 10 includes a solid top base 12 that terminates about an edge 14 to a raised ridge 16 around the periphery of the edge 14. The raised ridge 16 extends into a downwardly extending skirt 18. The skirt terminates into a rolled lip 20 formed around the entire terminal edge 22 of the skirt. The edge 22 is configured to bend around the edge of the pan. The disposable aluminum lid 10 can have various shapes, square, rectangular 10, oval, and circular 30. In another prior art lid often used for disposable aluminum pans, are cardboard lids 40. The lids also include a solid top base 42 that terminates at a periphery edge 44. The cardboard lid 40 often has one side made from a cardboard material and has a flat aluminum side or metalized polyester side. The cardboard lid 40 fits onto an aluminum pan and the edges of the pan bend and crimp around the periphery edge 44 of the cardboard lid 40. Similarly to the disposable aluminum lids, the cardboard lids can also come in various shapes, such as, but not limited to square, rectangular 40, oval, and circular 50.

The main problem with the prior art lids is the top base portions are solid material. As such, when placed on a pan and secured, the only way to see the contents is to free an edge of the lid or remove the lid entirely. This is not necessarily helpful when cooking or reheating contents, as the removal of the lid (either a section or entirely) releases heat and moisture. As such, there is a desire and necessity to have a means for seeing the contents of the pan without removing a portion of the lid or the entire lid.

The disposable aluminum lid with a window 100 is formed from stamping aluminum. Referring now also to FIGS. 2 through 11 there is shown a method of manufacturing the disposable aluminum lids with windows 100. In the method of manufacturing, a die machine press 200 includes an upper shoe 205 and a lower shoe 210. A sheet of aluminum 220, fed from a roll 215, is positioned between the shoes, which are then hydraulically or mechanically pressed together forming the lid. The upper and lower shoes 205/210 are configured to stamp the disposable aluminum lids 100 Excess aluminum can then be recycled for future use.

The disposable aluminum lids 100 when formed are then moved into a cutting shoe 230 for cutting the window into the lid. When pressed the disposable aluminum lids 100 includes a window 105. It is also possible that the forming shoes include the cutting member such that when pressed from the aluminum sheet the lid is automatically formed with the window. Alternatively, it is possible that the windows are cut into the aluminum sheets prior entering into the stamping shoes.

The disposable aluminum lids 100 are then pressed with a transparent film material 110 over the window 105. The transparent film material 110 can be shaped similar to the shape of the window except slightly larger such that a boarder portion of the transparent film material overlaps a boarder section 115 of the window 105 or alternatively, the shape of the transparent film material can always be a rectangle or square that is large enough to cover the window. An adhesive 120, resin, or tape is positioned on the boarder portion of the lid prior to the transparent film material 110 being pressed and secured to the aluminum lid. The disposable aluminum lids with windows 110 are then moved from the processing stage and stacked for transport. Alternatively, the transparent film material can simply be secured to the inside lid by heat sealing or thermal boding. This can be accomplished since the transparent film material has a surface that melts and fuses to the inside of the lid during the heat sealing or thermal boding stage. This creates an airtight seal. Preferably, the film material is a coextruded polyester film.

Referring now to FIGS. 12 and 13A, when manufacturing, the disposable aluminum lids with windows 300 includes a top section 305 and bottom section 307. The top section 305 has an inside edge 310 and an outside edge 320. The inside edge 310 terminates at a window 350 cut out of the top base 305, while the outside edge 320 terminates about to a raised ridge 325 around the periphery of the outside edge 320. The raised ridge 325 extends into a downwardly extending skirt 330 that surrounds the bottom section 307 of the lid. The skirt 330 terminates into a rolled lip 335 formed around the entire terminal edge 340 of the skirt 330. The terminal edge 340 of the skirt is configured to bend around the edge of a pan. A transparent film material 355 is secured over the window 350 on the bottom section 307. Heat sealing or thermal boding is used to secure the transparent film material to the bottom section around the window. Alternatively, an adhesive, epoxy, glue, or resin 360 is used to secure the transparent film material 355 to a boarder section 365 surrounding the window 350. Since the lid is used in connection with food, it is preferred that the adhesive is a food grade adhesive, food safe epoxy or resin.

In FIG. 13B, there is shown the disposable aluminum lid 300 with a window 355 placed over a disposable pan 357.

Referring now to FIGS. 14 and 15A, in a similar fashion, when the disposable lid is a cardboard lid 400, the lid 400 is fashioned by securing (by laminating and forming) a cardboard sheet to a metallic material side. The metallic material side can either be an aluminum foil, an aluminum spray, or a metalized polyester. The two sides forming a carboard side 410 and metallic material side 420. The two side are laminated together typically by an adhesive or through heat-sealing. As noted above, the adhesive would be a food-safe adhesive capable of withstanding exposure to heat during use. Once laminated, the cardboard lid is cut to the desired size and shape.

In the present invention, after the lid is formed, the lid would then go through an additional cutting process to cut out a shaped window 430 in the lid. A transparent film material 440 is then secured to the metallic material side 420 (either by heat sealing, thermal bonding, or by an adhesive 450). The transparent film material 440 would be larger than the window, such that a boarder 455 is formed around the window 430. It could have a profile similar to the profile of the window or simply be rectangular, square, or circular larger than then window to ensure it fully covers the window.

It is noted above, the window could be cut prior to, at the same time as, or after the shape of the lid is cut.

Referring now to FIGS. 15B and 15C, the cardboard lid 400 is then placed onto a pan 480 with the lip 482 of the pan folded over the lid 400 and the consumer able to view the contents of the pan through the transparent window 475. Similarly, the lid 575 has a transparent window 577 and is placed on pan 578 and the lip 579 folded over the terminal edge of the lid.

In various embodiments, the disposable aluminum lids and the disposable cardboard lids can have various shapes and include different shape windows. Referring now to FIG. 16A-30D , there is shown: (a) rectangular disposable lids with circular shaped windows 500 and 505 (FIGS. 16A-16D); (b) rectangular disposable lids with heart shaped windows 510 and 515 (FIGS. 17A-17D); (c) rectangular disposable lids with hexagonal shaped windows 520 and 525 (FIGS. 18A-18D); (d) rectangular disposable lids with triangular shaped windows 530 and 535 (FIGS. 19A-19D); (e) rectangular disposable lids with square shaped windows 540 and 545 (FIGS. 20A-20D); (f) rectangular disposable lids with diamond shaped windows 550 and 555 (FIGS. 21A-21D); (g) rectangular disposable lids with star shaped windows 560 and 565 (FIGS. 22A-22D); (h) circular disposable lids with circular shaped windows 570 and 575 (FIGS. 23A-23D); (i) circular disposable lids with heart shaped windows 580 and 585 (FIGS. 24A-24D); (j) circular disposable lids with hexagonal shaped windows 590 and 595 (FIGS. 25A-25D); (k) circular disposable lids with triangular shaped windows 600 and 605 (FIGS. 26A-26D); (l) circular disposable lids with square shaped windows 610 and 615 (FIGS. 27A-27D); (m) circular disposable lids with diamond shaped windows 620 and 625 (FIGS. 28A-28D); (n) circular disposable lids with star shaped windows 630 and 635 (FIGS. 29A-29D); and (o) circular disposable lids with rectangular shaped windows 640 and 645 (FIGS. 30A-30D).

In a second embodiment there is provided a disposable aluminum lid. The lid is stamped from aluminum. The lid is configured to include a base terminating around a periphery at an edge and the base has a top section and bottom section. A continuous skirt wall extends downwardly from the edge of the base to form a well around the bottom section. The continuous skirt being configured to bend. A window is formed through the base and further formed within the periphery of the base. A transparent film material is secured over the window on the bottom section of the base.

In a third embodiment there is provided a method of manufacturing a disposable aluminum lid comprising the steps of: (a) placing a sheet of aluminum between a pair of die shoes; (b) stamping the pair of die shoes together to form, from the sheet of an aluminum, a disposable aluminum lid, and wherein the disposable aluminum lid is defined to include a base with a top section and a bottom section, the base terminating around a periphery at an edge and a skirt downwardly extending from the edge of the base; (c) cutting a window through the disposable aluminum lid; and (d) securing a transparent film material over the window on the bottom section of the lid.

In a fourth embodiment of the invention, there is provided a disposable cardboard lid for a disposable pan. The lid includes a base having a cardboard material side and an aluminum material side secured to each other. The base has an outside terminal edge. A window is formed through the base. A transparent film material is secured to one side of either the carboard material side or aluminum material side.

In a fifth embodiment of the invention, there is provided a method of forming a disposable cardboard lid for a disposable pan. The method includes the steps of (a) providing a cardboard material; (b) providing an aluminum material; (c) laminating the cardboard material to the aluminum material to form a base; (d) cutting the base to a predefined shape with an outside terminal edge; (e) cutting a window through the base; and (f) securing a transparent film material to one side of either the cardboard material or the aluminum material.

In a sixth embodiment, the laminated material is received from a supplier and then the steps are as follows (a) cutting the laminated material to a predefined shape with an outside terminal edge; (b) cutting a window through the base; and (c) securing a transparent film material to one side of either the cardboard material or the metallic material.

In one or more of these embodiments, there may also be an adhesive secured around a boarder of the window on the bottom section to secure the transparent film material to the bottom section. In addition, the window may have a profile shape from one of the following shapes: rectangle, square, circle, heart, hexagon, triangle, diamond, and star. And yet, in addition, the disposable aluminum lid has a defined shape of one of the following shapes, rectangle, square, circle, and oval.

From the foregoing and as mentioned above, it will be observed that numerous variations and modifications may be effected without departing from the spirit and scope of the novel concept of the invention. It is to be understood that no limitation with respect to the specific methods and apparatus illustrated herein is intended or should be inferred. It is, of course, intended to cover by the appended claims all such modifications as fall within the scope of the claims.