U.S. patent application number 09/929466 was filed with the patent office on 2002-06-20 for printed inserts for thermoformed plastic disposable food containers.
Invention is credited to Melton, Bruce W..
Application Number | 20020074337 09/929466 |
Document ID | / |
Family ID | 26919317 |
Filed Date | 2002-06-20 |
United States Patent
Application |
20020074337 |
Kind Code |
A1 |
Melton, Bruce W. |
June 20, 2002 |
Printed inserts for thermoformed plastic disposable food
containers
Abstract
A beverage container lid has an insert area for placement of a
paper insert with graphics printed thereon.
Inventors: |
Melton, Bruce W.; (Hinsdale,
IL) |
Correspondence
Address: |
Hugh A. Abrams, Esq.
Sidley Austin Brown & Wood
Bank One Plaza
10 S. Dearborn Street
Chicago
IL
60603
US
|
Family ID: |
26919317 |
Appl. No.: |
09/929466 |
Filed: |
August 14, 2001 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60225122 |
Aug 14, 2000 |
|
|
|
Current U.S.
Class: |
220/713 ;
206/459.5 |
Current CPC
Class: |
B65D 2543/00046
20130101; G09F 23/00 20130101; B65D 51/245 20130101 |
Class at
Publication: |
220/713 ;
206/459.5 |
International
Class: |
A47G 019/22 |
Claims
What is claimed is:
1. A lid for a beverage container, comprising: a container
attachment portion for attachment to an associated beverage
container, a cover portion extending radially inward from said
container attachment portion, a drinking opening formed in said
cover portion, and an insert area formed in said cover portion,
said insert area positioned to hold a separate paper insert with
graphics printed thereon.
Description
[0001] This application claims the benefit of U.S. Provisional
Application Serial No. 60/225,122 filed Aug. 14, 2000.
BACKGROUND OF THE INVENTION
[0002] Thermoformed plastic disposable food containers, trays,
plates, cups, and cup lids, clamshell boxes and the like
(collectively, "thermoformed disposable food containers") are
becoming increasingly common. From a manufacturing point of view,
thermoformed containers have distinct advantages over other types
of plastic containers, chiefly, those that are injection-molded.
For example, thermoformed disposable food containers are thinner,
lighter, and use less resin material than injection-molded
containers. A variety of resins and pigments are available, singly
or in combination that can be used to produce a variety of colors
and degrees of transparency in thermoformed disposable food
containers, from black to crystal clear, and some current clamshell
designs use two different colors bonded together. Thermoforming
also involves a one-sided mold, substantially reducing moldmaking
costs when compared to the two-sided mold needed for injection
molding. But, most important of all, thermoforming is substantially
faster than injection-molding.
[0003] From a foodservice operator's point of view, thermoformed
disposable food containers are beneficial because they are widely
available, relatively inexpensive, stack in a fairly compact way,
and are highly effective at containing foods and liquids.
[0004] The state of the art in thermoforming today, however, has
its drawbacks. With rare exception, thermoformed disposable food
containers cannot be economically manufactured in small quantities.
Indeed, successful thermoformers aim to run one thermoforming
"line" running with the same mold 24 hours a day for months on end.
The result is that all thermoformed disposable food containers
basically look alike. Because it is difficult to differentiate
thermoformed disposable food containers unless they have a unique,
patented functional feature, this type of "commodity" thermoforming
is highly competitive.
[0005] Thus, from a food service provider's point of view,
thermoformed disposable food containers are viewed as little more
than efficient food packaging. With rare exception, foodservice
retailers use "stock" cup lids, clamshell boxes, and the like
because custom thermoforming is much more costly. For example, a
restaurant that wanted to include its name in a thermoformed food
container would need to have a mold made (or an insert to a larger
mold made) specifically for that customer's use. Because the mold
must be tailored to an individual customer's needs, mold costs are
relatively high, and the cost to the manufacturer of turning off
its thermoforming line to change molds for different customers is
also substantial. Finally, because so few thermoformers will
undertake low-volume "custom" work, the costs of shipping
thermoformed disposable food containers from a far-off custom
thermoformer can be relatively high. Putting aside the higher costs
of custom thermoformed disposable food containers, the technology
offers no opportunity for the use of a contrasting color and,
because the mold for each letter of text or recessed area of an
image must have a vacuum hole, it is difficult and prohibitively
expensive to produce a thermoforming mold with more than a few
words of text or a simple image.
[0006] In today's foodservice market, however, branding and image
is essential. Foodservice retailers invariably print logos, custom
designs, entertainment "tie-in" promotions, and the like on paper
bags and cups. Cup lids and thermoformed plastic food containers
are, however, typically the same from retailer to retailer. In many
instances, the thermoformed disposable plastic food container is
the foodservice operator's last link to its customers: they sip
through cup lids and they eat or serve from the clamshell box or
deli tray. Some foodservice operators have used printed,
adhesive-backed stickers to enhance the appearance of thermoformed
disposable plastic food containers, such as sandwich boxes and deli
trays, but this method of customization is expensive, has
significant size limitations, and the final appearance of the
package depends on the skill with which the foodservice employee
attaches the sticker. The glossy look of most stickers might also
be unappealing in certain situations, e.g., on the top of a hot cup
lid. Some thermoformers are printing directly on the plastic during
the manufacturing process, but, again, these technologies are
complicated due to the nature of the hot plastic, the molding
process, and the presence of static electricity. And, even without
these limitations, changing from one custom-printed thermoforming
job to another will be quite costly because the thermoforming line
must be shut down during the transition process.
SUMMARY OF INVENTION
[0007] The present invention takes advantage of the "quantities of
scale" offered by thermoforming and combines it with low-cost and
widely available flat paper printing technologies to overcome many
of the "image" disadvantages of thermoformed disposable food
containers today. The invention is a shallow recess incorporated
into existing or new thermoforming molds; this recess, when
combined with a small snap "rim," would accommodate thin printed
cards. The cards could be printed, embossed, or otherwise marked on
a wide variety of materials, including plastic, foil, and films,
although paper would most likely be the least expensive and the
most popular. The snap "rim" is indicated in FIGS. 14-16.
BRIEF DESCRIPTION OF DRAWINGS
[0008] FIG. 1 shows a hot dome lid insert;
[0009] FIG. 1A shows a side view of a hot dome lid insert;
[0010] FIG. 2 shows a hot dome lid insert;
[0011] FIG. 2A shows a dome lid insert;
[0012] FIG. 3 shows a hot flat lid insert;
[0013] FIG. 3A shows a side view of a hot flat lid insert;
[0014] FIG. 4 shows a cold lid insert;
[0015] FIG. 4a shows a side view of a cold lid insert;
[0016] FIG. 5 shows a cold lid insert;
[0017] FIG. 5a shows a side view of a cold lid insert;
[0018] FIG. 6 shows a cold lid insert;
[0019] FIG. 6a shows a side view of a cold lid insert;
[0020] FIG. 7 shows a clamshell box;
[0021] FIG. 7A shows a side view of a clamshell box;
[0022] FIG. 8A shows a clamshell box wit multiple insert rims;
[0023] FIG. 8B shows a side view of a clamshell box with multiple
insert rims;
[0024] FIG. 9A shows a deli tray;
[0025] FIG. 9B shows a side view of a deli tray;
[0026] FIG. 10A shows a plastic plate or deli tray bottom;
[0027] FIG. 10B shows a side view of a plastic plate;
[0028] FIG. 11 shows a thermoformed container top with large insert
panel;
[0029] FIG. 12 shows a thermoformed container top with small insert
panel, enhances display of container contents;
[0030] FIG. 13 shows a thermoformed container top with small insert
area for standard-size business card;
[0031] FIG. 14 shows a side view of a printed card on top of
container;
[0032] FIG. 15 shows a side view of a printed card on bottom of
container;
[0033] FIG. 16 shows finger indents for card removal;
[0034] FIG. 16A shows a side view of finger indents for card
removal;
[0035] FIG. 16B shows a top view of finger indents for card
removal;
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0036] As indicated in FIGS. 1 through 13, the foregoing snap
rim/printed card invention has wide application in thermoformed
plastic disposable hot cup lids, cold cup lids, clamshell boxes,
deli trays, and plates. The invention covers all of these
embodiments and any other in which a recess and snap rim are molded
into a thermoformed disposable food container for purposes of
accepting a flat card. The insert includes sip hole 1, paper inner
lid 3 and recessed flange 5.
[0037] The shallow recess and rim could be molded into current
thermoformed molds with only minor modifications and without
detracting from the appearance of the finished product. Indeed,
most thermoformed disposable food containers already incorporate
inset panels to add strength and enhance appearance. Thus, a
thermoformed disposable food container could be modified slightly
to incorporate the new technology, and the packaging would be as
useful as it was before even if the foodservice operator did not
want to use custom-printed inserts in the container.
[0038] Custom-printed inserts would, however, offer foodservice
operators significant advantages. Visually, a printed insert, in up
to four colors, would be far more eye-catching than a plain
"commodity" thermoformed plastic disposable food container. The
insert could be customized not only to identify the foodservice
operator and reinforce its "brand image," but also to serve as a
convenient removable "coupon," advertising flyer, or self-addressed
feedback card--uses for which the current labeling alternative,
self-adhesive stickers, are impractical. In this regard, FIGS. 16A
and 16B indicate a thermoformed recess and snap rim that has small
indents around the periphery of the printed card to allow for easy
removal. A small tab 7 could also be included in the printed card
to facilitate removal, as indicated in FIG. 3. The insert cards
could also serve as games, toys, or collectibles. For example, the
donut-shaped insert in FIG. 6 could be printed to depict a flying
saucer toy that could be removed and used by a child after the
beverage is consumed. Another embodiment would be to use a card
that, when likely, just before the formed and slightly cooled
pieces are die-cut) or after the thermoforming (either mechanically
or by hand). Equally important, however, is the prospect of
allowing foodservice operators to contract for their own printing
in the standard sizes. Thus, a foodservice operator could customize
the lids themselves, adding the printed cards at some point in the
preparation and serving process. For the smallest foodservice
operators, the insert cards could be produced with a personal
computer and an attached printer. Again, it is anticipated that the
shapes and sizes of the insert cards would, ideally, follow
standard printing formats, e.g., business cards, 4.times.5 inch
notecards, half sheets of paper, and the like, to simplify the
printing process and utilize card stock most efficiently.
[0039] None of the inconveniences and costs associated with custom
thermoforming applies to conventional printed card inserts. Print
shops are numerous and widespread, certainly more so than
thermoformers. Indeed, printing is a highly competitive and price
sensitive industry; if anything, it is more of a "commodity"
business than the thermoforming industry. Printing allows virtually
photographic detail and fine-point text. Four-color graphics are
visually exciting and permit images to be rendered quite
realistically.
[0040] In short, the use of a printed card insert and a shallow
snap rim design in a thermoformed disposable food container would
allow virtually unlimited customization of thermoformed disposable
food packaging without it affecting the speed and efficiency of a
thermoforming line or a printing line. The technologies could be
combined in the thermoforming process, by the thermoformer after
the container has been cut and before it is packaged, by a separate
jobber prior to final delivery, or by the foodservice operator
immediately before serving. The invention thus offers new
opportunities for customizing food packaging at a relatively low
cost.
* * * * *