U.S. patent application number 14/168922 was filed with the patent office on 2014-05-29 for paper-based container lids and methods for making the same.
This patent application is currently assigned to MEADWESTVACO CORPORATION. The applicant listed for this patent is MeadWestVaco Corporation. Invention is credited to Rune K. Haraldsson, Wade Harris, Bhagwandat Mohan, Jeremy D. Mowery, Joel C. Panek, Matthew E. Zacherle.
Application Number | 20140144923 14/168922 |
Document ID | / |
Family ID | 49117968 |
Filed Date | 2014-05-29 |
United States Patent
Application |
20140144923 |
Kind Code |
A1 |
Panek; Joel C. ; et
al. |
May 29, 2014 |
PAPER-BASED CONTAINER LIDS AND METHODS FOR MAKING THE SAME
Abstract
A paper-based container lid comprises a top wall, a side wall
connecting to the top wall, and a sealing channel formed on the
side wall for sealingly engaging a rim of the container and
securing the lid to the container, wherein the top wall and the
side wall are preferably formed from separate blanks.
Inventors: |
Panek; Joel C.; (Moseley,
VA) ; Harris; Wade; (Lumberton, TX) ; Mohan;
Bhagwandat; (Henrico, VA) ; Haraldsson; Rune K.;
(Ashland, VA) ; Zacherle; Matthew E.;
(Chesterfield, VA) ; Mowery; Jeremy D.;
(Germantown, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MeadWestVaco Corporation |
Richmond |
VA |
US |
|
|
Assignee: |
MEADWESTVACO CORPORATION
Richmond
VA
|
Family ID: |
49117968 |
Appl. No.: |
14/168922 |
Filed: |
January 30, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13973663 |
Aug 22, 2013 |
|
|
|
14168922 |
|
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|
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61692065 |
Aug 22, 2012 |
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Current U.S.
Class: |
220/713 |
Current CPC
Class: |
B65D 43/0214 20130101;
B65D 2543/00046 20130101; B65D 43/0212 20130101; B65D 2543/00092
20130101; B65D 2543/00027 20130101; A47G 19/2272 20130101; B65D
2543/00268 20130101 |
Class at
Publication: |
220/713 |
International
Class: |
A47G 19/22 20060101
A47G019/22 |
Claims
1) A lid for a container, comprising: a) a paperboard side wall
formed from a first blank, wherein the side wall extends about a
longitudinal axis and includes longitudinally opposed first and
second ends; and b) a paperboard top wall formed from a second
blank, wherein the first blank is different from the second blank,
i) wherein the top wall is connected to the side wall proximate the
first end, and ii) wherein the top wall includes an opening
therein.
2) The lid for a container as recited in claim 1, further
comprising a sealing channel formed in the side wall between the
first end and the second end.
3) The lid for a container as recited in claim 2, wherein the
sealing channel is projects radially.
4) The lid for a container as recited in claim 1, further
comprising a substantially vertical seam between the first end and
the second end of the side wall.
5) The lid for a container as recited in claim 4, wherein the seam
is compressed.
6) The lid for a container as recited in claim 4, wherein the
opening is positioned opposite of the seam.
7) The lid for a container as recited in claim 1, a) wherein the
side wall includes an inner surface, wherein the inner surface
includes a polymer coating, b) wherein the top wall includes a
lower surface and an upper surface, wherein the lower surface and
the upper surface each include a polymer coating, c) wherein the
upper surface of the top wall is connected to the inner surface of
the side wall by a polymer-to-polymer bond, and d) wherein the
lower surface of the top wall is connected to the inner surface of
the side wall by a polymer-to-polymer bond.
8) The lid for a container as recited in claim 1, a) wherein a
joint section is defined by where the first end of the side wall is
connected to the top wall, b) wherein the joint section includes a
top end, c) wherein the top end forms a lid rim, and d) wherein the
lid rim includes a substantially rounded section.
9) The lid for a container as recited in claim 8, wherein the
substantially rounded section of the lid rim is oriented toward the
longitudinal axis.
10) The lid for a container as recited in claim 8, wherein the
joint section further includes a middle section below the top end,
wherein the rim has a width associated therewith, wherein the
middle section has a width associated therewith, and wherein the
width of the rim is greater than the width of the middle
section.
11) The lid for a container as recited in claim 8, wherein the
joint section further includes a bottom end below the middle
section, and wherein the bottom end flares toward the longitudinal
axis.
12) The lid for a container as recited in claim 8, wherein the
opening is located below the rim.
13) The lid for a container as recited in claim 1, wherein the top
wall includes a debossed section, and wherein the opening is
located within the debossed section.
14) The lid for a container as recited in claim 13, wherein the top
wall includes an embossed section located adjacent to the debossed
section.
15) The lid for a container as recited in claim 2, wherein a
section of the side wall above the sealing channel is oriented
toward the longitudinal axis and wherein a section of the side wall
below the sealing channel is oriented away from the longitudinal
axis.
16) A lid for a container, comprising: a) a paperboard side wall
formed from a first blank, wherein the side wall extends about a
longitudinal axis and includes longitudinally opposed first and
second ends, i) wherein a sealing channel is formed in the side
wall between the first end and the second end, ii) wherein a
substantially vertical seam is formed between the first end and the
second end of the side wall, iii) wherein the side wall includes an
inner surface, wherein the inner surface includes a polymer
coating; and b) a paperboard top wall formed from a second blank,
wherein the first blank is different from the second blank, i)
wherein the top wall includes an opening therein. ii) wherein the
top wall includes a lower surface and an upper surface, wherein the
lower surface and the upper surface each include a polymer coating,
and iii) wherein the top wall is connected to the side wall
proximate the first end to define a joint section, (1) wherein the
upper surface of the top wall is connected to the inner surface of
the side wall by a polymer-to-polymer bond, and (2) wherein the
lower surface of the top wall is connected to the inner surface of
the side wall by a polymer-to-polymer bond.
17) The lid for a container as recited in claim 16, wherein the
sealing channel projects radially.
18) The lid for a container as recited in claim 16, wherein the
seam is compressed.
19) The lid for a container as recited in claim 16, wherein the
joint section includes a top end forming a lid rim having a
substantially rounded section.
20) The lid for a container as recited in claim 16, wherein the top
wall includes a debossed section, and wherein the opening is
located within the debossed section.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of application Ser. No.
13/973,663 filed on Aug. 22, 2013 which claims the benefit of U.S.
Provisional Application 61/692,065 filed on Aug. 22, 2012, entitled
Paper-Based Container Lids and Methods for Making. Both of the
foregoing applications are incorporated herein by reference in
their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The subject disclosure relates to paper-based container lids
and methods of making the same, and more particularly to lids for
containers, such as beverage cups, which can be economically
formed, are capable of being used with hot liquids, and include a
sealing channel that creates an enhanced sealing interface with a
corresponding rim formed on the container.
[0004] 2. Background of the Related Art
[0005] Hot beverages, such as coffee, tea or the like, are
frequently sold as a takeout item and supplied in disposable cups
with thin plastic lids fasten over the rim of drinking cups. Such
lids prevent spillage and evaporation of the beverage within the
cup, and help insulating the contents of the cup from the ambient
temperature by closing the cup opening. Drinking cup lids, such as
those used by restaurants, convenience stores, and coffee houses,
are commonly made of plastics. They are inexpensive and therefore
suitable for disposable use. A well-known method of manufacturing
plastic cup lids is by vacuum forming, which is a plastic
thermoforming process that involves forming thermoplastic sheets
into three-dimensional shapes through the application of heat and
pressure. During the vacuum forming process, the plastic material
is heated until it becomes pliable, then placed over a mold and
drawn in by a vacuum until it takes on the desired shape. The
vacuum thermoforming allows cup lids to be manufactured very
inexpensively.
[0006] U.S. Pat. No. 4,589,569 discloses a disposable lid of one
piece plastic construction that can be manufactured relatively
inexpensively. The lid is manufactured by a thermoforming
operation, preferably vacuum forming. The lid includes an annular
mounting portion for engaging the lip of the cup; an annular side
wall extending upwardly from the mounting portion; and a top wall
having a drinking opening and a recess formed adjacent the drinking
opening to accommodate the upper lip of the user.
[0007] Some plastics are not biodegradable, and increasing
environmental concerns drive the needs for inexpensive and
biodegradable lids as alternatives for disposable plastic lids.
[0008] Efforts to produce paper-based lids for containers/cups have
had limited commercial success due to the complicated manufacturing
process and the poor sealing between the cup body and the lid
sealing ring that results in leakage of fluid contents from the
cup. The poor lid sealing and leakage is worse when the cup is for
hot beverages. Lids made from a single paperboard blank do not
effectively seal around the rim of the containers. During the
manufacturing process, substantial crimps are formed in the sealing
ring portion of the lid, resulting in gaps when the ring attaches
to the rim of the container and consequently a source of fluid
leaks.
[0009] U.S. Publication No. 2010/0243722 addresses the leaking
problem by using paperboard lids manufactured without the
substantial crimps formed in the sealing rings. The lid includes a
single contiguous molded paperboard body configured to conformingly
couple to the container rim. The lid is formed by placing an
unformed paperboard blank inside a press machine that uses
compression forces to shape the paperboard blank into the lid. The
draw and pressure rings hold the blank in place, while the male and
female mold components of the machine compress the blank into a lid
shape. By holding the paperboard blank with draw and pressure rings
while the blank is pressed into the lid shape, the formation of
substantial crimps typically occurring during the press step can be
prevented.
[0010] There have been reports of paper-based cups with integrated
lids. For example, U.S. Pat. No. 6,592,504 discloses a disposable
paperboard cup that includes a bottom insert, and a substantially
truncated conical body with an integral lid and a cup opening. The
integral lid is movable between a raised position and a closed
position. The lid has a free edge with an opening that provides an
access to the fluid contents inside the cup when the lid is in the
closed position. The lid is formed from a semi-circular die-cut
piece adjoined to the body portion of the cup. The cup with
integrated lid requires complex folding mechanisms, rendering it
expensive and difficult to manufacture. Furthermore, the cup with
integrated lid possesses a wide top, which is subjected to spillage
and is difficult to achieve an adequate sealing between the lid and
the container body, resulting in leaking of the packaged
contents.
[0011] Moreover, Inmaco BV located in the Netherlands offers for
sale a paper-based cup lid. A cross-section of the cup-lid
interface in the Inmaco product is illustrated in FIG. 13E. As
shown therein, the Inmaco lid 80 includes a cylindrical sidewall 82
and a top wall 81. The sidewall 82 is spiral wound and is made out
of 3 layers of paperboard and adhesive and includes a
circumferentially formed bead 85 which extends radially inward from
the sidewall 82. When the lid 80 is placed on top of the rim "R" of
the cup, the sidewall 82 deflects so that the rim "R" of the cup
can pass by the circumferential bead 85. Once passed the bead 85,
the sidewall 82 relaxes and traps the rim "R" of the cup between
the bead 85, a flat section 87 of the sidewall 82 and the top wall
81.
[0012] As noted above, the bead 85 formed in the sidewall 82 around
the circumference of the Inmaco lid 80 secures the lid to an
appropriately sized container. The fit is fairly tight radially,
i.e. there is a close match between the outer diameter of the
container rim "R" and the inner diameter of the lid 80. However,
there is not a tight fit axially; the lid 80 can move up and down
and thus it does not provide good leak resistance for liquids. In
fact, in the lids tested by the inventors, the lid could move up
and down by as much as 1.5 mm. Moreover, since the sidewall 82 of
the lid in the sealing zone is flat (section 87) and rim "R" is
curved there is no mating contact between the sidewall 82 and rim
surfaces, and thus the seal is poor.
[0013] A further disadvantage of the Inmaco lid 80 is that the
sidewall has a spiral seam. It is difficult to minimize the visual
impact this seam by compressing it further, because this won't
necessarily make the gap between the ends of the sidewall blank
smaller. Moreover, using a spiral wound sidewall makes it extremely
difficult to register or position the seam at a specific location
around the periphery of the lids. For these reasons and to the best
knowledge of the inventors, the Inmaco lid has not been offered
commercially with a hole for drinking nor has it been used with
liquids.
[0014] An additional disadvantage of the Inmaco lid 80 is its
stacking height. Because the sidewall of the Inmaco lid 80 is
substantially straight, with no taper, and the bead 85 is formed
radially inward, the stacking height of the Inmaco lid 80 is
limited by the location of the bead 85 and the height of the skirt
below the bead.
[0015] It is known that a bead or fill line in a beverage container
such as a paper cup can be formed by utilizing a spinning forming
disc, wherein the disc is spun into a position near the top of the
sidewall of the paper container thereby creating a bead, groove or
fill line in the sidewall of the container. This apparatus requires
a cam follower in a machined cam track, a cam drive shaft in a
relatively complicated header assembly, and an auxiliary loader for
the spinning disc. Thus, a substantial number of precision moving
parts are required. Such units are therefore relatively expensive
to construct and to maintain.
[0016] To address these drawbacks, U.S. Pat. No. 4,247,277
disclosed a non-spinning apparatus for forming a fill line or
groove in paper cups or containers by axially compressing an
annulus of a resilient material into the inside of paper cups,
thereby causing a controlled deformation of the cup material
outwardly about its periphery. Rather than a rotating movement of
the spinning disc, the apparatus relies on the up- and
down-movement of the compressed resilient material for a formation
of the fill line or groove. The outward deformation occurs
internally of a cup die where a portion of the sidewall of a paper
cup or container confined within the die is forced by the
compressed annulus to form the fill line or groove. While this
apparatus is less complicated than the spinning forming discs
previously used for the same purpose, it is still a complicated
apparatus which requires moving parts that tend to wear, require
maintenance and replacement.
[0017] U.S. Pat. No. 5,637,332 discloses a simplified apparatus for
forming a fill line in a paper container such as a paper cup that
includes no moving parts. A fill line is formed by forcing a punch
of a mating ring into a finished cup positioned in a die which
includes an annular recess spaced below the rim of the finished
cup, and the annular recess terminates in a bottom edge to serve as
an anvil surface for forming the fill line.
[0018] U.S. Pat. No. 6,663,926 discloses an apparatus for forming a
rib on the side wall of the cup via an operation of the rib
processing tool performed outside the cup body, thereby improving
the process efficiency by eliminating a need of moving a rib
processing tool in and out against the cup body. Furthermore, the
apparatus allows the rib to be formed gradually in the
circumferential direction of the cup body, in accordance with the
relative rotation between the cup body and the rib processing tool.
Therefore, it is possible to reduce force added to the cup body
during the rib formation in comparison with the case in which the
entire rib is formed at once.
[0019] U.S. Pat. No. 7,753,832 discloses an apparatus for molding
an article produced from paperboard or cardboard, wherein a
momentary irradiation of the microwave frequency is exerted on the
molded board to improve its moldability. To form a cup with an
annular crease on the side wall, the cup is placed on a base and
supported at its side wall by a carrier ring having an annular
groove that is corresponding to the crease to be made in the cup.
The apparatus includes a base to support the cup bottom; a carrier
ring with an annular groove to support the cup side wall; a moving
tool; a crease forming tool connected to the moving tool, wherein
the crease forming tool is corresponding to the groove of the
carrier ring and the crease to be created on the cup side wall. The
moving tool is lowered inside the cup so that its lower end is
level with the groove of the carrier ring, and the irradiators on
the moving tool exert microwave frequency on the side of the cup at
the point where the crease is to be formed to permanently mold the
creased side wall.
[0020] Despite extensive research for paper-based container lids,
particularly for the drinking cup lids, several drawbacks remain.
Examples of such drawbacks described in part above include:
complexity of production; lack of recyclability either due to the
use of recyclable/compostable materials or the difficulties in
operating reclamation systems when the cup and the lid are made of
different materials; insufficient consumer acceptance due to
inadequacies in material "mouth feel" or design, decreased
aesthetic appeals when the packaged fluids stain the lid
manufactured from molded pulp; and poor lid performance due to
inadequate sealing of the lid to the cup, especially after several
usage cycles.
[0021] Accordingly, there is still a need for paper-based container
lids that can be produced economically and with less complicated
processes than known paper-based lids, and which provide acceptable
lid performance (if not enhanced) compared to known paper-based
lids. Moreover, there is a need for paper-based container lids
which can be used with hot liquids and are constructed to provide
an enhanced sealing interface with the containers so as to
minimize, if not eliminate, the leakage of contents packaged in the
containers.
SUMMARY OF THE INVENTION
[0022] The present disclosure is directed to a lid for a container
that includes, inter alia, a paperboard side wall formed from a
first blank, wherein the side wall extends about a longitudinal
axis and includes longitudinally opposed first and second ends; and
a paperboard top wall formed from a second blank, wherein the first
blank is different from the second blank. The top wall of the lid
is connected to the side wall proximate the first end and the top
wall includes an opening therein.
[0023] Preferably, the lid further includes a sealing channel
formed in the side wall between the first end and the second end.
In certain embodiments, the sealing channel projects radially
outward.
[0024] It is envisioned that the side wall of the lid can include a
substantially vertical seam between the first end and the second
end of the side wall. The seam can be compressed. Preferably, the
opening is positioned opposite of the seam.
[0025] In embodiments of the present lid disclosure, the side wall
includes an inner surface which has a polymer coating; the top wall
includes a lower surface and an upper surface, wherein the lower
surface and the upper surface of the top wall each include a
polymer coating. In such constructions, the upper surface of the
top wall is connected to the inner surface of the side wall by a
polymer-to-polymer bond and the lower surface of the top wall is
connected to the inner surface of the side wall by a
polymer-to-polymer bond.
[0026] It is envisioned that the lid of the present disclosure can
include a joint section defined by where the first end of the side
wall is connected to the top wall. In such constructions, the joint
section includes a top end that forms a lid rim and the lid rim
includes a substantially rounded section. In certain constructions,
the substantially rounded section of the lid rim is oriented toward
the longitudinal axis.
[0027] In certain embodiments of the present lid disclosure, the
joint section further includes a middle section below the top end,
wherein the rim has a width associated therewith, wherein the
middle section has a width associated therewith, and wherein the
width of the rim is greater than the width of the middle
section.
[0028] It is further envisioned that the joint section of the lid
can include a bottom end below the middle section, and wherein the
bottom end flares toward the longitudinal axis.
[0029] In certain constructions of the present invention, the
opening is formed in the lid below the rim. Moreover, the top wall
can include a debossed section, and wherein the opening is located
within the debossed section. The top wall can further include an
embossed section located adjacent to the debossed section.
[0030] The present disclosure is further directed to a lid for a
container that includes a paperboard side wall formed from a first
blank and a paperboard top wall formed from a second blank. The
side wall extends about a longitudinal axis and includes
longitudinally opposed first and second ends, wherein a sealing
channel is formed in the side wall between the first end and the
second end. A substantially vertical seam is formed between the
first end and the second end of the side wall and the side wall
includes an inner surface, wherein the inner surface includes a
polymer coating. In the present lid construction, the first blank
is different from the second blank. Moreover, the top wall includes
an opening and a lower surface and an upper surface. The lower
surface and the upper surface each include a polymer coating, and
the top wall is connected to the side wall proximate the first end
to define a joint section. Still further, the upper surface of the
top wall is connected to the inner surface of the side wall by a
polymer-to-polymer bond and the lower surface of the top wall is
connected to the inner surface of the side wall by a
polymer-to-polymer bond.
[0031] Preferably, the sealing channel projects radially
outward.
[0032] In certain embodiments, the seam is compressed.
[0033] It is envisioned that the joint section can include a top
end forming a lid rim having a substantially rounded section.
Moreover, the top wall can include a debossed section and the
opening is located within the debossed section.
[0034] The present disclosure is also directed to a lid for a
container that includes a side wall and a top wall. The side wall
extends about a longitudinal axis and has longitudinally opposed
first and second ends, wherein an outwardly projecting sealing
channel is formed in the side wall between the first end and the
second end. The top wall is connected to the side wall between the
outwardly projecting sealing channel and the first end of the side
wall.
[0035] In certain embodiments, the side wall is paperboard and the
top wall can also be paperboard.
[0036] It is envisioned that the outwardly projecting sealing
channel can have an upper portion associated therewith, and wherein
the top wall is connected to the side wall adjacent to the upper
portion of the outwardly projecting sealing channel.
[0037] Preferably, the top wall is connected to the side wall
adjacent to the first end.
[0038] Moreover, the top wall can include an opening formed
therein.
[0039] In certain constructions, the first end of the side wall
defines a joint section where the top wall is connected to the side
wall, wherein the joint section includes a bottom end and a top
end, and wherein the top end forms a lid rim. Preferably, in
embodiments wherein the top wall includes an opening formed, the
opening is positioned below the lid rim.
[0040] In certain embodiments wherein the top wall includes an
opening formed therein the opening is positioned approximately
coplanar with the bottom end of the joint section.
[0041] Preferably, the first end of the side wall includes a flange
section and a flap section which is folded over the flange section
to create a lid rim. The lid rim can includes an in-curled
portion.
[0042] The top wall can further includes an upwardly projection
peripheral flange which is sandwiched between the flange section
and the flap section of the first end of the side wall.
[0043] Preferably, at least a portion of the side wall is arranged
at an acute angle with respect to the top wall.
[0044] In certain embodiments, the outwardly projecting sealing
channel is continuous. Ideally, the shape of the outwardly
projecting sealing channel is selected to provide for mating
contact with a container rim.
[0045] The present disclosure is further directed to a lid for a
container that includes, among other elements, a side wall and a
top wall connected to the side wall. The side wall extends about a
longitudinal axis and includes longitudinally opposed first and
second ends. A sealing channel is positioned between the first end
and the second end and a seam runs substantially vertically between
the first end and the second end.
[0046] Preferably, the side wall is paperboard. Moreover, the top
wall can be paperboard.
[0047] It is envisioned that the seam can be compressed.
Preferably, the seam is compressed to reduce the seam thickness to
less than twice a material thickness for the side wall. Moreover,
the top wall can include an opening preferably positioned
diametrically opposite of the seam.
[0048] In certain embodiments, the sealing channel extends radially
outward from the longitudinal axis.
[0049] Preferably, the top wall includes an opening formed in an
embossed drinking area which is positioned below an upper rim
formed by the side wall of the lid.
[0050] The present disclosure is further directed to a lid and
container combination that includes, inter alia, a container and a
paperboard lid. The container having a side wall that extends about
a longitudinal axis and includes longitudinally opposed top and
bottom ends, the top end of the container including a rim. A bottom
wall is connected to the bottom end of the side wall.
[0051] The paperboard lid includes a side wall that extends about
the longitudinal axis and has longitudinally opposed first and
second ends, wherein an outwardly projecting sealing channel is
formed in the side wall between the first end and the second end. A
top wall is connected to the side wall between the outwardly
projecting sealing channel and the first end of the side wall,
wherein the top wall of the lid contacts the rim of the container
when the rim is engaged within the outwardly projecting sealing
channel.
[0052] Preferably, a first opening is formed in the top wall of the
lid that provides access to contents of the container. It is
envisioned that a second opening can be provided for venting.
[0053] In certain embodiments, the rim is circular. Moreover, the
outwardly projecting sealing channel can be a radially projecting
sealing channel. It is envisioned that the shape of the outwardly
projecting sealing channel approximates the shape of the container
rim.
[0054] In certain constructions of the lid and container
combination, the container is made from paperboard.
[0055] In is envisioned that in certain constructions, the
outwardly projecting sealing channel has an upper portion
associated therewith, and wherein the top wall is connected to the
side wall adjacent to the upper portion of the outwardly projecting
sealing channel. Still further, the top wall can be connected to
the side wall adjacent to the first end.
[0056] The present disclosure if further directed to a lid for a
container that includes, among other elements, a paperboard side
wall and a paperboard top wall. The paperboard side wall extends
about a longitudinal axis and has longitudinally opposed first and
second ends, wherein the side wall includes a sealing channel
positioned between the first end and the second end, and wherein
the side wall includes inner and outer surfaces each including a
polymer coating.
[0057] The paperboard top wall includes a lower surface and an
upper surface, wherein the lower and upper surfaces each include a
polymer coating; and wherein the first end of the side wall
includes a joint section where the side wall is connected to the
top wall such that the inner surface of the of the top wall is
joined to the inner surface of the side wall by a
polymer-to-polymer bond. Moreover, the outer surface of the top
wall is joined to the inner surface of the side wall by a
polymer-to-polymer bond.
[0058] In certain constructions, the sealing channel is a radially
projecting sealing channel. Moreover, the sealing channel can be
continuous. Still further, the sealing channel can have an upper
portion associated therewith, and wherein the top wall is connected
to the side wall adjacent to the upper portion of the sealing
channel.
[0059] It is also envisioned that the top wall can be connected to
the side wall adjacent to the first end.
[0060] Preferably, the top wall includes an opening formed
therein.
[0061] In certain constructions, the joint section includes a
bottom end and a top end, and wherein the top end forms a lid rim.
In embodiments wherein the top wall includes an opening formed
therein, the opening can be positioned below the lid rim.
Alternatively, the opening can be positioned approximately coplanar
with the bottom end of the joint section.
[0062] The present disclosure is also directed to a lid for a
container that includes, inter alia, a side wall and a top wall.
The side wall extends about a longitudinal axis and has a first end
and a second end, the second end being longitudinally opposed from
the first end. The side wall includes a sealing channel formed
between the first end and the second end.
[0063] A joint connects the side wall to the top wall proximate the
first end of the side wall, the joint including an upper portion
and a lower portion. Additionally, an opening is formed in the top
wall, wherein the opening is located below the upper portion of the
joint.
[0064] Preferably, the joint comprises a polymer-to-polymer bond.
Alternatively, the joint comprises an adhesive.
[0065] In certain constructions, the joint has a first cross
sectional thickness and the top wall has a second cross sectional
thickness, the first cross sectional thickness being greater than
the second cross sectional thickness. It is envisioned that he
first cross sectional thickness can be at least twice the second
cross sectional thickness.
[0066] It is envisioned that the top wall is formed from a first
blank and the side wall is formed from a second, separate
blank.
[0067] Preferably, the side wall circumferentially extends about
the longitudinal axis, and wherein the top wall is substantially
perpendicular to the longitudinal axis.
[0068] In certain constructions, at least one of the side wall and
the top wall is formed from a paper-based material selected from
the group consisting of paperboard, corrugated board, cardboard,
and combinations thereof.
[0069] The present disclosure is further directed to a
container-lid assembly that includes a container having a rim; and
one of the previously described container lids positioned over the
container such that the rim is received in the outwardly projecting
sealing channel.
[0070] Preferably, the container is a drinking cup. It is
envisioned that the rim is a rolled rim.
[0071] The present disclosure is further directed to a container
lid that includes a side wall and a top wall. The side wall is
formed from a first piece of paperboard and extends about a
longitudinal axis and includes longitudinally opposed first and
second ends. The side wall defines a sealing channel between the
first end and the second end, the sealing channel having an outer
diameter. The top wall is formed from a second piece of paperboard
and is connected to the first end of the side wall along a joint,
wherein the sealing channel is located between the joint and the
second end. The side wall includes a flared portion positioned
between the sealing channel and the second end, a maximum inside
diameter of the flared portion being greater than the sealing
channel outer diameter.
[0072] Preferably, the top wall is formed from a first blank and
the side wall is formed from a second, separate blank. In certain
constructions, the side wall circumferentially extends about the
longitudinal axis, and wherein the top wall is substantially
perpendicular to the longitudinal axis.
[0073] Still further, the present disclosure is directed to a lid
for a container that includes, among other elements, a paperboard
side wall and a paperboard top wall. The paperboard side wall is
formed from a first blank, wherein the side wall extends about a
longitudinal axis and includes longitudinally opposed first and
second ends. The paperboard top wall is formed from a second blank,
wherein the first blank is different from the second blank. The top
wall is connected to the side wall proximate the first end and the
side wall includes an in-curled rim portion associated with the
first end.
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] So that those having ordinary skill in the art to which the
present invention pertains will more readily understand how to
employ the systems and methods of the present invention,
embodiments thereof will be described in detail hereinbelow with
reference to the drawings, wherein:
[0075] FIG. 1 illustrates one embodiment of the disclosed lid 10
wherein the top wall 11 of the lid is recessed and includes an
opening or opening structure 15: FIG. 1A is a plan view of the lid,
FIG. 1B is a perspective view, FIG. 1C is a cross sectional view
showing the sealing channel 17 and the joint section 18 between the
top wall 11 and the side wall 12 of the lid; and FIG. 1D is a cross
sectional view showing a stack of three lids;
[0076] FIG. 2 illustrates several embodiments of a lid wherein the
top wall of the lid is recessed and a lower skirt 19 is provided.
FIG. 2A is a cross section view of the lid shown in FIG. 1. FIG. 2B
is a cross section of a lid 20 with a flared or bell-shaped skirt
29, for example formed by forming the skirt outward at point 29A or
lower. FIG. 2C is a cross section of a lid 30 with a top 31 and a
lengthened and flared or bell-shaped skirt 39, for example made by
forming the skirt outward at point 39A or lower;
[0077] FIG. 3A again illustrates the lid, while FIGS. 3B and 3C
illustrate blanks for the side wall and top wall of the lid;
[0078] FIG. 4A illustrates a step in forming the side wall of the
lid, while FIG. 4B illustrates a step in forming the top wall of
the lid;
[0079] FIG. 5A illustrates a further step in forming the side wall
of the lid, while FIG. 5B illustrates a further step in forming the
top wall of the lid;
[0080] FIGS. 6A to 6C illustrate steps in combining the side wall
and top wall to form the lid;
[0081] FIGS. 7A and 7B illustrate a perspective view and a cross
section view of a lid showing additional features;
[0082] FIGS. 8A and 8B illustrate tools for forming certain
features on the side wall of the lid;
[0083] FIGS. 9A and 9B illustrate tools being used to form certain
features on the side wall of the lid;
[0084] FIGS. 10A and 10B illustrate tools being used in a different
mode of operation;
[0085] FIGS. 11A and 11B illustrate tools being used in yet another
mode of operation;
[0086] FIGS. 12A and 12B illustrate tools being used in still
another mode of operation;
[0087] FIGS. 13A to 13D illustrate cross sections of several types
of cup lids;
[0088] FIG. 13E illustrates a cross section of the Inmaco lid;
[0089] FIG. 14 illustrates a further embodiment of the disclosed
lid 110 wherein the top wall 111 of the lid is recessed and
includes an opening or opening structure 115: FIG. 14A is a plan
view of the lid, FIG. 14B is a perspective view, FIG. 14C is a
cross sectional view showing the sealing channel 117 and the joint
section 118 between the top wall 111 and the side wall 112 of the
lid; and FIG. 14D is a cross sectional view showing a stack of
three lids; and
[0090] FIGS. 15A and 15B illustrate the blanks used to form the
container lid illustrated in FIGS. 14A-14D.
[0091] These and other aspects of the subject invention will become
more readily apparent to those having ordinary skill in the art
from the following detailed description of the invention taken in
conjunction with the drawings.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0092] Disclosed herein are detailed descriptions of specific
embodiments of the paper-based container lids, methods and
assemblies of the present invention. It will be understood that the
disclosed embodiments are merely examples of the way in which
certain aspects of the invention can be implemented and do not
represent an exhaustive list of all of the ways the invention may
be embodied. Indeed, it will be understood that the systems,
devices and methods described herein may be embodied in various and
alternative forms. The figures are not necessarily to scale and
some features may be exaggerated or minimized to show details of
particular components. Well-known components, materials or methods
are not necessarily described in great detail in order to avoid
obscuring the present disclosure. Any specific structural and
functional details disclosed herein are not to be interpreted as
limiting, but merely as a basis for the claims and as a
representative basis for teaching one skilled in the art to
variously employ the invention.
[0093] The present disclosure now will be described more fully, but
not all embodiments of the disclosure are necessarily shown. In
addition, many modifications may be made to adapt a particular
situation or material to the teachings of the disclosure without
departing from the essential scope thereof.
[0094] The paper-based container lid of present disclosure
includes, among other elements, a top wall and a side wall. The
side wall includes a first end and a second end, the first end
connecting to the top wall. The side wall further including a
sealing channel for sealingly engaging a rim of the container and
securing the lid to the container, wherein the top wall and the
side wall are formed from separate blanks.
[0095] The disclosed lid provides a cover for the container to
inhibit spillage and may reduce heat transfer between the packaged
contents and the surrounding atmosphere. The disclosed lid may be
manufactured economically using modified existing converting
machines (or custom-built machines) for the production of
containers, such as cups or bowls, wherein each container is made
of at least two main components: a bottom wall of the container and
a side wall of the container. The lid of present disclosure may be
formed in the similar manner as the container, namely the lid is
made of at least two main components (a top wall and a side
wall).
[0096] The disclosed paper-based lids may be used with containers
of various types. They may be used for fluid containers, such as
cups or bowls.
[0097] In one embodiment, the container is a drinking cup. In one
embodiment, the lid is for disposable cups of the type commonly
used as carry-out containers for beverages such as coffee and the
like. Such cups are commonly made of Styrofoam or paper. In one
embodiment, the disclosed lid is for the drinking cup containing
hot fluid, such as coffee cup.
[0098] In one embodiment, the container is a drinking cup having a
generally circular upper rim with a bead formed on it. Those
skilled in the art will readily appreciate that the lids disclosed
herein can be adapted for use with containers having rims which are
not circular, but may be other shapes, such as, but not limited to,
rectangular.
[0099] The top wall of the lid provides coverage for the contents
inside the container. The side wall of the lid provides an
engagement to the container, a seal to prevent leakage of packaged
fluid/contents, and structural rigidity. The sealing channel formed
in the side wall mechanically secures the lid in place to the
container and provides a seal between the lid and the container.
The sealing channel is sized to fit the container rim, providing a
snug friction fit between the lid and the container. Although the
sealing channel is shown in representative figures as an curved
channel, one skilled in the arts appreciates that the radius or
cross-section of sealing channel may be modified to accommodate the
shape of the container rim. For example, the cross-section of
sealing ring may be square, rectangular, oval, or oblong.
[0100] As described herein below, in certain embodiments the
container is a drinking cup and the lid may include at least one
opening structure to enable drinking from the cup without removal
of the lid. The opening structure may be formed in the top wall of
the lid. In one expression, the top wall of the lid may further
include a recess adjacent the opening structure to accommodate the
upper lip of the user drinking from the cup.
[0101] A variety of opening structures may be used for the lid of
present disclosure. In one embodiment, the drinking opening
structure may be a cut out structure. In one embodiment, the
drinking opening structure may be score lines defining a movable
portion that the user could penetrate or fold to gain access to the
interior of the cup.
[0102] In one embodiment wherein the container is a drinking cup,
the disclosed lid may include a vent hole formed on the top wall,
such as near the center of the top wall, to enable air to flow into
the cup as the user drinks from the cup to facilitate the flow of
liquid out of the cup through the drinking opening structure.
[0103] The top wall of the disclosed lid may have out-of-plane
features for positioning the drinking opening structure, for
appearance, to contain liquid that ends up above the lid and drain
it back into the cup, or for combinations of these reasons. The top
wall may include a debossed (i.e., depressed) feature which
surrounds the drinking hole. Additionally, the top wall may include
an embossed (raised) feature or features (not shown). The top wall
may include both depressed and raised features. Such depressed or
raised features may be formed in the top wall either in the blank
(flat) stage of FIG. 3C, or in the intermediate formation stage
shown in FIGS. 4B and 5B, or during or after assembly as shown in
FIGS. 6B and 6C.
[0104] Various connection methods may be used in the present
disclosure to join the lid top wall and the first end of the lid
side wall. Examples of such connections may include, but are not
limited to, a lap-joint, a wrapped edge, or combination thereof.
Bonding may be achieved with a poly-poly heat seal and/or an
adhesive. The lid side wall may be formed from a first blank, and
the lid top wall from a second blank separate from the first blank.
By "joint" in the present disclosure is meant the area where two
originally separate pieces or blanks of material are united or
connected together.
[0105] When desired, the second end of the lid side wall may
include a rolled or folded edge to provide stability and alignment
when sealing the disclosed lid to the container.
[0106] In one embodiment, the disclosed lid may include an outward
skirt structure to facilitate the engagement of the lid onto the
container. As the lid is pushed downwardly onto the rim of the
container, the skirt structure aids in centering the lid and in
engaging the sealing channel with the container rim. Furthermore,
the skirt may provide a contact surface for removing the disclosed
lid from the container.
[0107] The present disclosure also describes an apparatus that
includes:
[0108] a die for receiving a container or a container lid, the die
including an annular recess formed in an internal surface thereof,
a channel forming tool including a protruding structure having a
shape complementary with the annular recess of the die, the
protruding structure cooperating with the annular recess of the die
and engaging a portion of the sidewall of container or the
container lid, whereby when the channel forming tool is placed
inside the container or the container lid positioned in the die,
the protruding structure of the tool presses at least a portion of
the container or container lid into the recess such that a sealing
channel is formed on the container or container lid where the
protruding structure abuts the annular recess, and wherein either
the die, or the channel forming tool, or both are rotated during
the formation of sealing channel. In one embodiment, the portion of
the container or the lid being engaged by the channel forming tool
includes a side wall of the container or the lid.
[0109] The disclosed apparatus is suitable for forming a sealing
channel in a container or a container lid that provides an enhanced
sealing between the container and the lid.
[0110] The disclosed apparatus may be adapted to be fitted to the
converting machines commonly used for the production of containers
or container lids.
[0111] The depth, shape and the width of the sealing channel may be
adjusted to accommodate the end use applications of the containers.
These may be achieved by modifying the depth, shape and the width
of the protruding structure on the channel forming tool. The
disclosed apparatus may provide a sealing channel with increased
depth to allow for an improved sealing between the container and
the lid.
[0112] The disclosed apparatus may be used for the containers
and/or container lids of various types. The containers may be for
fluid containers, such as cups or bowls.
[0113] In one embodiment, the container is a drinking cup having a
generally circular upper rim with a bead formed on it. Paperboard
drinking cups may typically have a rolled bead on their upper edge.
However, the disclosed lid may also be used for cups made from
other materials which may have different forms of an upper rim,
such as a molded rim for a Styrofoam cup.
[0114] Referring now to the drawings wherein FIG. 1 illustrates one
embodiment of the disclosed container lid which has been identified
using reference numeral 10. Lid 10 includes a top wall 11 and a
side wall 12, which may be formed as separate pieces and then
connected together to form the lid 10. The side wall 12 may extend
(e.g., circumferentially extend) about a longitudinal axis L (FIG.
1B), and may include a first end 13 longitudinally opposed from a
second end 14. The top wall 11 may be transverse to the
longitudinal axis L, and may be connected to the first end 13 of
the side wall 12 at a joint section 18 to form the lid 10.
[0115] The side wall 12 of the lid 10 may include a sealing channel
17, which continuously (e.g., circumferentially) extends about the
side wall 12. Those skilled in the art will readily appreciate that
sealing channel 17 can be discontinuous without departing from the
scope of the present invention. The sealing channel 17 is sized and
shaped to closely receive the rim "R" of a container, as shown in
FIG. 13A, thereby securing the lid 10 to the container.
[0116] Referring to FIGS. 1A and 1B, the top wall 11 may include an
opening 15 that provides an access to the contents inside the
container without removal of the lid. As shown in FIGS. 1B-1C, the
top wall 11 may be formed such that the top wall surface is lower
than the joint section 18 of the top wall 11 and the side wall 12.
As shown in FIG. 1C, the side wall 12 may slope outward at an angle
.alpha.1, which may help with putting the lid on a cup, and may
allow better stacking of the lids as shown in FIG. 1D. The height
Hs of the stack may be determined in large part by the rim height
Hr. The rim height Hr and skirt height h1 may be chosen according
to manufacturing preference. In one example, the rim height Hr may
be approximately 5 mm and the skirt 19 height h1 approximately 21
mm. The angle .alpha.1 may be chosen according to manufacturing
preference. In one example, .alpha.1 may be about 7 degrees.
[0117] FIG. 2A again illustrates lid 10. FIG. 2B illustrates a lid
20 with a side wall 22 having a flared skirt 29, and FIG. 2C shows
another lid with a longer side wall 32 also flared. By "flared" is
meant that the side wall 22 is belled radially outward beyond the
usual slope .alpha.1 of the side wall. For example, the flared side
wall skirt 29 may extend generally at a flare angle .beta.1
relative to the side wall slope angle .alpha.1. In other words,
while the joint 28 may slope inwards at an acute angle .alpha.1
relative to the top wall 21, the flare portion 29 may have a slope
angle .alpha.2 that is greater than .alpha.1. The angle .alpha.2
may be approximately .alpha.1+.beta.1.
[0118] As shown in FIG. 2B, the diameter Di of the inside of the
flare should be greater than the diameter Do of the outside of the
sealing channel 27, so that the flare and the sealing channel are
not in contact with each other. This may reduce friction or
sticking between the lids. Friction or sticking is inconvenient to
the user, and may result in a variable stacking height for the
lids. With reduced friction between lids, the stack height Hs can
be more consistent (at approximately Hr times the number of lids in
the stack). The sealing channel may be located just below the top
wall as shown in FIG. 2, or it may be located further downward from
the top wall.
[0119] The seam (see area S in FIGS. 3A, 4A, 5A) of the side wall
22 (i.e., the area where the material overlaps to form a lap joint)
may be compressed so that the step height (difference in thickness)
at the joint is minimized. Minimizing the step height will minimize
the potential for leakage in the channel in the area of the seam.
Such seam compression may be done while the side wall is being
shaped (e.g. FIG. 5A) or while the sealing channel is being made
(e.g. FIG. 9A for example). One way to achieve relatively constant
side wall thickness is to pass the side wall 22 (e.g. at FIG. 5A)
between a pair of rollers separated by a set gap approximately
equal to the board thickness. Thus, most of the side wall thickness
may be relatively undisturbed (at a single thickness) but the
otherwise double thickness at seam S may be reduced to near or
equal to about 1.5 times a single thickness). Another way to
achieve relatively constant wall thickness at seam S is to
preferentially press or clamp the seam area. The overlap area may
also be skived (at least one layer being thinned) to help reduce
its thickness.
[0120] FIG. 3A shows an embodiment of the disclosed container lid
similar to that in FIG. 2B. Lid 20 includes a top wall 21 and a
side wall 22 that includes a first end 23 and a second end 24. As
shown in FIG. 3, the top wall 21 includes a cover 21A and a
vertical wall 21B extending upward from the cover 21A, and the
vertical wall 21B is received and sealed between two plies of the
side wall 22 at its first end 23 as joint section 28 to form a lid
20. The top wall may include an opening (see 15 in FIG. 1) that
provides an access to the contents inside the container without
removal of the lid. The joint section 28 may thus have three plies.
The joint section may 28 have a cross sectional thickness greater
than the cross sectional thickness of either top wall 21 or side
wall 22. The joint section 28 may have a cross sectional thickness
at least twice the thickness of either of the top wall 21 or the
side wall 22.
[0121] FIG. 3B shows an example blank for making the side wall 22.
For a lid having a diameter D, rim height Hr, and skirt height h1,
the side wall blank may have a length of about .pi.D, and a width
of about h1+2Hr. An overlap distance C may be provided at an end of
the blank for forming a longitudinal seam. The side wall 22 may be
made from paperboard, such as a paperboard cup stock. As a
non-limiting example, the caliper may be about 16.5 mils (0.016'').
The paperboard may lack any clay coating, and may be coated on each
side with about 0.75 mils to 1.0 mils of LDPE (low density
polyethylene). In one embodiment, no additional heat sealing or
adhesive components are used besides the LDPE and any associated
tie layer(s).
[0122] FIG. 3C shows a circular blank for making the top wall 21.
For a lid with a diameter D and rim height Hr, the diameter of the
blank may be approximately D+2Hr. The top wall 21 may be made from
paperboard, such as a paperboard cup stock. As a non-limiting
example, the caliper may be about 9.3 mils (0.0093''). The
paperboard may lack any clay coating, and may be coated on the side
to face the inside of the cup with about 0.75 mils to 1.0 mils of
LDPE (low density polyethylene), and on the outer side with about
0.5 mils to 1.0 mils of LDPE. In one embodiment, no additional heat
sealing or adhesive components are used besides the LDPE and any
associated tie layer(s).
[0123] FIG. 4A shows a step in forming the side wall 22 of the
container lid by bringing together (arrow M1) the ends of the side
wall blank of FIG. 3B, to form a band or loop. This may be
achieved, for example, by wrapping the side wall blank around a
cone shaped mandrel and adhering the ends together, such as with an
adhesive or heat. FIG. 4B shows a step in forming the top wall
wherein the top wall 21 of the lid by turning upward (arrow M2) the
perimeter of the circular blank. This may be achieved, for example,
by placing the top wall 21, in the form of a disk, over a circular
opening or circular cavity and using a pressing tool or vacuum to
press or draw the interior area of the disk into the opening or
cavity.
[0124] FIG. 5A shows a further step in forming the side wall 22 of
the container lid by overlapping the ends of the side wall blank of
FIG. 4B, along seam area S, which may overlap a distance C. FIG. 5B
shows an optional further step in forming the top wall wherein the
top wall 21 may be turned upward about 90 degrees (or even slightly
further to match the slope angle of the side wall.
[0125] FIG. 6A shows a further step in forming the lid where the
top wall 21 is moved (arrow M3) upward inside the loop of the side
wall 22, where (as shown in FIG. 6B for this example) the plane of
the top wall 21 may be about 1/3 up from the bottom of the side
wall 22 and about 2/3 down from the top edge of the side wall 22.
Next, the top edge of side wall 22 may be folded down and inward
(arrow M4) over the upstanding perimeter of the top wall 21. This
may be achieved, for example by using rollers or other tools to
bend the top edge inward and downward, and then using a pair of
wheels to press the folded top edge of the side wall into tight
sealing contact with the upstanding perimeter of the top wall as
shown by arrows M5 in FIG. 6C. The resulting structure is shown in
FIG. 6C. The triple layer of the rim of the lid may be sealed
together by heat and pressure and/or adhesive and pressure.
[0126] FIGS. 7A and 7B show a variation on the lid 40 where indents
are formed in the side wall 42. The indents may include formed
areas 46A and 46B that are formed inwardly and outwardly with
respect to one another. An alternate description of the indents is
that the inward formed areas 46A are inwardly formed creases, while
the outward formed areas are columnar regions positioned at a
larger radius than the inwardly formed creases. While the upper
boundary of the sealing channel 17 may thus be a continuous circle
as shown, the lower boundary may be a discontinuous series of arcs
joined by the columnar regions. When the lid 40 is placed onto a
cup, downward pressure may be applied to seat the sealing channel
onto the cup. The columnar regions 46B may serve to prevent the
sealing channel 17 and/or regions 46A from being crushed or
collapsed by this pressure.
[0127] Lid 40 may also have a flared side wall 49 as described
previously.
[0128] When appropriate, the surface of the disclosed lid may be
made from paperboard coated with various materials to impart
desired properties. For example, the lid may be made of
water-resistant coated paper such as a poly-coated paper or board.
The coating may be applied in advance, for example on-machine or
on-coater. The poly-coated surface may face inwardly (toward the
contents which the lid would cover) or the poly coating may be on
both surfaces. The paperboard itself may be chemically sized to
minimize wicking of liquids including but not limited to hot coffee
or other hot liquids.
[0129] In one embodiment, the disclosed paper-based lid may include
a polymeric-based coating on one side or both sides. The polymer
coating may impart liquid resistance to the paper and may
facilitate sealing the top wall to the side wall. A heat sealable
coating may be used. Optionally a clay coating or other coating may
be provided. Such coatings may provide useful properties, such as
improved printing characteristics for printing customer information
or other indicia on the lid.
[0130] Various paper-based substrates may be used for the top wall
of the disclosed lid. Examples of such materials include, but are
not limited to, paperboard, and combinations of paperboard with
other materials.
[0131] Various paper-based substrates may be used for the side wall
of the disclosed lid. Examples of such materials include, but are
not limited to, paperboard, and combinations of paperboard with
other materials.
[0132] In one embodiment, the top wall and the side wall of the
disclosed lids are made of the same type of the substrate.
[0133] In one embodiment, the top wall and the side wall of the
disclosed lids are made of different types of the substrates.
[0134] FIGS. 8 and 9 show one embodiment of an apparatus for
forming a sealing channel in a cup lid. The apparatus includes a
supporting die 101 for receiving a container or a container lid, a
channel forming tool 102 that includes an annular protruding
structure 103, and a rotating tool 104.
[0135] The supporting die may include more than one component to
facilitate the removal of the container or lid from the die after
the sealing channel is formed thereof. In FIG. 8, the supporting
die 101 includes components 101A and 101B that may be assembled
together to receive the container or lid, and may be easily
disassembled to facilitate the removal of the container or lid from
the supporting die 101. It is understood that the supporting die
may include more than two components, and the present disclosure is
in no way limited to only the apparatus with the supporting die
composed of two components as shown in FIG. 8.
[0136] Referring to FIGS. 8 and 9, the supporting die 101 includes
an annular recess 105 formed in its internal surface, wherein the
annular recess 105 has a complementary shape to that of the outer
edge of the protruding structure 103 on the channel forming tool
102.
[0137] FIG. 8 shows the apparatus not yet holding the cup side wall
42 or channel forming tool, which are added in FIG. 9. The lid may
be held in the tool by vacuum or by gripping fingers (not shown).
The channel forming tool suitable for use in the disclosed
apparatus may include one or more protruding structures. FIG. 9
shows the channel forming tool 102) with only one annular
protruding structure 103). However, one skilled in the art
recognizes that the channel forming tool of the disclosed apparatus
may include more than one protruding structure.
[0138] The disclosed apparatus may include a moving tool to rotate
the container or the container lid. FIG. 9 shows one embodiment of
the disclosed apparatus wherein the supporting die 101A, 101B
rotates (arrow M6) the lid (side wall 42, shaded) while channel
forming tool 102 is moved (arrow M7) so that the annular protruding
structure 103 contacts the lid side wall 42 to gradually displace
the side wall into the annular recess to form the desired sealing
channel. The annular protruding structure 103 as shown here may be
a disk-shaped wheel that may be rotated by contact with the channel
forming tool 102, or the protruding structure 103 may rotate on a
bearing upon channel forming tool 102. In other embodiments the
annular protruding structure 103 may not rotate or may rotate in
synchronization with the moving tool.
[0139] The supporting die 101A, 101B may be rotated in a milling
machine, and the channel forming tool 102 moved relative to the
work on the milling machine slide or table. Use of a milling
machine may be practical in testing situations. Instead of using a
milling machine, and/or for production, any equipment that provides
the desired actions may be used to produce the lid. Automated
equipment may be utilized.
[0140] Although the apparatus is shown with rotation M6 about a
horizontal axis, rotation could also be about a vertical or other
axis. Although the axis of the channel forming tool 102 (or
rotating tool) is shown to be parallel to the axis of rotation M6,
there may be instances where the channel forming tool 102 and/or
tool 104 are at an angle to the axis of rotation M6. For example,
if it is desired to form the sealing channel close to the lid top
41, the channel forming tool 102 and/or tool 104 may be held at an
angle so that annular protruding structure does not rub on the lid
top 41, or contact any depressed (inward) features that may
optionally be present on the lid top 41. Instead of, or in addition
to, using a rotating or rolling tool to form the sealing channel,
the sealing channel may also be create by pressing the paperboard
between a tool and a backing surface.
[0141] The annular protruding structure 103 may be moved a set
distance (as with a milling machine table or slide, using markings
on a lead screw or using a digital readout). Thus a set gap may be
achieved between the annular protruding structure 103 and the
annular recess, so that the side wall 42 at the sealing channel has
a relatively uniform thickness. This may entail compressing the
seam S more than the rest of the side wall.
[0142] Alternately as shown in FIG. 10, the container or lid
(shaded) and the supporting die 101 may remain still while the
channel forming tool 102 with its annular protruding structure 103
moves and rotates (arrow M8) to gradually create a sealing channel
on the container or lid.
[0143] Alternatively, in one embodiment of the disclosed apparatus,
both the channel forming tool 102 and the supporting die 101 may be
moved in relation to one another in any direction so long as their
movements facilitate a gradual formation of sealing channel on the
container or lid.
[0144] In one embodiment of present disclosure, in operation a
container or a lid is positioned in a supporting die with its side
wall against an internal surface of the die. Then, the channel
forming tool is placed inside the container or lid against its side
wall. The rotating tool moves the die, or the channel forming tool,
or both in relation to one another such that the protruding
structure of the channel forming tool presses a portion of the
container or lid side wall abutting the recess of the die to create
an annular sealing channel on the container or lid side wall. The
resulting container or lid is then removed from the supporting die,
either with or without a need for disassembly of the supporting
die.
[0145] The annular protruding structure 103, instead of being a
circular disk as shown in FIGS. 8-10, may be a disk which include
teeth or notches (not shown). Alternately or in addition, teeth or
notches may be formed on the moving tool 101A, 101B for example as
shown by notches 107 in FIG. 11B formed in annular recess 105.
Teeth or notches may be utilized to form indents 46A, 46B shown in
FIGS. 7A, 7B. Alternately, or in addition, raised or depressed
areas may be formed in the annular recess 105. However, it may be
easier to form such features on the protruding structure 103. The
protruding structure 103 and supporting tool 101 may be rotated in
synchronization to form indents 46A, 46B.
[0146] FIG. 12 shows one embodiment of the disclosed apparatus
wherein the supporting die 101A, 101B rotates (arrow M6) the lid
(side wall 42, shaded) while a flare forming tool 109 is moved
(arrow M7) so that a conical protruding structure 109B (or other
suitably shaped tool) contacts the lid side wall 42 to displace the
side wall into a bell-shaped or flared edge 29 (see FIG. 2B) below
the sealing channel. The bell-shaped or flared edge 29 may help
guide the lid onto the cup. The flare forming tool may be rotated
by contact with the channel forming tool 102 or the lid, or the
conical protruding structure 109B may rotate on a bearing upon tool
109A. In other embodiments the flare forming tool 109 may not
rotate or may rotate in synchronization with the moving tool. In
other embodiments the supporting die 101A, 101B may have an
enlarged open end to cooperate with the flare forming tool 109 in
forming the flare.
[0147] FIG. 13 shows cross sections of several cup lids. FIG. 13A
illustrates a cross section of the disclosed cup lid 20 seated on
the rim R of a cup. The cup lid 20 includes the top wall 21 and
side wall 22 joined together at joint 28. The formed sealing
channel 27 fits snugly on the rim R. The side wall 22 may be flared
as at 29.
[0148] FIG. 13B shows an existing plastic lid 50 that has a sealing
channel 57 with an approximately circular shape, and also a flared
section 59. As can be readily seen, the sealing channel is arranged
the rim of the cup is inserted upward into the channel. FIG. 13C
shows another existing plastic lid 60 that has a downwardly facing
sealing channel 67 with an approximately rectangular shape, and
also a flared section 69. FIG. 13D shows an existing plastic lid 70
that has a sealing channel 77 with an approximately rectangular
shape on an inner quadrant, and an approximately circular shape on
an outer quadrant, and also a flared section 79. FIG. 13E provides
a cross-sectional view of the interaction between the Inmaco lid
and a convention beverage cup. As noted previously, the bead formed
in the sidewall around the circumference of the Inmaco lid 80
secures the lid 80 to an appropriately sized container. The fit is
fairly tight radially, i.e. there is a close match between the
outer diameter of the container rim and the inner diameter of the
lid. However, there is not a tight fit axially; the lid can move up
and down and thus it is unlikely that it provides good leak
resistance. Moreover, since the sidewall of the lid in the sealing
zone is flat and rim is curved there is not mating contact between
the sidewall and rim surfaces, and thus the seal is poor.
[0149] In the construction of the present invention, the channel 27
formed in the sidewall 22 of the lid 20 acts against the radially
outward pressure created by the rim of the cup creating an enhanced
seal between the mating surfaces. The prior art embodiments shown
in FIGS. 13B through 13E do not exhibit such a mechanical
interaction.
[0150] Referring now to FIGS. 14A-14D there is illustrated a
further embodiment of the container lid of the present disclosure
which has been identified as reference numeral 100. Lid 100
includes, inter alia, a paperboard side wall 112 formed from a
first blank 130 (see FIG. 15B). The side wall 112 extends about a
longitudinal axis "L" and includes longitudinally opposed first and
second ends 113/114. A top wall 111 is formed from a second blank
140 (see FIG. 15A). As noted previously, the blanks 130/140 can be
made from the same material or they can be made from different
materials. For example, in certain embodiments, the blanks are both
paperboard.
[0151] As shown in FIG. 14C, the top wall 111 of the lid 100 is
connected to the side wall 112 proximate the first end 113. Top
wall 111 includes an opening 115 formed therein which will allow a
user access to the contents of the container without having to
remove lid 100. Those skilled in art will recognize that an
"opening" can include a hole provided in the lid during the
manufacturing process or an area of material, such as a region
surrounded by a perforation line, which is adapted to be removed by
the user of the lid.
[0152] As best viewed in FIG. 14C, lid 100 further includes a
sealing channel 117 formed in the side wall 112 between the first
end 113 and the second end 114. In the embodiment of the present
disclosure shown in this figure, the sealing channel 117 projects
radially outward from the longitudinal axis L.
[0153] The side wall 112 of the lid includes a substantially
vertical seam "S" that extends between the first end 113 and the
second end 114 of the side wall 112. The seam S is compressed to
reduce its step height. As shown in FIG. 14B, it is preferable to
have the opening 115 positioned opposite of the seam S, so as to
decrease the potential for leakage along the seam line when a user
is drinking from the container, for example.
[0154] The side wall 112 of lid 100 includes an inner surface 112i
which has a polymer coating. The top wall 111 includes a lower
surface 111L and an upper surface 111U which each include a polymer
coating. The upper surface 111U of the top wall 111 is connected to
the inner surface 112i of the side wall 112 by a polymer-to-polymer
bond and the lower surface 111L of the top wall 111 is connected to
the inner surface 112i of the side wall 112 by a polymer-to-polymer
bond. Those skilled in the art will readily appreciate that other
methods of joining the top wall to the bottom wall, including
methods that use an adhesive rather than a polymer-to-polymer bond
can be used in the present lid construction. Moreover, the outer
surface of the side wall may also include a polymer coating to
facilitate a polymer-to-polymer bond along the seam "S".
[0155] Lid 100 includes a joint section 118 defined by where the
first end 113 of the side wall 112 is connected to the top wall
111. The joint section 118 includes a top end 122 that forms a lid
rim 124 and the lid rim 124 includes a substantially rounded
section or in-curled section 126. The substantially rounded section
126 of the lid rim 124 is oriented toward the longitudinal axis L
and provides a surface with more pleasing mouth-feel for the user.
The opening 115 is formed in the lid 100 below the rim 124. As
shown in FIG. 14A, a second opening 144 is provided in the top wall
111 of the lid 100 for venting.
[0156] The joint section 118 further includes a middle section 128
below the top end 122. The rim 124 has a width associated therewith
and the middle section 128 has a width associated therewith. As
shown in the figure, the width of the rim 124 is greater than the
width of the middle section 128.
[0157] As shown in FIG. 14C, the joint section 118 of lid 100
includes a bottom end 129 below the middle section 128. The bottom
end 129 flares toward the longitudinal axis L and facilitates
creating the joint between the top wall 111 and the side wall
112.
[0158] Moreover, the top wall 111 includes a debossed section 132
and the opening 115 is located within the debossed section 132. The
top wall 111 further includes an embossed section 134 located
adjacent to and around the periphery of the debossed section 132.
The combination of these two features creates and area with liquid
can collect and return to the container through opening 115.
[0159] As shown in FIG. 14C, the outwardly projecting sealing
channel 117 has an upper portion associated therewith, and the top
wall 111 is connected to the side wall 112 adjacent to the upper
portion of the outwardly projecting sealing channel 117.
[0160] Referring now to the blank 130 shown in FIG. 15B. Blank 130
includes a flap section 137 separated from a flange section 138 by
fold line 160. When the lid is assembled, flap section 137 is
folded over the flange section 138 to create the lid rim 124. Below
the flange section 138 is a section of material that is bound
between dashed lines 162 and 164. This section of material is to
create the sealing channel 117. Between dashed lines 164 and 166 is
a section of material which is used to create a first flared
section 146 (see FIG. 14B) in the side wall 111. A second flared
section 148 is created in the sidewall between dashed lines 166 and
168 and the material located below dashed line 168 may be trimmed
off.
[0161] As shown in FIG. 15A, blank 140 includes a line 142 which
represents the line on which the upwardly projection peripheral
flange 145 is formed in the top wall 111 either by folding or
pressing. During the assembly process for certain embodiment of the
present invention, peripheral flange 145 is sandwiched between the
flange section 137 and the flap section 138 of the side wall
112.
[0162] Referring to FIG. 14D which illustrates three lids 100A,
100B and 100C in a stacked arrangement. By flaring outwardly the
second end 114 of the side wall 112, the stack height of the lids
can be reduced. The outward slope may also help with putting the
lid on a cup. As described with respect to FIG. 1D, the height Hs
of the stack may be determined in large part by the rim height Hr.
The rim height Hr and skirt height h1 may be chosen according to
manufacturing preference.
[0163] As described with respect to FIG. 2B, the diameter Di of the
inside of the flare should be greater than the diameter Do of the
outside of the sealing channel 117, so that the flare and the
sealing channel are not in contact with each other. This may reduce
friction or sticking between the lids. Friction or sticking is
inconvenient to the user, and may result in a variable stacking
height for the lids. With reduced friction between lids, the stack
height Hs can be more consistent (at approximately Hr times the
number of lids in the stack). The sealing channel 117 may be
located just below the top wall as shown in FIG. 14C, or it may be
located further downward from the top wall.
[0164] The containers suitable for use in the present disclosure
may include paper-based materials, plastics, composite materials,
or combinations thereof. Various paper-based substrates may be used
for the containers. Examples of such materials include, but are not
limited to, paperboard, corrugated board, cardboard, and
combinations thereof.
[0165] It is believed that the present disclosure includes many
other embodiments that may not be herein described in detail, but
would nonetheless be appreciated by those skilled in the art from
the disclosures made. Accordingly, this disclosure should not be
read as being limited only to the foregoing examples or only to the
designated embodiments.
* * * * *