U.S. patent application number 14/060312 was filed with the patent office on 2015-04-23 for beverage container.
This patent application is currently assigned to MeadWestvaco Corporation. The applicant listed for this patent is MeadWestvaco Corporation. Invention is credited to Steven Burton, Christopher C. Jameson.
Application Number | 20150108146 14/060312 |
Document ID | / |
Family ID | 52825262 |
Filed Date | 2015-04-23 |
United States Patent
Application |
20150108146 |
Kind Code |
A1 |
Jameson; Christopher C. ; et
al. |
April 23, 2015 |
Beverage Container
Abstract
A beverage container may include a base container including a
side wall that extends about a longitudinal axis to define an
internal volume, an overwrap positioned over the side wall, and an
adhesive connecting the overwrap to the side wall, the adhesive
extending substantially circumferentially around the side wall to
form a ring of adhesive around the base container, wherein the ring
of adhesive is configured to space the overwrap from the side wall,
and wherein the ring of adhesive is configured to structurally
reinforce the side wall.
Inventors: |
Jameson; Christopher C.;
(Richmond, VA) ; Burton; Steven; (Richmond,
VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
MeadWestvaco Corporation |
Richmond |
VA |
US |
|
|
Assignee: |
MeadWestvaco Corporation
Richmond
VA
|
Family ID: |
52825262 |
Appl. No.: |
14/060312 |
Filed: |
October 22, 2013 |
Current U.S.
Class: |
220/592.16 |
Current CPC
Class: |
B65D 81/3869
20130101 |
Class at
Publication: |
220/592.16 |
International
Class: |
A47G 19/22 20060101
A47G019/22; B65D 81/38 20060101 B65D081/38 |
Claims
1. A container comprising: a base container comprising a side wall
that extends about a longitudinal axis to define an internal
volume; an overwrap positioned over said side wall; and an adhesive
connecting said overwrap to said side wall, said adhesive
consisting essentially of a single ring extending substantially
circumferentially around said side wall.
2. The container of claim 1 wherein said base container comprises
an upper end portion and a lower end portion, and wherein said ring
is positioned proximate said upper end portion.
3. The container of claim 1 wherein said ring comprises a
continuous substantially straight band of said adhesive.
4. The container of claim 1 wherein said ring comprises a thickness
of at least about 5 points.
5. The container of claim 1 wherein said ring comprises a thickness
of at least about 10 points.
6. The container of claim 1 wherein said ring comprises a width of
at least about 5 points.
7. The container of claim 1 wherein said adhesive comprises an
organic filler and an organic binder.
8. The container of claim 1 having a wet/hot rigidity of at least
about 810 grams-force.
9. The container of claim 1 having a wet/hot rigidity of at least
about 850 grams-force.
10. The container of claim 1 having a dry rigidity and a wet/hot
rigidity, wherein said wet/hot rigidity is at least about 60
percent of said dry rigidity.
11. The container of claim 1 having a dry rigidity and a wet/hot
rigidity, wherein said wet/hot rigidity is at least about 800
grams-force, and wherein said wet/hot rigidity is at least about 60
percent of said dry rigidity.
12. The container of claim 1 comprising at most about 0.8 grams
(dry weight) of said adhesive.
13. The container of claim 1 being about a 20-ounce container and
weighing at most about 26 grams.
14. A container comprising: a base container comprising a side wall
that extends about a longitudinal axis to define an internal
volume, said side wall comprising an upper end portion and a lower
end portion; an overwrap positioned over said side wall; and an
adhesive connecting said overwrap to said side wall, said adhesive
extending substantially circumferentially around said side wall to
form at least one ring around said base container proximate said
upper end portion, wherein said container has a wet/hot rigidity of
at least about 810 grams-force.
15. The container of claim 14 wherein said wet/hot rigidity is at
least about 850 grams-force.
16. The container of claim 14 wherein said wet/hot rigidity is at
least about 875 grams-force.
17. The container of claim 14 having a dry rigidity, wherein said
wet/hot rigidity is at least about 60 percent of said dry
rigidity.
18. The container of claim 14 having a dry rigidity, wherein said
wet/hot rigidity is at least about 65 percent of said dry
rigidity.
19. The container of claim 14 having a dry rigidity, wherein said
wet/hot rigidity is at least about 68 percent of said dry
rigidity.
20. The container of claim 14 comprising at most about 0.8 grams
(dry weight) of said adhesive.
21. The container of claim 14 comprising at most about 0.5 grams
(dry weight) of said adhesive.
22. The container of claim 14 with the proviso that only one ring
of said adhesive is present.
23. The container of claim 14 being about a 20-ounce container and
weighing at most about 26 grams.
24. A container comprising: a base container comprising a side wall
that extends about a longitudinal axis to define an internal
volume, said side wall comprising an upper end portion and a lower
end portion; an overwrap positioned over said side wall; and an
adhesive connecting said overwrap to said side wall, said adhesive
extending substantially circumferentially around said side wall to
form at least one ring around said base container proximate said
upper end portion, wherein said container has a dry rigidity and a
wet/hot rigidity, said dry rigidity being at least about 1,100
grams-force, said wet/hot rigidity being at least about 60 percent
of said dry rigidity.
25. The container of claim 24 wherein said dry rigidity is at least
about 1,200 grams-force.
26. The container of claim 24 wherein said dry rigidity is at least
about 1,300 grams-force.
27. The container of claim 24 wherein said wet/hot rigidity is at
least about 65 percent of said dry rigidity.
28. The container of claim 24 wherein said wet/hot rigidity is at
least about 68 percent of said dry rigidity.
29. The container of claim 24 wherein said wet/hot rigidity is at
least about 810 grams-force.
30. The container of claim 24 wherein said wet/hot rigidity is at
least about 850 grams-force.
31. The container of claim 24 wherein said wet/hot rigidity is at
least about 875 grams-force.
32. The container of claim 24 comprising at most about 0.8 grams
(dry weight) of said adhesive.
33. The container of claim 24 comprising at most about 0.5 grams
(dry weight) of said adhesive.
34. The container of claim 24 with the proviso that only one ring
of said adhesive is present.
35. The container of claim 24 being about a 20-ounce container and
weighing at most about 26 grams.
36. A container comprising: a base container comprising a side wall
that extends about a longitudinal axis to define an internal
volume; an overwrap positioned over said side wall; and an adhesive
connecting said overwrap to said side wall, wherein said container
is a 20-ounce container weighing at most about 26 grams, and
wherein said container has a wet/hot rigidity of at least about 810
grams-force.
37. The container of claim 36 wherein said wet/hot rigidity is at
least about 850 grams-force.
38. The container of claim 36 having a dry rigidity, wherein said
wet/hot rigidity is at least about 60 percent of said dry
rigidity.
39. The container of claim 36 having a dry rigidity of at least
about 1,100 grams-force.
40. The container of claim 36 comprising at most about 0.8 grams
(dry weight) of said adhesive.
41. The container of claim 36 comprising at most about 0.5 grams
(dry weight) of said adhesive.
42. A container comprising: a base container comprising a side wall
that extends about a longitudinal axis to define an internal
volume; an overwrap positioned over said side wall; and an adhesive
connecting said overwrap to said side wall, wherein said container
is a 20-ounce container, wherein said container comprises at most
about 0.8 grams (dry weight) of said adhesive, and wherein said
container has a wet/hot rigidity of at least about 810
grams-force.
43. The container of claim 42 comprising at most about 0.5 grams
(dry weight) of said adhesive.
44. The container of claim 42 wherein said wet/hot rigidity is at
least about 850 grams-force.
45. The container of claim 42 having a dry rigidity, wherein said
wet/hot rigidity is at least about 60 percent of said dry
rigidity.
46. The container of claim 42 having a dry rigidity of at least
about 1,100 grams-force.
Description
FIELD
[0001] The present disclosure is generally related to containers
and, more particularly, to beverage containers.
BACKGROUND
[0002] Beverage containers, such as beverage cups, are used to hold
various beverages, including cold beverages, such as soda and iced
tea, and hot beverages, such as coffee and tea. Disposable beverage
containers, such as paperboard-based beverage containers, need to
have sufficient structural rigidity to hold the beverage while
being sufficiently lightweight for shipping and to reduce cost.
[0003] Unfortunately, hot beverages rapidly cool once placed in a
typical beverage container, while cold beverages rapidly warm. A
significant portion of the cooling/warming is typically effected by
heat transfer across the walls of the beverage container.
Furthermore, heat transfer across the walls of the beverage
containers may significantly increase the surface temperature of
the beverage container, which may render the beverage container too
hot to comfortably handle, or may significantly decrease the
surface temperature of the beverage container, which may render the
beverage container too cold to comfortably handle.
[0004] Additionally, the portion of the beverage container at the
upper end (e.g., near the opening of the beverage container) is
often times flimsy and can be accidentally crushed when a consumer
grips the cup, thus, damaging the beverage container and causing
the beverage to spill.
[0005] Efforts have been made to reduce heat transfer across the
walls of the beverage container and reduce the likelihood of the
beverage container from collapsing. Unfortunately, these efforts
have encountered various obstacles. For example, the side walls may
be thickened, which increases the cost and weight of the beverage
container. Additional stiffeners, such as a corrugated overwrap,
may be used; however, stiffeners may provide a thermally conductive
pathway from the side wall of the beverage container to the
exterior of the overwrap. Polystyrene foam beverage containers may
provide improved insulation, but tend to be fragile and are not
biodegradable. Environmentally friendly beverage containers, while
more structurally robust than polystyrene foam containers, tend to
provide only limited insulation.
[0006] Accordingly, those skilled in the art continue with research
and development efforts in the field of beverage containers.
SUMMARY
[0007] In one embodiment, the disclosed container may include a
base container including a side wall that extends about a
longitudinal axis to define an internal volume, an overwrap
positioned over the side wall, and an adhesive connecting the
overwrap to the side wall, the adhesive consisting essentially of a
single ring extending substantially circumferentially around the
side wall. The ring of adhesive may space the overwrap from the
side wall. Additionally, the ring of adhesive may structurally
reinforce the side wall.
[0008] In another embodiment, the disclosed container may include a
base container having a side wall that extends about a longitudinal
axis to define an internal volume, the side wall including an upper
end portion and a lower end portion, an overwrap positioned over
the side wall, and an adhesive connecting the overwrap to the side
wall, the adhesive extending substantially circumferentially around
the side wall to form a ring around the base container proximate
the upper end portion, wherein the container has a wet/hot rigidity
of at least 810 grams-force.
[0009] In another embodiment, the disclosed container may include a
base container including a side wall that extends about a
longitudinal axis to define an internal volume, the side wall
including an upper end portion and a lower end portion, an overwrap
positioned over the side wall, and an adhesive connecting the
overwrap to the side wall, the adhesive extending substantially
circumferentially around the side wall to form at least one ring
around the base container proximate the upper end portion, wherein
the container has a dry rigidity and a wet/hot rigidity, the dry
rigidity being at least about 1,100 grams-force, the wet/hot
rigidity being at least about 60 percent of the dry rigidity.
[0010] In another embodiment, the disclosed container may include a
base container including a side wall that extends about a
longitudinal axis to define an internal volume, an overwrap
positioned over the side wall, and an adhesive connecting the
overwrap to the side wall, wherein the container is a 20-ounce
container weighing at most about 26 grams, and wherein the
container has a wet/hot rigidity of at least about 810
grams-force.
[0011] In another embodiment, the disclosed container may include a
base container including a side wall that extends about a
longitudinal axis to define an internal volume, an overwrap
positioned over the side wall, and an adhesive connecting the
overwrap to the side wall, wherein the container is a 20-ounce
container, wherein the container includes at most about 0.8 grams
(dry weight) of the adhesive, and wherein the container has a
wet/hot rigidity of at least about 810 grams-force.
[0012] In yet another embodiment, disclosed is a method for
manufacturing a beverage container, the method may include the
steps of: (1) providing a base container including a side wall that
extends about a longitudinal axis to define an internal volume, the
side wall including an upper end portion and a lower end portion,
(2) providing an overwrap, (3) applying an adhesive to at least one
of the side wall and the overwrap, the adhesive extending
substantially circumferentially around the side wall to form a ring
of adhesive around the base container proximate the upper end
portion of the side wall, and (4) forming a layered structure
including the side wall, the overwrap, and the ring of adhesive
positioned between the side wall and the overwrap, wherein the ring
of adhesive defines a gap between the overwrap and the side
wall.
[0013] Other embodiments of the disclosed beverage container will
become apparent from the following detailed description, the
accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a front elevational view of one embodiment of the
disclosed beverage container;
[0015] FIG. 2 is a front elevational view, in section, of the
beverage container of FIG. 1;
[0016] FIG. 3 is a front elevational view of the base container of
the beverage container of FIG. 1;
[0017] FIG. 4 is a cross-sectional view of a portion of the side
wall of the beverage container of FIG. 1; and
[0018] FIG. 5 is a front elevational view of a 20-ounce cup
constructed as one specific, non-limiting example of the disclosed
beverage container.
DETAILED DESCRIPTION
[0019] The following detailed description refers to the
accompanying drawings, which illustrate specific embodiments of the
disclosure. Other embodiments having different structures and
operations do not depart from the scope of the present disclosure.
Like reference numerals may refer to the same element or component
in the different drawings.
[0020] The disclosed reinforced container may be formed as a
multi-wall (e.g., double-walled) beverage cup, such as a 12-ounce,
16-ounce, or 20-ounce disposable beverage cup. The reinforced
container may have a generally frustoconical shape, as shown in the
drawings, though reinforced containers having various shapes and
configurations may be constructed without departing from the scope
of the present disclosure.
[0021] Referring to FIGS. 1 and 2, the disclosed reinforced
container, generally designated 10, may include may include a base
container 12 and an overwrap 14. An adhesive 16 may be positioned
between the base container 12 and the overwrap 14 to connect the
overwrap 14 to the base container 12. Other techniques for further
securing the overwrap 14 to the base container 12, such as use of
mechanical fasteners, heat sealing or an interference fit, are also
contemplated.
[0022] Thus, the reinforced container 10 may be formed as a layered
structure that includes the base container 12, the overwrap 14, and
the adhesive 16 to form a side wall 40 (FIG. 4) of the beverage
container 10. Additional layers, such as additional adhesive layers
(not shown) and additional overwrap layers (not shown), may be
included without departing from the scope of the present
disclosure.
[0023] Referring to FIG. 3, the base container 12 may include a
side wall 18 and a base wall 20. The side wall 18 of the base
container 12 may include an upper end portion 22 and a lower end
portion 24, and may extend circumferentially about a longitudinal
axis A to define an internal volume 26 (FIG. 2). The base wall 20
may be connected to the lower end portion 24 of the side wall 18 to
partially enclose the internal volume 26. The upper end portion 22
of the side wall 18 may define an opening 28 (FIG. 2) into the
internal volume 26.
[0024] The upper end portion 22 of the side wall 18 of the base
container 12 may optionally include a circumferential rim 30. The
rim 30 may be formed by outwardly rolling the upper end portion 22
of the side wall 18. Those skilled in the art will appreciate that
the rim 30 may provide a structure to which a lid (not shown) may
be releasably connected to seal the opening 28 (FIG. 2) into the
internal volume 26.
[0025] Referring to FIG. 4, the side wall 18 of the base container
12 may include an inner surface 32 and an outer surface 34. The
inner surface 32 of the side wall 18 may define (or may be
proximate) an interior surface 50 of the side wall 18 (e.g., an
interior surface of the side wall 40 of the beverage container 10).
The side wall 18 may have a cross-sectional thickness T.sub.1 and a
rigidity sufficient to impart the side wall 18 of the base
container 12 with sufficient structural integrity to maintain the
desired shape of the beverage container 10 when a beverage (not
shown) is placed in the internal volume 26 (FIG. 2).
[0026] In a first example construction, the base container 12 may
be a paperboard container. For example, the base container 12 may
be formed by shaping a paperboard blank (not shown) on a
cup-forming machine, such as the PMC 1002 cup/container machine
available from Paper Machinery Corporation of Milwaukee, Wis. The
paperboard blank may have a cross-sectional thickness T.sub.1 of at
least about 6 points, such as about 8 to about 24 points, wherein 1
point equals 0.001 inch.
[0027] In a second example construction, the base container 12 may
be a polymeric container. As one example of the second
construction, the base container 12 may be formed by shaping a
polymeric blank (not shown), such as polycarbonate or polyethylene
terephthalate blank, on a cup-forming machine, such as the PMC
1002P container machine available from Paper Machinery Corporation.
As another example of the second construction, the base container
12 may be formed by vacuum molding, extrusion molding, injection
molding or thermoforming a polymeric material, such as
polycarbonate, polyethylene terephthalate or polystyrene.
[0028] At this point, those skilled in the art will appreciate that
the base container 12 may be formed from various materials using
various techniques, and may be configured in various shapes and
sizes, without departing from the scope of the present
disclosure.
[0029] Optionally, the inner surface 32 of the side wall 18 may be
coated with a moisture barrier layer 52, thereby rendering the
interior surface 50 of the side wall 18 resistant to moisture
penetration when the internal volume 26 is filled with a liquid
(not shown), such as coffee or soda. The moisture barrier layer 52
may have a cross-sectional thickness ranging from about 0.5 to
about 3.5 points, wherein 1 point equals 0.001 inches. For example,
the moisture barrier layer 52 may be (or may include) a layer of
polyethylene that has been laminated, extrusion coated or otherwise
connected (e.g., with adhesives) to the inner surface 32 of the
side wall 18. Other moisture barrier materials useful in the
moisture barrier layer 52 are commercially available and known to
the skilled artisan.
[0030] Referring again to FIGS. 1 and 2, the overwrap 14 may
circumferentially extend about the side wall 18 of the base
container 12. The overwrap 14 may include an upper end portion 44
positioned, for example, proximate (e.g., at or near) the upper end
portion 22 of the side wall 18 of the base container 12. The
overwrap 14 may include a lower end portion 46 positioned, for
example, proximate the lower end portion 24 of the side wall 18 of
the base container 12.
[0031] The overwrap 14 may have an overall surface area that is
less than the overall surface area of the side wall 18 (e.g., the
outer surface 34 of the side wall 18) of the base container 12.
Therefore, the overwrap 14 may cover only a portion of the side
wall 18 of the base container 12. As one example, the overwrap 14
may cover at least 50 percent of the side wall 18 of the base
container 12. As another example, the overwrap 14 may cover at
least 60 percent of the side wall 18 of the base container 12. As
another example, the overwrap 14 may cover at least 70 percent of
the side wall 18 of the base container 12. As another example, the
overwrap 14 may cover at least 80 percent of the side wall 18 of
the base container 12. As another example, the overwrap 14 may
cover at least 90 percent of the side wall 18 of the base container
12. As yet another example, the overwrap 14 may cover at most 95
percent of the side wall 18 of the base container 12.
[0032] Referring again to FIG. 4, the overwrap 14 may include an
inner surface 36 and an outer surface 38, and may have a
cross-sectional thickness T.sub.2. The outer surface 38 of the
overwrap 14 may define (or may be proximate) the exterior surface
54 of the overwrap 14 (e.g., an exterior surface of the side wall
40 of the beverage container 10).
[0033] In an example construction, the overwrap 14 may be formed
from paperboard. The paperboard may be bleached or unbleached, and
may have a basis weight of at least about 85 pounds per 3000 square
feet and a cross-sectional thickness T.sub.2 of at least about 6
points, wherein 1 point equals 0.001 inch. For example, the
overwrap 14 may be formed from paperboard, such as linerboard or
solid bleached sulfate (SBS), having a basis weight ranging from
about 180 to about 270 pounds per 3000 square feet and a thickness
T.sub.2 ranging from about 12 to 36 points.
[0034] Optionally, the paperboard used to form the overwrap 14 may
include various components and optional additives in addition to
cellulosic fibers. For example, the paperboard used to form the
overwrap 14 may optionally include one or more of the following:
binders, fillers (e.g., ground wood particles), organic pigments,
inorganic pigments, hollow plastic pigments, expandable
microspheres and bulking agents, such as chemical bulking agents.
Overwraps 14 formed from materials other than paperboard, such as
polymeric materials, are also contemplated.
[0035] The overwrap 14 may be formed by die-cutting a sheet of
stock material, such as paperboard, to produce an overwrap blank
(not shown). The overwrap blank may include a substantially
trapezoidal, keystone shape to allow the overwrap 14 to closely
correspond to the frustoconical shape of the base container 12, as
shown in FIGS. 1 and 2.
[0036] In an example implementation, the overwrap blank may be
wrapped onto the base container 12 to form the layered structure of
the side wall 40 of the beverage container 10. Alternatively, the
overwrap blank may first be assembled into a sleeve and then the
sleeve-shaped overwrap 14 may be positioned over the base container
12 (e.g., the base container 12 may be received by the overwrap 14)
to form the layered structure of the side wall 40 of the beverage
container 10.
[0037] Optionally, the overwrap 14 may include a plurality of
bosses, which may be formed by embossing and/or debossing the
overwrap 14, as disclosed in U.S. Ser. No. 12/910,951 filed on Oct.
25, 2010, the entire contents of which are incorporated herein by
reference.
[0038] In one specific, non-limiting example, the beverage
container 10 may be formed from a paperboard-based base container
12, a paperboard-based overwrap 14, and a substantially
biodegradable adhesive 16 (e.g., a latex adhesive). Therefore, the
beverage container 10 may be substantially biodegradable.
[0039] Referring to FIGS. 1 and 3, the adhesive 16 may extend
circumferentially about the side wall 18 of the base container 12.
For example, the adhesive 16 may form a ring 48 around the side
wall 18 of the base container 12. The ring 48 of adhesive 16 may be
located between the side wall 18 of the base container 12 and the
overwrap 14. For example, the ring 48 of adhesive 16 may be
disposed proximate the upper end portion 22 of the sidewall 18 of
the base container 12 and the upper end portion 46 of the overwrap
14.
[0040] Optionally, one or more additional rings (not shown) of
adhesive 16 may be positioned vertically below ring 48.
[0041] In an example construction, the adhesive 16 (e.g., the ring
48 of adhesive 16) may extend in a continuous, substantially
straight band around the side wall 18 of the base container 12, as
shown in FIG. 1. In another example construction, the adhesive 16
may extend in a continuous, non-straight band (e.g., sinuous, wavy,
zigzag, swirled, or the like) around the side wall 18 of the base
container 12. In another example construction, the adhesive 16 may
include a non-continuous plurality of band segments (e.g., strands)
extending circumferentially around the side wall 18 of the base
container 12. In yet another example construction, the adhesive 16
may include a non-continuous plurality of beads extending
circumferentially around the side wall 18 of the base container
12.
[0042] Since the adhesive 16 may be limited to a single ring 48, a
relatively small amount of adhesive 16 may be used, which may
reduce overall container weight while still providing rigidity. For
a typical 20-ounce container, about 0.4 to about 1.5 grams (wet
weight) of adhesive 16 may be used to form the ring 48, such as
about 0.6 to about 1.2 grams (wet weight), or about 0.8 to about
1.0 grams (wet weight). Depending on the solids content of the
adhesive formulation used, after drying to an equilibrium moisture
content, about 0.1 to about 0.8 grams (dry weight) of adhesive 16
may remain on the container 10, such as about 0.3 to about 0.6
grams (dry weight), or about 0.4 to about 0.5 grams (dry weight).
For larger containers (e.g., 24-ounce or 36-ounce cups),
proportionally more adhesive 16 may be used, while for smaller
containers (e.g., 12-ounce or 16-ounce cups), proportionally less
adhesive 16 may be used.
[0043] Referring again to FIG. 4, the side wall 40 of the
reinforced container 10 may be formed as a layered structure that
includes the side wall 18 of the base container 12, the overwrap
14, and the ring 48 of adhesive 16. The adhesive 16 may be disposed
between the side wall 18 of the base container 12 and the overwrap
14 to connect the overwrap 14 to the side wall 18 of the base
container 12. The overwrap 14 may be spaced from the side wall 18
of the base container 12 by the ring 48 of adhesive 16 to define a
gap 42 (e.g., an annular region) therebetween.
[0044] The adhesive 16 may include a thickness T.sub.3 and a width
W (e.g., a bead) upon application (e.g., to the base container 12).
The thickness T.sub.3 of the adhesive 16 may define the radial
dimension of the gap 42 (e.g., the spaced-apart distance between
the side wall 18 of the base container 12 and the overwrap 14).
[0045] As one example, the thickness T.sub.3 of the adhesive 16 may
be at least 5 points. As another example, the thickness T.sub.3 of
the adhesive 16 may be at least 10 points. As another example, the
thickness T.sub.3 of the adhesive 16 may be at least 20 points. As
another example, the thickness T.sub.3 of the adhesive 16 may range
from about 10 to about 40 points. As yet another example, the
thickness T.sub.3 of the adhesive 16 may range from about 20 to
about 30 points.
[0046] As one example, the width W of the adhesive 16 may be at
least 5 points. As another example, the width W of the adhesive 16
may be at least 10 points. As another example, the width W of the
adhesive 16 may be at least 20 points. As another example, the
width W of the adhesive 16 may range from about 10 to about 40
points. As another example, the width W of the adhesive 16 may
range from about 20 to about 30 points. As yet another example, the
width W of the adhesive 16 may be substantially equivalent to the
thickness T.sub.3 of the adhesive 16.
[0047] Thus, the ring 48 of adhesive 16 may function as a spacer
that spaces the overwrap 14 from the base container 12 by a
distance corresponding to the thickness T.sub.3 of the adhesive 16.
The spacing between the overwrap 14 and the base container 12 may
define the gap 42 between the overwrap 14 and the base container
12. The gap 42 may insulate the beverage container 10. Portions of
the gap 42 not filled with the adhesive 16 may be filled with
ambient air.
[0048] Those skilled in the art will appreciate that depending upon
the method of construction, the adhesive 16 may be applied to the
outer surface 34 (FIG. 4) of the side wall 18 of the base container
12 and may protrude radially outward from of the side wall 18 of
the base container 12 to define the gap 42. Alternatively, the
adhesive 16 may be applied to the inner surface 36 (FIG. 4) of the
overwrap 14 and may protrude radially inward from of the overwrap
14 to define the gap 42.
[0049] Those skilled in the art will appreciate that various
adhesives, including water-based adhesive (e.g., latex adhesives)
and organic solvent-based adhesive, may be used to connect the
overwrap 14 to the base container 12.
[0050] In one particular embodiment, the adhesive 16 may be a
thermally insulating adhesive. An adhesive may be deemed thermally
insulating if it has a thermal resistance per unit of thickness
that is greater than the thermal resistance per unit of thickness
of the overwrap 14. For example, the ratio of the thermal
resistance per unit of thickness of the adhesive 16 to the thermal
resistance per unit thickness of the overwrap 14 may be at least
about 1.25:1, such as 1.5:1, 2:1 or even 3:1.
[0051] A suitable thermally insulating adhesive 16 may be formed as
a composite material that includes an organic binder and a filler.
The organic binder may comprise 15 to 70 percent by weight of the
adhesive 16 and the filler may comprise 2 to 70 percent by weight
of the adhesive 16.
[0052] The organic binder component of the thermally insulating
adhesive 16 may be any material, mixture or dispersion capable of
bonding the overwrap 14 to the side wall 18 of the base container
12. The organic binder may also have insulating properties.
Examples of suitable organic binders include latexes, such as
styrene-butadiene latex and acrylic latex, starch, such as
ungelatinized starch, polyvinyl alcohol, polyvinyl acetate, and
mixtures and combinations thereof.
[0053] The filler component of the thermally insulating adhesive 16
may include an organic filler, an inorganic filler, or a
combination of organic and inorganic fillers. Organic fillers
include hard organic fillers and soft organic fillers. Examples of
suitable hard organic fillers include sawdust and ground wood.
Examples of suitable soft organic fillers include cellulose pulp,
pearl starch, synthetic fiber (e.g., rayon fiber), gluten feed,
corn seed skin and kenaf core (a plant material). Examples of
suitable inorganic fillers include calcium carbonate, clay,
perlite, ceramic particles, gypsum and plaster. For example,
organic filler may comprise 2 to 70 percent by weight of the
thermally insulating adhesive 16 and inorganic filler may comprise
0 to 30 percent by weight of the thermally insulating adhesive
16.
[0054] All or a portion of the filler may have a relatively high
particle size (e.g., 500 microns or more). The use of high particle
size filler material may provide the thermally insulating adhesive
16 with structure such that the adhesive 16 functions to further
space the overwrap 14 from the side wall 18 of the base container
12. For example, the thermally insulating adhesive 16 may be formed
as a composite material that includes an organic binder and a hard
organic filler, such as sawdust, that has an average particle size
of at least 500 microns, such as about 1000 to about 2000
microns.
[0055] In another particular embodiment, the adhesive 16 (e.g., a
thermally insulating adhesive) may be a foam. The foam may be
formed by mechanically whipping the components of the adhesive 16
prior to application. Optionally, a foam-forming agent may be
included in the adhesive formulation to promote foam formation. As
one example, 10 to 60 percent of the foam of the adhesive 16 may be
open voids, thereby facilitating the absorption of moisture from
the exterior surface 54 of the beverage container 10. As another
example, 10 to 30 percent of the foam of the adhesive 16 may be
open voids.
[0056] In another particular embodiment, the adhesive 16 may be
formed from a binder-filler formulation having a pseudoplasticity
index in the range of 0.3 to 0.5. Such a pseudoplasticity index may
provide the adhesive 16 with a sufficient minimum thickness, while
preserving the ability to apply the formulation at a low viscosity.
For example, the formulation may have a low shear viscosity in the
range of 2,000 to 50,000 centipoises and a high shear viscosity in
the range of 100 to 5,000 centipoises. Thus, the viscosity of the
adhesive 14 may be sufficient to maintain the thickness T.sub.3
defining the gap 42 and keep the overwrap 14 spaced away from the
side wall 18 of the base container 12 when the overwrap 14 is
applied to the base container 12.
[0057] In addition to spacing the overwrap 14 away from the side
wall 18 of the base container 12, the ring 48 of adhesive 16 may
function as a structural support and provide structural rigidity to
the base container 12. Those skilled in the art will recognize that
the weakest region of a paperboard-based beverage container is the
upper end portion proximate the opening.
[0058] Thus, by structurally reinforcing the side wall 18 of the
base container 12 with the ring 48 of adhesive 16, the structural
rigidity of the side wall 40 of the beverage container 10 may be
increased while minimizing the required thickness T.sub.1 (FIG. 4)
of the side wall 18 of the base container 12 and the required
thickness T.sub.2 (FIG. 4) of the overwrap 14.
[0059] For example, the adhesive 16 having a psuedoplasticity index
in the range of 0.3 to 0.5 may provide a structural adhesive that
forms a thermally insulating adhesive layer (e.g., the ring 48)
with a sufficient minimum thickness (e.g., T.sub.3), while
preserving the ability to apply the adhesive 16 at a low viscosity.
The adhesive 16 may have a lower apparent viscosity at higher shear
rates (e.g., high shear viscosity in the range of 100 to 5,000
centipoises) and a higher apparent viscosity at lower shear rates
(e.g., low shear viscosity in the range of 2,000 to 50,000
centipoises). The adhesive 16 having a pseudoplasticity index
between 0.3 and 0.5 may require less work to apply the adhesive 16
to a work surface (e.g., the side wall 18 of the base container 12
and/or the overwrap 14) due to the low viscosity at the high shear
rate. For example, the adhesive 16 may thin and flow readily in
response to a higher shear rate, such as when the adhesive 16 is
pumped or squeezed through a nozzle or brushed or rolled during
application, but will retain its shape in response to a lower shear
rate, such as compression between the overwrap 14 and the base
container 12.
[0060] Thus, the ring 48 of adhesive 16 may provide a structure
that maintains a minimum thickness (e.g., T.sub.3) (FIG. 4) between
the side wall 18 of the base container 12 and the overwrap 14 and
provides resistance to a compression forces F (FIG. 1) applied to
the upper end portion 11 of the beverage container 10, such as when
the beverage container 10 is gripped by the consumer.
[0061] As one option, the adhesive 16 may additionally include a
plasticizer. The plasticizer may comprise 0.5 to 10 percent by
weight of the adhesive 16. Examples of suitable plasticizers
include sorbitol, Emtal emulsified fatty acids, and glycerine.
[0062] As another option, the adhesive 16 may additionally include
sodium silicate, which may act as a filler, but is believed to aid
in binding and curing of the binder by rapidly increasing viscosity
of the binder during the drying process. The sodium silicate may
comprise 0 to 15 percent by weight of the adhesive 16, such as
about 1 to about 5 percent by weight of the adhesive 16.
[0063] As yet another option, the adhesive 16 may be formulated to
be biodegradable.
[0064] As a specific example, the adhesive 16 may include
styrene-butadiene or acrylic SRB latex (binder), wood flour
(organic filler), Aero Whip.RTM. (foam stabilizer available from
Ashland Aqualon Functional Ingredients of Wilmington, Del.), corn
fibers (organic filler), calcium carbonate (inorganic filler) and
starch (binder), wherein the components of the adhesive 16 have
been mechanically whipped together to form a foam. Other examples
of suitable adhesives are described in greater detail in U.S. Ser.
No. 61/287,990 filed on Dec. 18, 2009, the entire contents of which
are incorporated herein by reference.
[0065] It has been discovered that heat transfer across the gap 42
(e.g., from proximate the base container 12 to proximate the
overwrap 14) may be greatest at the adhesive 16, even when a
thermally insulating adhesive is used (i.e., air is generally a
better insulator). Therefore, when the beverage container 10 is
filled with a hot liquid (not shown), such as coffee, the average
surface temperature of the overwrap 14 may be lower relative to the
average surface temperatures of side wall 18 of the base container
12 due to the gap 42 between the overwrap 14 and the base container
12, as shown in FIG. 2.
[0066] Thus, a sufficient amount of adhesive 16 may be used to
ensure a proper connection between the overwrap 14 and the base
container 12. However, the adhesive 16 may be concentrated between
the base container 12 and the overwrap 14 at locations that
minimize heat transfer across the gap 42. For example, the adhesive
16 may be concentrated proximate the upper end portion 44 of the
overwrap 14, rather than between the base container 12 and a
central portion 56 (FIG. 1) of the overwrap 14. Therefore, heat
transfer to the central portion 56 may be minimized, thereby
beneficially reducing the average surface temperature of the
central portion 56 of the overwrap 14 (e.g., the gripped portion of
the beverage container 10) when the beverage container 10 is filled
with a hot liquid (not shown).
[0067] For example, as shown in FIG. 2, a layered structure (e.g.,
the side wall 40) of the beverage container 10 may be formed by the
side wall 18 of the base container 12 and the overwrap 14 adhered
together by the ring 48 (FIG. 1) of adhesive 16, such as a
biodegradable adhesive applied as an adhesive formulation that
includes an adhesive component (binder), a foaming agent, and a
filler.
[0068] Due to improved resistance to compression forces F (FIG. 1),
the disclosed beverage container 10 may have a wet/hot rigidity, as
determined using the deflection-based wet/hot rigidity test
outlined herein, of at least about 700 grams of force
(grams-force). In one expression, the disclosed beverage container
10 may have a wet/hot rigidity of at least 800 grams-force. In
another expression, the disclosed beverage container 10 may have a
wet/hot rigidity of at least 810 grams-force. In another
expression, the disclosed beverage container 10 may have a wet/hot
rigidity of at least 825 grams-force. In another expression, the
disclosed beverage container 10 may have a wet/hot rigidity of at
least 850 grams-force. In another expression, the disclosed
beverage container 10 may have a wet/hot rigidity of at least 850
grams-force. In another expression, the disclosed beverage
container 10 may have a wet/hot rigidity of at least 875
grams-force. In yet another expression, the disclosed beverage
container 10 may have a wet/hot rigidity of at least 900
grams-force.
[0069] Unlike some commercially available (prior art) double wall
cups, the disclosed beverage container 10 may retain a substantial
amount of rigidity even after being filled with a hot beverage. In
one expression, the wet/hot rigidity of the disclosed container 10
may be at least 50 percent of the dry rigidity. In another
expression, the wet/hot rigidity of the disclosed container 10 may
be at least 55 percent of the dry rigidity. In another expression,
the wet/hot rigidity of the disclosed container 10 may be at least
60 percent of the dry rigidity. In another expression, the wet/hot
rigidity of the disclosed container 10 may be at least 65 percent
of the dry rigidity. In yet another expression, the wet/hot
rigidity of the disclosed container 10 may be at least 68 percent
of the dry rigidity.
[0070] Accordingly, the disclosed beverage container 10 may include
an overwrap 14 connected over a base container 12 by an adhesive
16, wherein the beverage container 10 is structurally reinforced by
at least one ring 48 of adhesive 16 extending circumferentially
around the side wall 18 of the base container 12 and the overwrap
14 is spaced away from the base container by the adhesive 16 to
define a gap 42. Furthermore, the adhesive 16 may be arranged
between the overwrap 14 and the base container 12 such that the
surface of the overwrap 14 is cooler than the surface of the base
container 12 when the beverage container 10 is filled with a hot
liquid.
EXAMPLES
Example 1
20-Ounce Cup
[0071] The 20-ounce cup 100 shown in FIG. 5 was constructed from a
base container 112 and an overwrap 114. The cup 100 had a height H
of about 6.3 inches, an upper end diameter D.sub.1 of about 3.6
inches, and a lower end diameter D.sub.2 of about 2.1 inches. The
cup had a total weight of about 25.6 grams.
[0072] The base container 112 was formed from poly-coated (internal
side only) paperboard having a caliper thickness of about 13 points
(1 point=0.001 inches). The base container 112 included a rolled
rim 130.
[0073] The overwrap 114 was formed from uncoated paperboard having
a caliper thickness of about 16.5 points. The overwrap 114 included
three debossings 102 circumferentially extending about the overwrap
114 and protruding into engagement with the base container 112. The
overwrap 114 was wrapped around the base container 112 and the free
ends of the overwrap 114 were secured together along a seam
104.
[0074] The overwrap 114 was secured to the base container 112 with
a single ring 148 of adhesive 116 extending circumferentially
around the base container 112. The ring 148 of adhesive 116 was
positioned proximate the upper end of the cup 100, slightly below
the rolled rim 130.
[0075] The adhesive 116 was formulated as shown in Table 1.
TABLE-US-00001 TABLE 1 Component Function Parts (by weight) Water
Solvent/Carrier 30.79 Stadex 235 Binder 16.93 Celvol 502 Binder
14.93 Latex-Acronal S 504 Binder 21.24 Propylene glycol Plasticizer
3.85 Triton X100 Surfactant 1.23 Berchem 4842 Dispersant 0.25
Nalcon 7647 Biocide 0.15 Wood flour Filler 10.62
[0076] The Stadex 235 (dextrin from Tate & Lyle of London,
United Kingdom) was mixed with cold water for 15 minutes and then
cooked to 190.degree. C. Celvol 502 (polyvinyl alcohol resin from
Celanese International Corporation of Dallas, Tex.) was slowly
added. The mixture was mixed for 15 minutes and then cooled to
100.degree. C. The pH was adjusted to at least 8. The Acronal S 504
(latex from BASF Aktiengesellschaft Corporation of Germany) was
then added, followed by additions of propylene glycol and Triton
X100 (surfactant from The Dow Chemical Company of Midland, Mich.).
After mixing for 10 minutes, Berchem 4842 (dispersant from Bercen
Inc. of Dunham Springs, La.) was added. After 10 additional minutes
of mixing, Nalcon 7647 (slimicide from Nalco Company of Naperville,
Ill.) was added. Then, after 10 additional minutes of mixing, the
viscosity was measured using a #7 spindle at 50 rpm. Water was
added as necessary to achieve a viscosity in the range of 1,400 to
1,600 cps. Finally, the wood flour was added to bring the final
viscosity within the range of 14,000 to 16,000 cps. The adhesive
composition had a solids content in the range of 47 to 53
percent.
[0077] Approximately 0.8 to 1.0 grams (wet weight) of the adhesive
formulation was used to form the ring 148 of adhesive 116. After
drying to an equilibrium moisture content, at most about 0.5 grams,
specifically about 0.2 to about 0.4 grams, of the adhesive 116
remained on the cup 100.
Example 2
Wet/Hot Rigidity Test
[0078] The 20-ounce cups of Example 1 were tested for wet/hot
rigidity. The result was a wet/hot rigidity averaging at about 895
grams-force, which is significantly higher than competitive paper
and polymer-based cups currently on the market. It is believed that
a similar wet/hot rigidity value would be obtained for cups
constructed in a similar manner, but at other sizes, such as
12-ounce and 16-ounce sizes.
[0079] The "wet/hot rigidity" test is a modification of the Solo
deflection test known in the industry and disclosed in U.S. Pat.
No. 8,152,018 to Smith et al., the entire contents of which are
incorporated herein by reference. The wet/hot rigidity test is
performed under TAPPI standard conditions. The seam 104 is
positioned 90 degrees from the direction of the applied force. The
deflection speed should be such that it takes about 3 to 4 seconds
to achieve 0.25 inches of deflection. However, unlike the
traditional Solo deflection test, the wet/hot rigidity test is
performed while the container under test is filled with water at a
temperature of 205.degree. F., and after the hot water has been in
the container under test for 3 minutes.
[0080] Thus, the wet/hot rigidity test measures the peak force
required to deflect a container filled with hot liquid by 0.25
inches at a point that is one-third of the way down from the upper
edge of the container.
Example 3
Dry Rigidity Test
[0081] The 20-ounce cups of Example 1 were also tested for dry
rigidity. The result was a dry rigidity averaging at about 1,300
grams-force. It is believed that a similar dry rigidity value would
be obtained for cups constructed in a similar manner, but at other
sizes, such as 12-ounce and 16-ounce sizes.
[0082] The "dry rigidity" test is performed under TAPPI standard
conditions using the same procedure used for the wet/hot rigidity
test, but with a dry cup (i.e., without filling the cup with water
at a temperature of 205.degree. F. or otherwise heating the cup
outside of TAPPI standard conditions).
[0083] Thus, like the wet/hot rigidity test, the dry rigidity test
measures the peak force required to deflect a container by 0.25
inches at a point that is one-third of the way down from the upper
edge of the container.
Example 4
Rigidity Retention
[0084] Comparing the wet/hot rigidity of a cup to the dry rigidity
provides an indication of rigidity retained by the cup after the
cup is placed into use. The "rigidity retention" may be expressed
as a percentage by dividing the wet/hot rigidity by the dry
rigidity, and then multiplying by 100.
[0085] For the 20-ounce cups of Example 1, the rigidity retention
was about 68.8 percent, which was calculated by dividing the
wet/hot rigidity (895 grams-force from Example 2) by the dry
rigidity (1,300 grams-force from Example 3).
Comparative Examples
[0086] For comparison, the following commercially available
20-ounce cups were tested for dry rigidity performance and wet/hot
rigidity performance: (1) the HOLD&GO.RTM. insulated paper hot
cup (about 27.9 grams total cup weight) from International Paper,
Inc. of Memphis, Tenn.; (2) the Seda Double Wall insulated cup
(about 28.1 grams total cup weight) from Seda International
Packaging Group SpA of Naples, Italy; (3) the SOLO.RTM. DUO
SHIELD.RTM. insulated paper hot cup (about 24.6 grams total cup
weight) from Solo Cup Operating Corporation of Lake Forest, Ill.;
(4) the CHINET.RTM. RC cup COMFORTCUP.RTM. (about 27.8 grams total
cup weight) from Huhtamaki Inc. of De Soto, Kans.; (5) the DUNKIN'
DONUTS.RTM. foam cup from Dunkin' Donuts of America, Inc. of
Quincy, Mass.; (6) a basic paper cup; and (7) the THERMO GRIP.TM.
cup (about 26.5 grams total cup weight) from LBP Manufacturing,
Inc. of Cicero, Ill. The test results, as well as the rigidity
retention, are provided in Table 2.
TABLE-US-00002 TABLE 2 Total Wet/Hot Dry Cup Rigidity Rigidity
Rigidity Weight (grams- (grams- Retention Sample Cup (grams) force)
force) (percent) 1 Hold &Go 27.9 804 2,741 29.3 2 Seda 28.1 696
1,061 65.6 3 Solo Duo Shield 24.6 659 1,007 65.4 4 Chinet RC 27.8
614 904 67.9 5 Dunkin' Donuts -- 584 753 77.5 6 Paper -- 530 690
76.8 7 Thermo Grip 26.5 484 949 51.0
[0087] Although various embodiments of the disclosed beverage
container have been shown and described, modifications may occur to
those skilled in the art upon reading the specification. The
present application includes such modifications and is limited only
by the scope of the claims.
* * * * *