INSULATING WRAPPER SLEEVE FOR CONTAINER

Abstract

An insulating wrapper sleeve for a container is provided. The wrapper sleeve can include an interior insulating layer and an exterior base layer. The insulating layer can include disruptions in the form of corrugations, embossments, debossments or apertures in various configurations along the surface of the insulating layer. To form the sleeve, the insulating layer is secured to the base layer and the disruptions create air gaps between the insulating layer and the base layer. The ends of the sleeve can then be secured together and adapted to receive a container so that the interior portion of the insulating layer contacts and rests against the sidewall of a container. The air gaps created within the sleeve provide for increased thermal characteristics of the container and sleeve combination.

Description

BACKGROUND OF THE INVENTION

The present invention relates to a container wrapper sleeve configured for providing thermal protection between a user of the container and the user. There are currently several means for providing insulated containers, particularly disposable food and drink containers, such as coffee cups. Such disposable containers are normally constructed from polystyrene foam or paperboard materials. Containers made from polystyrene foam have desirable thermal insulation properties, but are environmentally unfriendly because they are not biodegradable or easily recyclable. Containers made of paperboard are more environmentally friendly, but can have poor thermal insulation properties. In response to the poor insulating properties of paperboard, it is common to incorporate a wrapper or sleeve around the paperboard container. The wrapper often includes an insulating layer between the container sidewall and the wrapper outer sidewall. However, such wrappers are generally inefficient at providing adequate insulation, effectively securing the insulating layer to the outer wrapper sidewall, and providing for economic use of materials.

Accordingly a need exists for an insulating wrapper sleeve for a container that can provide adequate insulation and effectively secure the insulating layer to the outer layer with an economic use of paperboard and adhesive.

SUMMARY OF THE INVENTION

The present invention is directed generally to an insulating wrapper sleeve for a container, such as a cup. The wrapper sleeve can be configured for placement around the container and can conform to the general shape of the container sidewall. The insulating wrapper sleeve can include an inner insulating insert layer and an outer base layer. The insulating layer can include one or more disruptions that create air gaps between the insulating layer and base layer when placed together. The disruptions can be in the form of corrugations, embossments, apertures or other similar formations. The air gaps formed by the disruptions can help provide the thermal insulating characteristics of the wrapper sleeve.

The insulating layer and base layer can be stacked together to foam the wrapper sleeve and can be secured together in a variety of different methods and configurations. According to one embodiment of the present invention, the entire insulating insert is secured to the outer base layer. In another embodiment, only the edges of the insulating insert are secured to the outer base layer. In yet another embodiment, the insulating layer is secured to the outer base layer only along the non-raised regions of the insulating layer created by the disruptions. In each of these configurations, the securement of the insulating insert to the outer base layer prevents the edges of the insulating insert from freely migrating relative to the outer base layer. Alternative securement methods and configurations can also be used in alternative embodiments of the present invention.

Other aspects and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments and the accompanying drawing figures.

DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawing, which forms a part of the specification and is to be read in conjunction therewith in which like reference numerals are used to indicate like or similar parts in the various views:

FIG. 1 is a perspective view of a container with an insulating wrapper sleeve being wrapped around the container in accordance with one embodiment of the present invention;

FIG. 2 is a perspective view of a container and an insulating wrapper sleeve in accordance with one embodiment of the present invention;

FIG. 3 is a plan view of an insulating wrapper sleeve with a corrugated insulating layer in accordance with one embodiment of the present invention;

FIG. 4 is a plan view of an insulating wrapper sleeve with a corrugated insulating layer in accordance with one embodiment of the present invention;

FIG. 5 is a plan view of an insulating wrapper sleeve with an embossed or debossed insulating layer in accordance with one embodiment of the present invention;

FIG. 6 is an exploded perspective view of an insulating wrapper showing an insulating layer and an outer base layer in accordance with one embodiment of the present invention;

FIG. 7 is side view of a container and an insulating wrapper sleeve in accordance with one embodiment of the present invention;

FIG. 8 is a partial plan view of an insulating wrapper sleeve with an insulating layer and an outer base layer in accordance with one embodiment of the present invention; and

FIG. 9 is a partial plan view of a container and an insulating wrapper sleeve wrapped around the container in accordance with one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures. It will be appreciated that any dimensions included in the drawing figures are simply provided as examples and dimensions other than those provided therein are also within the scope of the invention.

The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled.

Referring to the figures, the present invention is directed generally to an insulating wrapper sleeve 10 according to several alternative embodiments. Sleeve 10 can be configured for placement around a container 12, as shown in FIGS. 1 and 2, in order to provide container 12 with improved thermal insulation properties as described in greater detail below.

Sleeve 10 can comprise an outer base layer 14 and an inner insulating layer 16 as best shown in FIG. 3-5. Sleeve 10 can be formed by joining outer base layer 14 and inner insulating layer 16 as described in greater detail below Inner insulating layer 16 can act as a spacer between outer base layer 14 and an outer sidewall 18 of container 12, thereby creating a gap 20 between outer base layer 14 and container sidewall 18 as best shown in FIG. 2. Gap 20 reduces the thermal conduction from the hot or cold contents of container 12 and outer base layer 14 to shield a user's hands from the hot or cold contents within container 12.

Container 12 can be formed according to any one of a number of methods and configurations currently known in the art. Container 12 can be constructed from paper, paperboard, plastic, plastic-covered paper, laminated paperboard, thermoplastic materials, expanded polystyrene and the like. Container sidewall 18 can have a generally frustoconical shape such that the diameter of container 12 is greater at its upper region than at is lower region. Sidewall 18 can be enclosed around a bottom panel with an overlapping side seam. Container 12 can also have an outwardly rolled upper lip. The foregoing represents just one possible embodiment and it will be appreciated by those skilled in the art that shapes and configurations different from the above-mentioned construction for container 12 may serve equally as well.

Outer base layer 14 can be constructed from a variety of types of materials, including but not limited to recycled material, paperboard material, foam material, potato starch material, and plastic material and the like. The thickness of outer base layer 14 can vary from embodiment to embodiment. According to the embodiment shown in the figures, outer base layer 14 has a thickness less than that of insulating layer 16; however, in alternative embodiments, the thickness of outer base layer 12 can be greater than that of insulating layer 16. Sleeve 10 can also be configured in any number of sizes relative to container 12. For example, according to one embodiment, as shown in FIG. 7, sleeve 10 is configured with a height less than that of container 12 so that sleeve 10 covers a substantial portion of container sidewall 18 but not all of container sidewall 18. Alternatively, sleeve 10 can have a height much less than the height of container 12 as shown in FIG. 2. The height of sleeve 10 can also be designed for being adaptable to containers 18 of different shapes and sizes. According to yet another embodiment, sleeve 10 can have a height approximately equal to that of container 12 so that sleeve 10 essentially serves as an additional outer sidewall for container 12.

As shown in FIGS. 3-6, outer base layer 14 can have a generally rectangular shape with side edges 22 and 24 and top and bottom edges 26 and 28, respectively. Side edges 22 and 24 can be slightly angled inward with respect to the base layer 12 so that they are orientated at an acute angle to each other according to one particular embodiment as shown in FIG. 4. Opposing top and bottom edges 26 and 28, respectively, can be curved and orientated generally concentrically with respect to one another according to one embodiment as also shown in FIG. 4. Such a configuration is well known and enables sleeve 10 to better conform to the frustoconical sidewall 18 of container 12. However, it is recognized that alternative shapes with a different number of edges and alternative orientations may be used in the construction of outer base layer 14. For example, when designed for use with a cylindrical container (not shown), outer base layer 14 can be generally orthogonal with generally parallel side edges 22 and 24 and generally parallel top and bottom edges 26 and 28. In other alternative embodiments (not shown), outer base layer 14 can have a non-orthogonal or rectangular configuration.

Insulating layer 16 can be constructed from any suitable material, including but not limited to paperboard, foam material, cardboard, corrugated cardboard, laminated paperboard, plastic and thermoplastic materials and the like. Insulating layer 16 can have disruptions 30 in the form of corrugations and/or dimpled surfaces, embossments, cuts, gaps, holes or other apertures, which can create a plurality of air gaps 32. Other similar methods to create disruptions 30 in the insulating layer 16 material can also be used in alternative embodiments of the present invention. FIGS. 3-4 show insulating layer 16 having disruptions 30 in the form of corrugations according to one embodiment. FIG. 5 shows insulating layer 16 having disruptions 30 in the form of embossments 34 according to an alternative embodiment. Disruptions 30 can be in any configuration or pattern. For example, disruptions 30 in the faun of corrugations can be vertically orientated, diagonally orientated, horizontally orientated or any other orientation. Additionally, the corrugations can also be in the form of wavy lines. Disruptions 30 in the form of embossments, debossments or apertures can be any shape and orientated in any suitable pattern.

The disruptions 30 can define the thickness of insulating layer 16. For example, the depth of the corrugations, embossments or debossments forming disruptions 30 can define the thickness of insulating layer 16; however where cuts, holes or the like are used as the disruptions 30, the thickness of insulating layer 16 can be the thickness of the material used. Similarly, when insulating layer 16 is constructed from a material having porous properties, where air gaps 32 are defined within insulating layer 16, the thickness of insulating layer 16 can be the thickness of the material used.

Insulating layer 16 can have any number of different shapes and configurations. According to one embodiment, as shown in FIG. 4, insulating layer 16 has a generally rectangular shape with side edges 34 and 36 and top and bottom edges 38 and 40, respectively, similar to outer base layer 14. However, it is recognized that alternative shapes with a different number of edges and alternative orientations may be used in the construction of the insulating layer 16. Insulating layer 16 can also be any size relative to outer base layer 14 and container 12. Preferably, insulating layer 16 is sized to fit within the edges of outer base layer 14, but in certain embodiments, insulating layer 16 can be larger than outer base layer 14.

As shown in FIG. 3, insulating layer 16 can be sized to approximately the same dimensions as outer base layer 14 according to one embodiment of the present invention. In such an embodiment, the edges, 34, 36, 38 and 40 substantially align with edges 22, 24, 26 and 28 when insulating layer 16 and outer base layer 14 are placed together.

As shown in FIG. 4, insulating layer 16 can be sized to be slightly smaller than outer base layer 14 according to another embodiment of the present invention. In this embodiment, the sizing of insulating layer 16 allows for a perimeter edge 42 to exist around the perimeter of outer base sheet 14 when insulating layer 16 and outer base sheet 14 are placed together. Depending on the particular embodiment, the insulating layer 16 can be smaller along one or more of the top, bottom, right side and/or left side.

The insulating wrapper sleeve 10 is formed by stacking the insulating layer 16 on top of the outer base layer 14 such that at least some portion of an inner surface 44 of outer base layer 14 touches at least some portion of an outer surface 46 of insulating layer 16. In one embodiment, the entire outer surface 46 of insulating layer 16 touches inner surface 44 of outer base layer 14. In other embodiments only part of outer surface 46 of insulating layer 16 is in contact with outer base layer 14.

Insulating layer 16 and outer base layer 14 can be affixed or adhered together by using glued, sealant, or other adhesive capable of providing a paper-to-paper, paper-to-foam or paper-to-plastic bond, depending upon the nature of the materials used to form insulating layer 16 and outer base layer 14. Exemplary adhesives that can be used include pressure sensitive adhesives, hot melt adhesives, contact adhesives, and drying adhesives. The adhesive 48 can be applied to outer surface 46 of insulating layer 16 or inner surface 44 of outer base layer 14. It is also envisioned that adhesive 48 can be applied to both outer surface 46 of insulating layer 16 and inner surface 44 of outer base layer 14.

Adhesive 48 can be applied in any suitable manner, including but not limited to the specific embodiments described below. In one embodiment, adhesive 48 is applied to the entire inner surface 44 of outer base layer 14 that will be in contact with outer surface 46 of insulating layer 16. Alternatively or additionally, adhesive 48 can be applied to outer surface 46 of insulating layer 16 that will be in contact with inner surface 44 of outer base layer 14. According to one embodiment, adhesive 48 need not be applied to raised portions 50 of insulating layer 16 that form the air gaps 32. In such an embodiment, adhesive 48 is applied only to portions of insulating layer 16 that contact outer base layer 14 (and/or applied only to portions of outer base layer 14 that contact insulating layer 16), as best shown in FIG. 8. Adhesive 48 can be applied along the entirety of the outer edges of insulating layer 16 and omitted in interior regions of insulating layer 16. Adhesive 48 can also be applied in any number of different patterns or designs. For example, adhesive 48 can be applied in the form of vertical lines, horizontal lines, diagonal lines, or any combination thereof. Adhesive 48 can also be applied by way of circles, arcs, dots, or any other suitable shapes, patterns or methods. It is also anticipated that adhesive 48 will be applied only to certain portions of the surfaces 44 and/or 46, such as only the upper region, middle region, lower region, etc.

In one embodiment, adhesive 48 is applied to inner surface 44 and/or outer surface 46 so that insulating layer 16 is fixedly attached to outer base layer 14 and insulating layer 16 is not free to migrate relative to outer base layer 14. This can be accomplished by applying adhesive 48 along the outer edges of insulating layer 16 (including side edges 34 and 36 and top and bottom edges 38 and 40, respectively) so that the perimeter of insulating layer 16 is fixedly connected to outer base layer 14. In such an embodiment, insulating layer 16 is unable to migrate relative to outer base layer 14 when adhesive 48 is also applied to the interior region of insulating layer 16 or when adhesive 48 is not applied to the interior region of insulating layer 16. This can also be accomplished by applying adhesive 48 to the entire contact region between insulating layer 16 and outer base layer 14, part of the contact region, or to one or more edges 34, 36, 38 and 40 of insulating layer 16

FIG. 3 shows one embodiment of sleeve 10 whereby insulating layer 16 is approximately the same size as outer base layer 14 and the area of outer base layer 14 is approximately equal to the area of insulating layer 16. When insulating layer 16 is secured to outer base sheet 14, the entire inner surface 44 of outer base layer 14 is covered by the entire outer surface 46 of insulating layer 16. Here, adhesive 48 can be applied to the entire inner surface 44 of outer base sheet 14 (and/or adhesive 48 can be applied to the entire outer surface 46 of insulating layer 16). Alternatively, as shown in FIG. 8, adhesive 48 can be applied only to the contacting regions 52 and not to raised portions 50 of the distortions 30 of insulating layer 16. FIG. 8 shows distortions 30 in the form of corrugations, however, the above described adhesive 48 application applies equally to embossments, debossments and other forms of distortions 30. Even when adhesive 48 is applied only to the contact regions of insulating layer 16, insulating layer 16 can still remain fixedly secured to outer base layer 14 so that insulating layer 16 is not able to migrate freely relative to outer base layer 14.

FIG. 4 shows another embodiment of sleeve 10 where insulating layer 16 is smaller in size than outer base layer 14 and the entire area of insulating layer 16 can fit within the area of outer base layer 14. As shown in FIG. 4, insulating layer 16 and outer base layer 14 can maintain approximately the same shape; however, the area of outer base layer 14 is greater than the area of insulating layer 16. In such an embodiment, edges 22, 24, 26 and 28 of outer base layer 14 extend beyond edges 32, 34, 36 and 38 of insulating layer 16, creating perimeter edge 42 when insulating layer 16 and outer base layer 14 are affixed together. In such an embodiment, adhesive 48 can be applied so that the entire outer surface 46 of insulating layer 16 is secured to inner surface 44 of outer base layer 14, yet adhesive 48 is not applied to the perimeter edge 42. As a result, adhesive 48 need only be applied to the portion of outer base layer 14 that will be covered by insulating layer 16 when the two are affixed together. In alternative embodiments, adhesive 48 can be applied to one-hundred percent of outer surface 46 of insulating layer 16, less than one-hundred percent of outer surface 46, in only specific regions or any other suitable manner.

After insulating layer 16 and outer base layer 14 are secured together to form sleeve 10, sleeve 10 can be wrapped around container 12 and secured to container 12 to form an insulated container. When sleeve 10 is wrapped around container 12, the inner surface 54 of insulating layer 16 can contact the container sidewall 18. In embodiments where outer base layer 14 extends beyond insulating layer 16, outer base layer 14 can also contact container sidewall 18. Sleeve 10 can be secured to container 12 with an adhesive or through the use of a commonly known sealing technology, such as heat sealing or sonic welding.

Alternatively, sleeve 10 can be prepared for future use. In such an embodiment, the lateral ends 56 and 58 of sleeve 10 are secured together to place sleeve 10 in a frustoconical or cylindrical configuration so that it may later be applied to a container 12. The formed sleeves 10 can be stacked similar to how frustoconical containers are stacked for storage and transportation. Alternatively, sleeve 10 can be formed by securing ends 56 and 58 together and then folding sleeve 10 into a flat configuration so that it can be packaged for storage and transportation as commonly known in the art.

The ends 56 and 58 of sleeve 10 can be secured together in an overlapping configuration, a butt-seam configuration, or any other method commonly known in the art. In an overlapping configuration, second end 58 can overlap first end 56. Between the overlapping portions of the first and second ends 56 and 58, an adhesive can be applied to secure the ends 56 and 58 together to form seam 60. A heat sealing method can also be used where a coating of polyethylene or other heat-sealable coating is applied to one or both ends 56 and 58 along the overlapping region and then heat and/or pressure is applied to fuse the ends 56 and 58 together. In an embodiment where edges 34 and 36 of insulating layer 16 extend to edges 22 and 24 of outer base layer 14, as shown in FIG. 9, inner surface 54 of insulating layer 16 at end 58 can be secured to outer base layer 14 at end 56 along seam 60. In such an embodiment, raised portions 50 of insulating layer 16 at seam 60 can be compressed or otherwise pressed flat to reduce air gaps 32 along seam 60 to reduce the thickness of sleeve 10 at seam 60. In an embodiment where edges 34 and 36 of insulating layer 16 do not extend to edges 22 and 24 of outer base layer 14, outer base layer 14 at first end 56 can be secured to outer base layer 14 at second end 58 along seam 60.

In a butt-seam configuration, ends 56 and 58 meet but do not overlap at seam 60 and ends 56 and 58 are bonded at their edge. Similar to as described above, raised portions 50 of insulating layer 16 can be pressed flat along seam 60 in order to reduce the thickness sleeve 10 along seam 60, as best shown in FIG. 9.

Ends 56 and 58 of sleeve 10 can also be secured to the container sidewall 18 through an adhesive or similar heat-sealing method. In the overlapping configuration, first end 56 can be secured to the container sidewall 18 at seam 60 or at a position set back from seam 60. Second end 58 can also be secured to the container sidewall 18 at a position set back from seam 60. In the butt-seam method, both ends 56 and 58 can be secured to the container sidewall 18 along seam 60 or at a position set back from seam 60, depending on the particular embodiment.

From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

The constructions described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention. As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The tams “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.

Claims

1. An insulating wrapper sleeve for a container, said sleeve comprising: an insulating layer having a plurality of edges defining a perimeter; andan base layer having a plurality of edges defining a perimeter;wherein said insulating layer is affixed to said base layer so that said plurality of edges of said insulating layer cannot freely migrate relative to said base layer.

2. The insulating wrapper sleeve of claim 1, wherein said insulating layer has a plurality of disruptions defined therein, said disruptions creating a plurality of air gaps between said insulating layer and said base layer when said insulating layer and said base layer are affixed.

3. The insulating wrapper sleeve of claim 2, wherein said disruptions are configured in the fonts of corrugations.

4. The insulating wrapper sleeve of claim 2, wherein said disruptions are configured in the form of embossments.

5. The insulating wrapper sleeve of claim 2, wherein said disruptions form a plurality of raised portions of said insulating layer and a plurality of contacting portions of said insulating layer.

6. The insulating wrapper sleeve of claim 2, wherein said insulating layer is affixed to said base layer only at contacting portions of said insulating layer.

7. The insulating wrapper sleeve of claim 1, wherein said insulating layer is affixed to said base layer only along said plurality of edges of said insulating layer.

8. The insulating wrapper sleeve of claim 1, wherein said insulating layer and said base layer are approximately the same size so that said plurality of edges of said insulating layer are substantially aligned with said plurality of edges of said base layer.

9. The insulating wrapper sleeve of claim 1, wherein said insulating layer is smaller in size that said base layer so that said base layer contains an outer perimeter edge region when said insulating layer is affixed to said base layer.

10. The insulating wrapper sleeve of claim 1, wherein an outer surface of said insulating layer contacts an inner surface of said base layer when said insulating layer and said base layer are affixed together, and wherein said outer surface is affixed to said inner surface by an adhesive layer applied to the entirety of said outer surface contacting said inner surface.

11. The insulating wrapper sleeve of claim 1, wherein said sleeve includes a first edge lateral end and a second lateral end and wherein said lateral edges are connected together to form a generally frustoconical sleeve.

12. A container comprising an inner sidewall and an outer sleeve, said outer sleeve comprising: an insulating layer having a plurality of edges; anda base layer having a plurality of edges;wherein said insulating layer is secured to said base layer so that said plurality of edges said insulating layer are not free to migrate relative to said base layer, and wherein said outer sleeve is secured to said inner sidewall of said container.

13. The container of claim 12, wherein said insulating layer is secured to said base layer along said plurality of edges of said insulating layer.

14. The container of claim 12, wherein an entire outer surface of said insulating layer is secured to said base layer.

15. The container of claim 12, wherein said insulating layer is configured with a plurality of disruptions creating air gaps between said insulating layer and said base layer and between said insulating layer and said inner sidewall of said container.

16. The container of claim 15, wherein said disruptions further form a plurality of raised portions not in contact with said base layer and a plurality of contacting portions in contact with said base layer.

17. The container of claim 16, wherein said insulating layer is secured to said base layer along the plurality of contacting portions.

18. The container of claim 15, wherein said disruptions are in the form of corrugations.

19. The container of claim 15, wherein said disruptions are in the form of embossments.

20. An insulating wrapper sleeve configured to placement around a sidewall of a container, said wrapper sleeve comprising: an insulating layer defined by a plurality of edges, said insulating layer comprising: a plurality of corrugations extending in a generally vertical direction between two of said plurality of edges of said insulating layer;a plurality of raised portions formed by said corrugations; anda plurality of contacting portions formed by said corrugations; anda base layer defined by a plurality of edges;wherein all of said contacting portions of said insulating layer are affixed to said base layer so that said plurality of edges of said insulating layer are not free to migrate relative to said base layer.