Packaging system for distrubuting and dispensing disposable cups and lids

Abstract

A packaging system suitable for distributing and dispensing disposable cups and lids includes a protective sleeve as well as a polymer envelope. The protective sleeve is configured to receive a nested stack of lids at its upper portion as well as a nested stack of cups at its lower portion. In one preferred embodiment a separator disk separates the two nested stacks and the cups are paperboard cups adapted for hot beverages by having foamed insulation on their outer surface. In another preferred embodiment, a pressure-sensitive adhesive mount is provided which can be removed from a mounting surface without leaving substantial pressure-sensitive adhesive residue on the surface.

Description

TECHNICAL FIELD

[0002] The present invention relates generally to packaging and dispensers for disposable cups and lids. In a preferred embodiment, the invention provides protective packaging for an ensemble of disposable cups and their associated lids, wherein the cups are paperboard cups provided with foamed insulation on their outer surface. In another embodiment, the protective sleeve is provided with a pressure sensitive adhesive mount which can be removed from a wall or door without leaving substantial pressure- sensitive adhesive residue.

BACKGROUND ART

[0003] Packaging systems and dispensers for disposable cups are known in the art. There is disclosed in U.S. Pat. No. 4,520,946 to Gould et al. a packaging system for disposable cups. A package in accordance with the '946 patent includes two or more individual cup dispensing units, each unit having a carton holding a stack of nested tapered cups. Each carton of dispensing unit is a paperboard carton having a generally circular opening in a top wall through which the tapered cups protrude and which opening is surrounded by a series of short radial cuts defining yieldable tabs on the wall which permit the top most protruding cup to be pulled through the opening. The bottom wall of the carton is formed with a generally circular opening either fully cut or defined by a series of radial cuts which permits the protruding tapered cup of a similar, adjacent carton to extend through the bottom opening into the carton to form a compact dispensable unit package which may be shrink wrapped for shipping and display.

[0004] U.S. Pat. No. 3,625,395 to Salazar discloses a dispenser carton for holding nested articles such as paper cups. The carton includes a sleeve formed of foldably interconnected panels, each of which are foldable to define a closure element. Each flap has a weakened line to define a removable closure portion and a fixed closure portion. Upon removal of the removable part an opening is created, the edge of which engages the sides of the lowermost of the stack of nested articles.

[0005] The following patents relate to cup dispensers and are of more general interest. U.S. Pat. No. 6,325,243 to Bennett discloses a device for dispensing cups which includes a flexible sleeve for receiving a stack of nested cups and a dispensing member coupled thereto. U.S. Pat. No. 5,301,802 to Nemeroff discloses a set of drinking cups provided with individual identifying indicia. The cups may be distributed in paper cartons (FIGS. 1 and 2) or in a polymer bag (FIG. 3). Likewise, U.S. Pat. No. 3,581,934 to Sciascia discloses an adjustable cup dispenser having a minimum of parts, namely an elongated housing for receiving a stack of cups and a control sleeve which effects a positive size adjustment for supporting the stack of cups which may be of varying sizes.

[0006] Despite the many options available for the distribution and dispensing of disposable cups, existing systems do not adequately protect the product and provide convenience of having a cup provided with its associated lid, especially for hot container beverage applications. Likewise, there exists a need for a self-mounting disposable cup dispenser which can be conveniently located where the cups are to be used.

SUMMARY OF INVENTION

[0007] It has been found that conventional packaging simply does not adequately protect the lids, which are quite fragile, when provided with their associated cups. Indeed, recent purchases of retail PerfecTouch® Dixie product that contains both lids and cups have been found to contain cracked lids that are unusable. Cracking is due to the weight of the case and so forth resting on the relatively fragile lids. There is thus provided in accordance with the present invention a two section cardboard tube such as are used in containers or on a tissue core which would house the majority of the product. The lower portion of one cup would protrude from the lower section of the tube so that consumer could touch the highly tactile insulation layer of the PerfecTouch® disposable cup product. A cardboard disk may be used to separate the two sections of the tube. Above the cups and the disk in the upper tube would be the lids which rest just below the upper edge of the cupboard tube. A clear plastic sleeve covers the entire tube, except in some embodiments a portion of the cup that is sticking out of the tube and optionally the top of the tube. The plastic sleeve has, for example, a tear strip in a circle at the top of the tube that may be removed and provide a dispensing mechanism for the lids. The tube itself may also have a tear strip at the top to make dispensing easier. A plastic sleeve or envelope may also have a tear strip at the lower edge to allow dispensing of the cups out of the bottom of the tube. By tilting the tube in either direction, cups or lids are easily dispensed. The clear, poly envelope allows consumers to view the lids at the top while the cardboard tube would protect the relatively fragile lids from cracking under the weight of other product or cases stacked on top by supporting the weight on the relatively sturdy cups and the cardboard disk.

[0008] There thus is provided in accordance with the present invention a packaging system for distributing and dispensing disposable cups and lids comprising:

[0009] a) a protective sleeve defining an elongated cavity having at one end thereof a first dispensing aperture and at the other end thereof a second dispensing aperture;

[0010] b) a nested stack of disposable lids disposed in the elongated cavity of the protective sleeve adjacent the first dispensing aperture of the protective sleeve;

[0011] c) a nested stack of disposable cups disposed in the elongated cavity of the protective sleeve adjacent the second dispensing aperture of the protective sleeve disposed such that a lower portion of the outermost cup of the stack protrudes through the second aperture;

[0012] d) a polymer film envelope secured about the protective sleeve adapted to retain the stack of lids and the stack of cups within the protective sleeve for distribution; and

[0013] e) optionally the polymer film envelope further comprising a first tearable portion adjacent the first dispensing aperture and a second tearable portion adjacent the second dispensing aperture, the tearable portions being configured to allow for dispensing of the lids and cups from the protective sleeve upon rupture of the tearable portions.

[0014] Typically, the protective sleeve is a cylindrical cardboard sleeve and the film envelope is a shrink wrap envelope. The sleeve may be provided with a tearable portion which can be removed to facilitate dispensing. In a preferred embodiment, the stack of nested lids comprises a plurality of domed lids. The lids may be thermoformed or produced by any other suitable means. In some cases the lower portion of the outermost cup protrudes through the polymer film envelope so that it may be grasped by a consumer.

[0015] The cups may be paperboard cups if so desired and are preferably provided with foamed polymer insulation on their outer surfaces. The foamed insulation on the outer surface may be formed in-situ by action of moisture present in the paperboard with a polymer film applied to the paperboard if so desired. Alternatively, the foamed polymer insulation is syntactic polymer foam. The foamed insulation may be applied in a pattern whereby the outer surface of the cup has portions with foamed polymer insulation and portions without foamed polymer insulation.

[0016] In a preferred embodiment, the polymer envelope is a shrink wrap envelope and the protective sleeve has disposed therein a separator member between the nested cups and the nested lids.

[0017] In another embodiment a packaging system for distributing and dispensing disposable cups and lids includes a protective sleeve defining an elongated cavity having at one end thereof a first dispensing aperture and at the other end thereof a second dispensing aperture. A nested stack of disposable lids is disposed in the elongated cavity of the protective sleeve adjacent the first dispensing aperture of the protective sleeve and a nested stack of disposable cups is disposed in the elongated cavity of the protective sleeve adjacent the second dispensing aperture of the protective sleeve disposed such that the lower portion of the outermost cup of the stack protrudes through the second aperture. The protective sleeve is provided with tab means for releasably retaining the cups within the sleeve as well as a polymer envelope covering the lower portion of the outermost cup of the stack which protrudes through the second dispersing aperture. The protective sleeve further includes a mounting portion including a pressure sensitive adhesive capable of securing the sleeve loaded with the cups and lids to a vertical support and which mounting portion is removable from the vertical support without leaving a substantial amount of pressure sensitive adhesive residue thereon.

[0018] In still yet another embodiment there is provided a packaging system for distributing disposable cups including:

[0019] a) a protective sleeve defining an elongated cavity as well as a sleeve opening;

[0020] b) a nested stack of disposable cups disposed in the elongated cavity;

[0021] c) tab means about the sleeve opening configured to releasably retain the stack of nested cups within the sleeve; and

[0022] d) means for mounting the sleeve on a vertical support, including a pressure-sensitive adhesive capable of securing the sleeve loaded with cups to the vertical support and which mounting portion is removable from the vertical support without leaving a substantial amount of pressure-sensitive adhesive residue thereon.

[0023] Preferably the means for mounting the sleeve includes a polymeric adhesive tape having a length-wise elongation at break of from about 50% to about 1200%. That tape may be a foamed polymeric tape having a thickness of at least about 30 mils or so. Typically, the tape has a Young's modulus of less than about 2400 psi.

[0024] The tape includes a polymeric backing material selected from polyethylene, including high density polyethylene, low density polyethylene, linear low density polyethylene, and linear ultra-low density polyethylene; polypropylene and polybutylenes; polyvinyl chlorides, both plasticized and unplasticized; and polyvinyl acetates; ethylene methacrylate copolymers; ethylene/vinyl acetate copolymers; acrylonitrile-butadiene-styrene copolymers, and ethylene/propylene copolymers; acrylic polymers and copolymers; polyurethanes; and combinations of the foregoing.

[0025] So also the pressure-sensitive adhesive on the tape backing is preferably selected from natural rubber; olefins; silicones; polybutadienes; styrene-isoprene-styrene; styrene-ethylene-butylene-styrene; styrene-butadiene-styrene block copolymers; as well as copolymers of isooctylacrylate and acrylic acid.

[0026] The tab means of the disposable dispensers includes a plurality of tabs in some embodiments projecting inwardly from the sleeve wall to define a cup dispensing aperture. In some cases, the tabs have different lengths. The tabs may be integrally formed with the protective sleeve or disposed on an annular support affixed to the protective sleeve as is described hereinafter. The protective sleeve may be a polymeric blow molded protective sleeve or in some cases a paperboard (chip board) protective sleeve. Further details will become apparent from the following description, drawings and claims.

BRIEF DESCRIPTION OF DRAWINGS

[0027] The invention is described in detail below with reference to the various Figures wherein like numbers designate similar parts and wherein:

[0028] FIG. 1 is a view in perspective of a first embodiment of the packaging system of the present invention;

[0029] FIG. 2 is a view in elevation and partial section of the packaging system of FIG. 1;

[0030] FIG. 3 is a view in perspective of a second embodiment of the packaging system of the present invention;

[0031] FIG. 4 is a view in elevation and section of the embodiment of FIG. 3;

[0032] FIGS. 5 and 6 are views in elevation and section of disposable cups which may be used in connection with the packaging system of the present invention;

[0033] FIG. 7 is a schematic view showing an alternate embodiment of the present invention wherein a strip of paperboard is used to form a protective sleeve for the lids only in a package of cups and associated lids;

[0034] FIG. 8 is a view in perspective of another packaging system and dispenser in accordance with the present invention;

[0035] FIG. 9 is a bottom view of the dispenser of FIG. 8;

[0036] FIG. 10 is a schematic detail showing the mounting of the dispenser of FIGS. 8 and 9 to a vertical wall;

[0037] FIG. 11 is a plan view of a dispensing ring which may be attached to a protective sleeve of the packaging system of the present invention; and

[0038] FIG. 12 is a view in perspective of yet another packaging system of the present invention.

DETAILED DESCRIPTION

[0039] The invention is described in detail below with reference to the various figures for purposes of exemplification and illustration only. Modifications within the spirit and scope of the present invention will be readily apparent to those of skill in the art. The present invention is defined in the appended claims.

[0040] Referring to FIGS. 1 and 2 there is shown a first embodiment of the inventive packaging system 10 which is used for distributing and dispensing cups and lids. The packaging system is particularly suitable for beverage cups adapted to receive hot beverages such as coffee, tea and the like, wherein it is often desirable to have an associated lid, but is suitable for any cup with a fragile lid.

[0041] In FIGS. 1 and 2 there is shown a packaging system 10 including a protective sleeve 12 having an elongated central cavity 14 and defining a first dispensing aperture 16 as well as a second dispensing aperture 18.

[0042] The sleeve may be formed of cardboard or the like, or any other suitable material which will protect the lids from being crushed. A preferred construction of the sleeve may be from a wound and adhered sheet of cardboard of the general class used for tubular packaging and/or used as cores for tissue or towel. Such construction is well known in the art.

[0043] A nested stack of disposable lids 20 is disposed in the central cavity adjacent first dispensing aperture 16. Likewise, a nested stack of disposable cups 22 is disposed adjacent second dispensing aperture 18 of sleeve 12. A polymer envelope 24 is secured about the sleeve and the cups and lids in order to retain them within the protective sleeve 12, the lower portion of the outermost cup indicated at 30 protrudes through second dispensing aperture 18 so that it may be readily grasped by user. Cups with particularly pleasing tactile properties are preferred such as the PerfecTouch® cups sold by Georgia-Pacific Corporation, Dixie Division. The polymer envelope has a first tearable portion 26 defined by a perforated perimeter as well as a second tearable portion 28 defined by another perforated perimeter about the terminal portions of protective sleeve 12. The tearable portions are removed when it is desired to remove a cup and/or lid from the packaging system. So also, the dashed lines at 26 may designate a tear strip defined in sleeve 12 by perforations, which tear strip can be removed to facilitate dispensing.

[0044] If so desired, the packaging system may be tilted one way or the other to facilitate dispensing of the articles. In preferred embodiments the polymer film envelope is a shrink wrap envelope and the nested stack of lids are domed lids which may be produced, for example, by thermoforming.

[0045] In some cases lower portion 30 of the outermost cup protrudes through the polymer film so that the lower portion thereof is available to a consumer. The cups are preferably paperboard cups provided with foamed polymer insulation on their outer surfaces as will be described hereinafter.

[0046] In FIGS. 3 and 4 there is shown another embodiment of the inventive packaging system. Packaging system 110 includes a sleeve 112 defining a cavity 114. Sleeve 114 also defines a first dispensing aperture 116 and a second dispensing aperture 118. A nested stack of disposable lids 120 is disposed adjacent first dispensing aperture 116 and a nested stack of disposable cups 122 is disposed adjacent second dispensing aperture 118. Between the nested stacks of lids and cups there is provided a cardboard disk 121 which serves to separate the respective stacks. A polymer film envelope 124 is formed of shrink wrap and has a first, upper tearable portion 126 having a generally circular perimeter defined by perforations and a lower second tearable portion 128 also having a perimeter defined by perforations. The lower portion 130 of the outermost cup protrudes downwardly through the second dispensing aperture of sleeve 112 and through polymer envelope 124 as described in connection with similar parts of the embodiment of FIGS. 1 and 2.

[0047] There is thus provided in accordance with the present invention a packaging system which provides for the convenient dispensing of cups and their associated lids without the need for multiple dispensing systems. Moreover the lids are protected by the protective sleeves from breakage during shipping and handling which has been found to be particularly troublesome with respect to small quantities of lids. Separator disk 121 prevents unwanted movement of product when the dispenser is tipped. If so desired disk 121 can be secured at 132 to sleeve 112.

[0048] While the inventive packaging system can be used in connection with a variety of cups and their associated lids, the dispenser and packaging system of the present invention is particularly preferred for paperboard cups adapted for hot beverages having on their outer surface foamed polymer insulation. Suitable foamed polymer insulation material is described in co-pending patent application U.S. Ser. Nos. 09/018,563 and 10/36,347, both of Swoboda et al. and both entitled “Coated Paperboards and Paperboard Containers Having Improved Tactile and Bulk Insulation Properties, Attorney Docket Nos. 1935-1 and 1935-2, filed Feb. 4, 1998 and Sep. 6, 2002, respectively, the disclosures of which are incorporated herein by reference. Suitable foamed insulation applied to the paperboard cups of the inventive packaging system also include those foamed insulation materials described in U.S. Pat. Nos. 5,766,709; 5,759,624; 5,725,916; 5,415,340; 5,490,631; 5,278,194; 4,902,722; 4,435,344; 4,425,449; 4,237,171; and 3,864,181. The disclosures of the foregoing applications and listed United States patents is hereby incorporated by reference. Particularly suitable paperboard cups with foam insulation layers are disclosed in U.S. Pat. Nos. 5,576,709 and 4,435,344. In these patents a foam insulation layer is produced by foaming a polymer material in-situ on the outer surface of a paper cup. In the '709 patent the thickness of the foam layer is controlled by printing, or application of mineral oil to the surface of the polymer film. In U.S. Pat. No. 4,435,344 of Iioka et al. the foam is produced in-situ by action of the moisture present in the paperboard with a polymer film applied to the outer surface of the paperboard. So also, it will be appreciated from the foregoing patents and applications that syntactic foams are readily applied to the outer surface of paperboard used to make the cups utilized in connection with the invention as will be appreciated from U.S. Pat. No. 4,902,722 to Melber. Such foams can be applied over the entire surface of the side wall of the cups or may be applied in a printed pattern as will be appreciated by reference to FIGS. 5 and 6 hereof. The terminology “syntactic foam” refers generally to a quasi-foam formed by insulating particles and a polymeric binder. The particles may be hollow microspheres, for example, or simply a particulate material with relatively low thermal conductivity.

[0049] Referring to FIG. 5 there is shown a cup 210 provided with a sidewall 212 and a bottom wall 214. About its upper periphery the cup 210 has a brim 216. Sidewall 212 is formed of a paper or a paperboard layer 218 having coated on its inner surface an impermeable film 220. The film is preferably formed of a high density polymer material and is impervious to moisture. Additionally bottom wall 214 includes a paper or paperboard layer 222 having formed thereon a moisture impervious film 224. The outer surface of paperboard layer 218 is coated with a low density synthetic resin film 226 on its surface. This low density film of plastic synthetic resin film 226 when heated expands to form a heat insulating foam as will be appreciated from the aforesaid U.S. Pat. No. 5,766,709. It has further been found that by applying a mineral oil film 242 on the film of plastic resin film 226 the expansion of the thermoplastic and synthetic film when heat treated is enhanced.

[0050] Referring to FIG. 6, there is shown a pattern 310 of printed syntactic foam material arranged in continuous longitudinal lines 312 as well as a plurality of segments 314. It is thus defined on a paperboard surface portions which are coated such as at 314 and 312 and unfoamed regions indicated at 316. Such insulated surfaces for hot beverage cups are contemplated within the spirit and scope of the present invention which is defined in the appended claims.

[0051] Referring to FIG. 7, there is shown schematically another embodiment of the present invention wherein there is provided a protective sleeve 320 formed from a strip of paperboard 322 which is optionally joined to itself by adhesive indicated at 324 and optionally provided with die-cut tabs 328, 330 adapted to hold a plurality 332 of nestable thermoformed lids. Each lid, such as lid 334 has a domed shape including a lid top 336 and sidewall 338. The lids have an overall diameter, D, of about 3¾ inches in some embodiments and an overall height, H, of about ¾ of an inch. Preferably, the lids are thermoformed lids and have a height of at least about 10% of the lid diameter, with at least about 15% or 20% being even more preferred, even though the sidewall may make the lids more fragile than flat lids.

[0052] The sleeve has a height, H′, which is larger than the height of a single lid by ¼ to 1 inch so that it can accommodate a plurality of lids, which are placed within the sleeve. The cups are generally less fragile than the lids, so that sleeve 320 is conveniently substituted for sleeve 12 of FIG. 1 or sleeve 112 of FIG. 3; especially when cup damage during distribution is not a problem. Thus, the lids are within sleeve 320, while the lids are not.

[0053] Referring to FIGS. 8 through 10 there is shown a dispenser 410 including a protective sleeve 412 provided with a cap 414 as well as a mounting portion 416. The protective sleeve is configured to accept a stack 418 of disposable cups as shown in the diagram. Preferably, the cups protrude through a dispensing aperture and are covered by a polymeric envelope such as envelope 420 which may be a shrink wrap envelope if so desired. The mounting portion has a mounting wall 422 which is perhaps better seen in FIG. 10 which is an enlarged detail of the dispenser mounted on a vertical support such as wall or door 438. Affixed to mounting wall 422 is a first layer of adhesive 424 as well as a foam backing 426 which has the characteristics described below. On the backing is a pressure-sensitive adhesive layer 428 as well as a release layer 430 which covers the pressure-sensitive adhesive during shipping of the container, that is, until it is ready to use.

[0054] Layer 424 secures backing 426 to wall 422 of the dispenser. At the bottom of dispenser 410 is a dispensing aperture 432 which has a plurality of tabs, such as tabs 434 and 436 that project inwardly from the walls of sleeve 412 to define the dispensing aperture as shown.

[0055] The protective sleeve is made by extrusion blow-molding as is well known and seen, for example, in U.S. Pat. Nos. 6,312,248 to Lopez et al. and 4,549,977 to Joshi et al. The dispensing tab such as tabs 434 and 436 may be integrally formed with protective sleeve 412 or may be carried on a thermoformed or injection molded disk.

[0056] A blow-molded protective sleeve may be made of any suitable material such as polyethylene terephthalate or other thermoplastic. Suitable materials may include: polystyrene; polycarbonate; styrene; acrylonitrile; polyvinyl chloride; polyolefin polymers including polypropylene, cyclic polyolefin copolymers, polyethylene, polybutylene polymers and the like; polyamide polymers; polysulfones; polyacetals; polyarylates; polyacrylonitrile-stryrene copolymers; polyolefin ionomers; styrene-acrylonitrile copolymers; environmentally degradable polymers and mixtures thereof.

[0057] Dispenser 410 is mounted on vertical support 438 by way of the pressure-sensitive adhesive layer 428. An important feature of the present invention is that layer 428 is capable of supporting a fully loaded dispenser, and yet does not leave a substantial amount of adhesive residue when the dispenser is removed from a wall such as wall 438. To this end, backing 426 is made from a plastic material which has an elongation at break of at least 50% and up to about 1200%. The tape also includes a tab or portion 440 which does not have adhesive thereon. This tab is pulled in order to fracture the adhesive bond between layer 428 and wall 438 as will be appreciated from the discussion which follows. Further details may be found in U.S. Pat. No. 6,231,962 to Bries et al.; U.S. Pat. No. 6,001,471 also to Bries et al. as well as U.S. Pat. No. 5,516,581 to Kreckel et al.

[0058] Elongation at break and Young's modulus (elastic modulus) in respect of a tape or a backing or a polymeric layer in the backing of a tape is measured for purposes of the instant specification and claims following ASTM D882, incorporated herein by reference, using an Instron™ Model 1122 Tensile Tester (available from Instron Corporation, Canton, Mass. 02021) or other suitable device. For elongation at break measurements, tape samples are cut to ½″×4″ strips (1.27 cm×10.2 cm) and the Instron™ is set for a 2-inch (5.08 cm) gauge length, 20 inch/minute (50.8 cm/minute) cross-head speed and 20 lb. (9.1 kg) full scale load. For Young's modulus measurements, a backing or a polymeric layer for use in a backing is cut to ½″×10″ strips (1.27 cm×25.4 cm) and the Instron™ is set for an 8-inch (20.3 cm) gauge length, 1-inch/minute (2.54 cm/minute) cross-head speed and 20 lb. (9.1 kg) full scale load.

[0059] Representative examples of materials suitable for either a polymeric foam or solid polymeric film layer in the backing of the tape include polyolefins, such as polyethylene, including high density polyethylene, low density polyethylene, linear low density polyethylene, and linear ultra low density polyethylene, polypropylene, and polybutylenes; vinyl copolymers, such as polyvinyl chlorides, both plasticized and unplasticized, and polyvinyl acetates; olefinic copolymers, such as ethylene/methacrylate copolymers, ethylene/vinyl acetate copolymers, acrylonitrile-butadiene-styrene copolymers, and ethylene/propylene copolymers; acrylic polymers and copolymers; polyurethanes; and combinations of the foregoing. Mixtures or blends of any plastic or plastic and elastomeric materials such as polypropylene/polyethylene, polyurethane/polyolefin, polyurethane/polycarbonate, polyurethane/polyester, can also be used.

[0060] Polymeric foam layers for use in the backing of the tapes generally will have a density of about 2 to about 30 pounds per cubic foot, particularly in tape constructions where the foam is to be stretched to effect debonding.

[0061] Preferred for polymeric foam layers in the backing of the tapes are polyolefin foams. Polymeric foam layers are most preferably polyolefin foams available under the trade designations Volextra.TM. and Volara.TM. from Voltek, Division of Sekisui America Corporation, Lawrence, Mass. 01843.

[0062] Solid polymeric film backings are preferably selected from polyethylene and polypropylene films, with the most preferred materials being linear low density and ultra low density polyethylene films. A preferred polyethylene film is that available under the trade designation Maxilene.TM.200 from Consolidated Thermoplastics Company, Schaumburg, Ill. 60173.

[0063] The backing may vary in overall thickness so long as it possesses sufficient integrity to be processable and handleable and provides the desired performance in respect to stretching properties for debonding the backing or tape from a surface. The specific overall thickness selected for a backing will depend upon the physical properties of the polymeric foam layer or layers and any solid polymeric film layer forming the backing. Where only one polymeric film or foam layer of a multi-layer backing is intended to be stretched to effect debonding, that layer should exhibit sufficient physical properties and be of a sufficient thickness to achieve that objective.

[0064] A polymeric film layer preferably will be about 0.4 to 10 mils in thickness, and will most preferably be about 0.4 to 6 mils in thickness.

[0065] The adhesive of the adhesive layer can comprise any pressure-sensitive adhesive, with the particular adhesion properties being dependent on the use of the tape, with the preferred adhesion properties generally ranging from about 4 N/dm to about 200 N/dm, preferably from about 25 N/dm to bout 100 N/dm, at a peel angle of 180.degree., measured according to PSTC-1 and PSTC-3 and ASTM D 903-83 at a peel rate of 12.7 cm/min. Adhesives having higher peel adhesion levels usually require backings having higher tensile strength.

[0066] Pressure-sensitive adhesives suitable for application to one side of the backing and/or the other in the tapes of the invention include tackified rubber adhesives, such as natural rubber; olefins; silicones; synthetic rubber adhesives such as polyisoprene, polybutadiene, and styrene-isoprene-styrene, styrene-ethylene-butylene-styrene and styrene-butadiene-styrene block copolymers, and other synthetic elastomers; and tackified or untackified acrylic adhesives such as copolymers of isooctylacrylate and acrylic acid, which can be polymerized by radiation, solution, suspension, or emulsion techniques. Preferred are synthetic rubber adhesives or acrylics.

[0067] Especially preferred adhesives inherently possess more cohesive strength than adhesive strength to the mounting surface.

[0068] The thickness of each adhesive layer can range from about 0.6 mils to about 40 mils (about 0.015 to about 1.0 mm), preferably from about 1 mils to about 16 mils (about 0.025 to about 0.41 mm). In this preferred range of thicknesses, the thicker layers tend to cause the tapes to be more easily removable than do thinner layers. This is in contrast to conventional methods of removal, such as removal by peeling at peel angles of 90.degree. or higher. In general, thicker layers of adhesive tend to cause the tapes to exhibit higher peel strength at a peel angle of 180.degree. than do thinner layers. When the tapes of the present invention are released by stretching at a low angle, i.e., under 35.degree., the adhesive tends to be constrained by the backing and substrate for a single-coated adhesive tape and by the backing and two substrates for a double-coated adhesive tape, and is forced to undergo significant elongation. Under these conditions, the adhesive layer (or each adhesive layer) contracts, which reduces its cross-sectional area. Since the cross-sectional area, i.e., thickness times width, of a thinner layer of adhesive is already less than that of a thicker layer of adhesive, stress, i.e., force per unit area, is greater in the thinner layer of adhesive than in the thicker layer of adhesive. This leads, in effect, to a stiffening of the adhesive. Because stiffer layers offer more resistance to deformation, the force required for debonding is greater. The exposed adhesive layer or layers may be laminated to a conventional release liner prior to use.

[0069] Adhesives for adhering one polymeric foam layer to either another polymeric foam layer or a solid polymeric film layer include those pressure-sensitive adhesive compositions described above. Preferably the adhesive layer for adjoining one polymeric layer of the backing to another will be about 1 to 10 mils (about 0.025 to 0.25 mm) in thickness. Other methods of adhering the polymeric layers of the backing to one another include such conventional methods as coextrusion or heat welding.

[0070] The tape can be produced by any conventional method for preparing pressure-sensitive adhesive tapes. For example, the adhesive can either be directly coated onto the backing, or it can be formed as a separate layer and then later laminated to the backing.

[0071] Removing the tape from the surface of a substrate can be carried out by simply stretching the tape in a direction up to an angle of about 35 degrees from the surface. Preferably, the tape can be removed from the surface of a substrate by stretching the tape at an angle of no greater than about 10 degrees. Removal at the appropriate angle will result in leaving no substantial or appreciable adhesive residue and in preventing the surface of the substrate from being damaged.

[0072] Debonding of a highly elongated adhesive tape at low angles is characterized by a “sharp” type of crack propagation. Like fracture of glassy materials, a sharp crack leads to high stress concentration at the crack front, where there is a low volume of adhesive material (in which stress may be dissipated). High stress concentration at the crack front leads to what is called brittle cleavage failure of the adhesive. Such failure typically occurs with low force (because of the low amount of energy dissipated in the adhesive material) and is cleanly interfacial.

[0073] In contrast, for higher peeling angles, i.e., angles generally greater than 35 degrees, the backing tends not to stretch and the adhesive tends to undergo filamentation and rupture cohesively. Like fracture of glassy materials, propagation of a “blunt” crack is preceded by crazing. In this model, the observed filamentation of the adhesive at higher angles serves principally as an energy dissipation mechanism, analogous to craze fibrils found in glassy materials. The greater the energy dissipation, the greater the resistance to peeling and the higher the force required to peel the tape. A larger volume of material is involved in energy dissipation, and, as stated previously, stress is less concentrated. The adhesive filaments rupture cohesively to leave residue of adhesive on the surface and/or cause damage to the surface.

[0074] There is shown in FIG. 11 a dispensing ring 442 having a diameter 443 as well as tabs 444, 446, 448 and so on defining a dispensing aperture 445 corresponding to aperture 432 of FIG. 8. Note that the dispensing tabs such as tabs 444 and 446 are of different lengths so that dispensing aperture 445 has different dimensions 452 and 450. In other words, it is plain from the diagram that because tab 446 and its opposing tab are larger than tabs 448 and its opposing tab distance 450 is shorter than distance 452. Any number of tabs may be utilized in making the packaging system and dispenser of the invention; however, anywhere from about 4 to about 8 tabs is believed preferred. Suitable geometries for the dispensing rings and/or tabs are described in co-pending U.S. patent application Ser. No. 10/405,393, filed Apr. 2, 2003 (Attorney Docket No. 2383; GP-01-29), now U.S. Pat. No. ______.

[0075] In FIG. 12 there is shown yet another packaging system configured in accordance with the present invention.

[0076] Packaging system 510 includes a protective cardboard sleeve 512 surrounding a stack of cups 514 and includes a mounting portion 516 corresponding to mounting portion 416 described above. In the embodiment shown in FIG. 12, protective sleeve 512 is made of chipboard and is of rectangular shape so that the protective sleeve may be folded flat for shipment to a packaging center. The sleeve is provided with a dispensing ring such as ring 442 of FIG. 11 as well as a polymer envelope 518 to hold the stack 514 in position during shipping. Polymer envelope 518 may be a shrink wrap envelope if so desired. Mounting portion 516 includes the features of mounting portion 416 of the embodiment of FIGS. 8 through 10.

[0077] While the invention has been described in connection with several examples, modifications to those examples within the spirit and scope of the invention will be readily apparent to those of skill in the art. In view of the foregoing discussion, relevant knowledge in the art and references including co-pending applications discussed above in connection with the Background and Detailed Description, the disclosures of which are all incorporated herein by reference, further description is deemed unnecessary.

Claims

1. A packaging system for distributing and dispensing disposable cups and lids comprising: a) a protective sleeve defining an elongated cavity having at one end thereof a first dispensing aperture and at the other end thereof a second dispensing aperture; b) a nested stack of disposable lids disposed in the elongated cavity of the protective sleeve adjacent the first dispensing aperture of the protective sleeve; and c) a nested stack of disposable cups disposed in the elongated cavity of the protective sleeve adjacent the second dispensing aperture of the protective sleeve disposed such that the lower portion of the outermost cup of the stack protrudes through the second aperture.

2. The packaging system according to claim 1, further comprising a polymer film envelope secured about the protective sleeve adapted to retain the stack of lids and the stack of cups within the protective sleeve for distribution.

3. The packaging system according to claim 1, wherein the polymer film envelope further comprises a first tearable portion adjacent the first dispensing aperture and a second tearable portion adjacent the second dispensing aperture, the tearable portions being configured to allow for dispensing of the lids and cups from opposed portions of the protective sleeve upon rupture of the tearable portions adjacent the opposed apertures.

4. The packaging system according to claim 1, wherein the protective sleeve is a cylindrical cardboard sleeve.

5. The packaging system according to claim 1, wherein the protective sleeve is provided with a tear strip to facilitate dispensing.

6. The packaging system according to claim 1, wherein the polymer film envelope is a shrink wrap envelope.

7. The packaging system according to claim 1, wherein the nested stack of lids comprises domed lids.

8. The packaging system according to claim 7, wherein the domed lids are thermoformed lids.

9. The packaging system according to claim 1, wherein the lower portion of the outermost cup protrudes through the polymer film envelope so as to be exposed to a consumer.

10. The packaging system according to claim 1, wherein the nested stack of disposable stacks comprises paperboard cups.

11. The packaging system according to claim 10, wherein the paperboard cups are provided with foamed polymer insulation on their outer surfaces.

12. The packaging system according to claim 11, wherein the foamed insulation on the outer surface of the cups is formed in-situ by action of moisture present in the paperboard with polymer film applied to the paperboard.

13. The packaging system according to claim 11, wherein the foamed polymer insulation is syntactic foam.

14. The packaging system according to claim 11, wherein the foamed polymer insulation is applied in a pattern whereby the outer surface of the cup has portions with foamed polymer insulation and portions without foamed polymer insulation.

15. A packaging system for distributing and dispensing disposable cups and lids comprising: a) a protective sleeve defining an elongated cavity having at one end thereof a first dispensing aperture and at the other end thereof a second dispensing aperture; b) a nested stack of disposable lids disposed in the elongated cavity of the protective sleeve adjacent the first dispensing aperture of the protective sleeve; c) a nested stack of disposable cups disposed in the elongated cavity of the protective sleeve adjacent the second dispensing aperture of the protective sleeve disposed such that a lower portion of the outermost cup of the stack protrudes through the second aperture; and d) a separator member disposed in the elongated cavity of the protective sleeve between the nested stack of disposable lids and the nested stack of disposable cups.

16. The packaging system according to claim 15, further comprising a shrink wrap envelope secured about the protective sleeve adapted to retain the stack of lids and the stack of cups within the protective sleeve for distribution.

17. The packaging system according to claim 15, wherein the shrink wrap envelope further comprises a first tearable portion adjacent the first dispensing aperture and a second tearable portion adjacent the second dispensing aperture, the tearable portions being configured to allow for dispensing of the lids and the cups from opposed ends of the protective sleeve upon rupture of the tearable portions.

18. The packaging system according to claim 15, wherein the protective sleeve is a cylindrical cardboard sleeve.

19. The packaging system according to claim 15, wherein the protective sleeve is provided with a tear strip to facilitate dispensing.

20. The packaging system according to claim 15, wherein the stack of nested lids comprises domed lids.

21. The packaging system according to claim 20, wherein the domed lids are thermoformed lids.

22. The packaging system according to claim 15, wherein the lower portion of the outermost cup protrudes through the shrink wrap envelope.

23. The packaging system according to claim 15, wherein the nested stack of cups comprises paperboard cups.

24. The packaging system according to claim 23, wherein the paperboard cups comprise paperboard cups provided with foamed polymer insulation on their outer surfaces.

25. The packaging system according to claim 24, wherein the foamed insulation on the outer surface of the cups is formed in-situ by action of moisture present in the paperboard cups with polymer film applied to the paperboard.

26. The packaging system according to claim 24, wherein the foamed polymer insulation is syntactic foam.

27. The packaging system according to claim 24, wherein the foamed polymer insulation is applied in a pattern whereby the outer surface of the cup has portions with foamed polymer insulation and portions without foamed polymer insulation.

28. In a packaging system including a plurality of cups and a plurality of lids therefore, the improvement comprising a protective sleeve disposed about the lids effective to reduce breakage thereof.

29. The improvement according to claim 28, wherein the protective sleeve is a paperboard sleeve with die cut tabs.

30. The improvement according to claim 28, wherein the plurality of cups, the plurality of lids and the protective sleeve are disposed in a polymer envelope.

31. The improvement according to claim 28, wherein the polymer envelope is a shrink wrap envelope.

32. The improvement according to claim 28, wherein the plurality of lids are thermoformed domed lids having a sidewall with an overall height which is at least about 10% of the lid diameter.

33. The improvement according to claim 28, wherein the plurality of lids are thermoformed domed lids having a sidewall with an overall height of at least about 15% of the lid diameter.

34. The improvement according to claim 28, wherein the plurality of lids are thermoformed domed lids having a sidewall with an overall height of at least about 20% of the lid diameter.

35. A packaging system for distributing and dispensing disposable cups and lids comprising: a) a protective sleeve defining an elongated cavity having at one end thereof a first dispensing aperture and at the other end thereof a second dispensing aperture; b) a nested stack of disposable lids disposed in the elongated cavity of the protective sleeve adjacent the first dispensing aperture of the protective sleeve; c) a nested stack of disposable cups disposed in the elongated cavity of the protective sleeve adjacent the second dispensing aperture of the protective sleeve disposed such that the lower portion of the outermost cup of the stack protrudes through the second aperture; d) wherein the protective sleeve is provided with tab means for releasably retaining the cups within the sleeve; e) a polymer envelope covering the lower portion of the outermost cup of the stack which protrudes through the second dispensing aperture; and f) the protective sleeve being further provided with a mounting portion including a pressure-sensitive adhesive capable of securing the sleeve loaded with cups and lids to a vertical support and which mounting portion is removable from the vertical support without leaving a substantial amount of pressure-sensitive adhesive residue thereon.

36. A packaging system for distributing and dispensing disposable cups comprising: a) a protective sleeve defining an elongated cavity as well as a sleeve opening; b) a nested stack of disposable cups disposed in the elongated cavity; c) tab means about the sleeve opening configured to releasably retain the stack of nested cups within the sleeve; and d) means for mounting the sleeve on a vertical support, including a pressure-sensitive adhesive capable of securing the sleeve loaded with cups to the vertical support and which mounting portion is removable from the vertical support without leaving a substantial amount of pressure-sensitive adhesive residue thereon.

37. The packaging system according to claim 36, wherein the means for mounting the sleeve includes a polymeric tape having a lengthwise elongation at break of from about 50% to about 1200%.

38. The packaging system according to claim 37, wherein the polymeric tape comprises a foam polymeric backing having a thickness of at least about 30 mils.

39. The packaging system according to claim 37, wherein the tape has a Young's modulus of less than about 2400 psi.

40. The packaging system according to claim 37, wherein the tape includes a polymeric backing material selected from polyethylene, including high density polyethylene, low density polyethylene, linear low density polyethylene, and linear ultra-low density polyethylene; polypropylene, and polybutylenes; polyvinyl chlorides, both plasticized and unplasticized; polyvinyl acetates; ethylene/methacrylate copolymers; ethylene/vinyl acetate copolymers; acrylonitrile-butadiene-styrene copolymers; and ethylene/propylene copolymers; acrylic polymers and copolymers; polyurethanes; and combinations of the foregoing.

41. The packaging system according to claim 37, wherein the tape has a pressure-sensitive adhesive applied thereto selected from natural rubbers; olefins; silicones; polybutadeines; styrene-isoprene-styrense; styrene-ethylene-butylene-styrenes; styrene-butadiene-styrene block copolymers; and copolymers of isooctylacrylate and acrylic acid.

42. The packaging system according to claim 36, wherein the tab means includes a plurality of tabs projecting inwardly from the sleeve wall to define a dispensing aperture.

43. The packaging system according to claim 42, wherein the plurality of tabs includes tabs of different lengths.

44. The packaging system according to claim 42, wherein the tabs are integrally formed with the protective sleeve.

45. The packaging system according to claim 42, wherein the tabs are disposed on an annular support affixed to the protective sleeve.

46. The packaging system according to claim 36, wherein the protective sleeve is a blow-molded protective sleeve.

47. The packaging system according to claim 36, wherein the protective sleeve is a paperboard protective sleeve.