Embodiments relate to vessels and methods of making the same, and more particularly to drinking vessels, and to vessels used for pouring liquid and/or non-liquid substances, composed from flexible materials.
It is known in the prior art to provide disposable liquid containers such as paper cups. These cups are generally coated with a substance that prevents the paper container from absorbing or leaking the liquid contained therein. Furthermore, in the restaurant arena, such as fast food restaurants, coffee shops, etc., a separate lid, for example a plastic lid, is provided as a complement to such cups in order to help prevent spillage of a hot or cold beverage, for example. The lids are often plastic lids and some have an opening for insertion of a straw while others form a narrow opening conducive to direct user consumption.
However, since these cups often come in a variety of sizes, a restaurant or coffee shop will generally be required to stock lids in multiple sizes to complement the variety of cup sizes. Accordingly, providing consumers with a variety of cup sizes in the form of devices known in the prior art requires the use of separate items (i.e., the cup and corresponding lid), generally made of different materials and further requires coordination and assembly of these items prior to serving a patron. Furthermore, more organizations are on a quest to provide more environmentally safe products such as 100 percent recyclable cups, which may be harder to facilitate with cups made of different materials than their corresponding lids.
In accordance with one embodiment, a vessel for holding and dispensing contents includes a base region that has a width across its top. The base has an inner side wall that defines an interior volume. A top region of the base has two opposing flaps: an inner flap and an opposing outer flap. In some embodiments, the two flaps are delineated from the base region by two respective paths.
The inner flap includes a dam flap, or dam tab, extending from a free edge (e.g., the edge of the inner flap that is opposite the place where the inner flap folds from the base region). The flaps are disposed so that, when folded along their respective paths, they define an elevated spout having a spout opening, and the dam flap forms a folded edge dam between the outer and inner flaps, the folded edge dam extending up the spout towards the spout opening. For example, in some embodiments, the inner flap, including the dam flap, is wider than the width of the vessel and has a scored outer edge defining the dam flap, so that when the inner flap is folded down, the dam flap contacts the side wall of the vessel and this action folds the dam flap upward along the score line, thus forming the folded edge dam.
In some embodiments, the dam flap has a length defined along the free edge of the inner flap, and a width extending away from the free edge, the length greater than the width. In some embodiments, the dam flap extends more than one half of the length of the free edge of the inner flap.
Further, when the inner and outer flaps are folded, the dam flap and the inner side wall cooperate to define a channel to direct substances towards the spout opening when the vessel is being used for drinking or pouring those substances.
A dam flap may have a single section, or may include two (or more) segments divided by (one or more) V-shaped gaps, such that when the inner flap is folded down, the segments of the dam flap are raised upward and fold between the inner flap and the folded outer flap, and fit together in a fashion closing the V-shaped gap between the segments.
Some embodiments may include straw holes. For example, the flaps and/or the base of the vessel may include one or more straw holes. To that end, the inner and outer flaps may contain straw holes, or serrations configured to allow a portion of the flap to be punched out to form one or more straw holes. In some embodiments, each of the inner flap and outer flap may have corresponding straw holes that, when the outer flap is folded down over the inner flap, the straw holes overlap to cooperate to form a single straw hole allowing a straw to pass through the flaps to extend between the interior volume and the exterior of the vessel.
In some embodiments, the spout may include one or more serrations configured to enlarge the spout opening when the serrations are torn, compressed, stretched, or otherwise distorted.
Various embodiments may include a variety of other features. For example, in some embodiments, the inner flap may include a drain aperture configured to allow material to flow into the volume of the vessel from a space in-between the inner and outer flaps.
The outer flap may, in some embodiments, include an adhesive tab configured to secure the outer flap to the base of the vessel, or adhesives on an inner surface of the outer flap and/or adhesives on an outer surface of the inner flap, to secure the outer flap to the top of the inner flap.
Some embodiments may include features to help seal the spout opening. For example, some embodiments include a spout cover tab extending from the spout and configured to fold over and cover the spout opening. Some embodiments further include an adhesive on the spout cover tab, the adhesive configured to releasably attach a free end of the spout cover tab to the vessel spout when the spout cover tab is folded over the spout opening. Alternately, some embodiments include a plug closure configured to removably fit within the spout opening. For example, a plug closure may include a stopper portion and a base portion, the stopper portion extending from the base portion and configured to fit within the spout opening, and the base portion configured to remain outside of the spout opening when the stopper portion is within the spout opening, for example so as to prevent the plug closure from completely falling through the spout opening.
Alternately, some embodiments include a cap closure molded over the spout to cover the spout opening.
In some embodiments, edges of a surface, such as the edge of a flap, for example, and/or fold paths (e.g., scores or creases) may be waterproofed, for example by the application to the edges and/or creases of a waterproofing substance.
Various embodiments may be formed or fabricated in a variety of ways from a variety of materials. For example, in some embodiments, the vessel is formed from an insulating material. In some embodiments, the vessel may be fabricated by injection modeling, by thermoforming, or by rolling, scoring and forming from a sheet.
The foregoing features of embodiments will be more readily understood by reference to the following detailed description, taken with reference to the accompanying drawings, in which:
Embodiments provide a vessel having features that assist in retaining the content of the vessel and making the vessel more user-friendly. Various embodiments include a dam flap that folds between an inner flap and an outer flap to form a foldable dam that impedes the escape of vessel content from the inner volume of the vessel and guides vessel content to a spout.
The inner flap and outer flap fold across a base of the vessel. The inner flap, which is folded first, is wider than the width of the base of the vessel at the level of the fold and has a fold line near its edge. Thus when this inner flap is first folded down, the free edge of this flap hits the sidewall of the vessel body and this contact bends the free edge of the inner flap upward along the score line forming a “folded edge” dam. This “folded edge” dam can either be one segment or have two or more segments divided by one or more V-shape cuts to allow each segment to fold down and fit together seamlessly. After the inner flap is folded down, the second outer flap is folded down on top of the inner flap. The outer flap holds the inner flap in place and forms a restrictive channel for substances to flow up the spout. The restrictive channel is formed by the outer and inner flaps together with the “folded edge” dam, which is present in between the outer and inner flaps. This vessel design allows substances to be poured safely through the spout opening, without significant spillage even when the user compresses the vessel. Further, the “folded edge” dam does not rely on any adhesives or sealants that can interfere with stacking and nesting of said vessels.
As used in this description and the accompanying claims, the following terms shall have the meanings indicated, unless the context otherwise requires:
To “affix” a sheet of material is to form a connection between that sheet and another surface. Such a connection may be created using an adhesive layer applied between overlapping portions, or spanning adjacent portions, of the sheet and the other surface being connected. The connection may alternatively, or in addition, be achieved by crimping, fusing, or welding of the sheet to the other surface, under conditions, for example, including the application of one or more of pressure and heat.
“Cooperating” apertures are apertures in different surfaces, or different locations of a single surface that align, for example when folded over one another, to form an aperture (which may be referred to as a “compound aperture”) through which an object like a drinking straw could pass.
A “frusto-conical” shape includes a shape similar to a frustum of a cone, including, for example, a pyramidal section having rounded edges, so as to approximate a frustum of a cone.
An “insulating material” is a material capable of being formed into a vessel as described herein, and which has a thermal conductivity of less than 0.2 watts per meter kelvin [(W/(mK)].
A “fold path” is a path along-which a flap, tab, or material may be folded, and may include for example scoring paths and creases.
The reference numbers in the attached figures are as follows:
Vessel 100 includes a top or cover formed from two overlapping flaps. In the current view, flap 140 is visible since it is the outer flap in this embodiment. The overlapping flaps form a portion of an elevated pouring or drinking portion that includes a spout 171 and an aperture 172. The spout 171 is configured so that when the spout 171 is inserted in the mouth of a user in use of the vessel for drinking, the lips of the user may come into contact with the material over a full 360-degree angular extent of the material disposed around the periphery of the aperture. The spout 171 allows the user to easily pour or drink from the cup 100, but helps prevent spillage of a beverage, for example, contained in the vessel 100. Unlike a traditional gable top milk carton, such as that provided in U.S. Pat. No. 2,826,349 which can be opened to form a spout for pouring, the vessel is designed so that a user may completely surround the aperture in the spout with her lips when consuming the contents of the vessel.
The flaps 120 and 140 are configured such that when both flaps are folded along their respective curved fold paths (121, 141), the outer flap 140 overlies the inner flap 120, and at least a portion of the outer edge 124 of the inner flap 120 may coincide with the scored path (designated 141) of the opposing outer flap 140, and the flaps 120 and 140 define an elevated pouring or drinking portion 197 having a spout 171 formed between an extension 102 of the base region 101 and at least one of the two flaps 120 and 140.
Flaps 120 and 140 each form a portion of both spout 171 and opposing peak 176. Spout 171 and opposing peak 176 are opposite one another in the upper region of the vessel. Accordingly, tilting vessel 100, for example, for consumption of a beverage contained therein through spout 171, moves the beverage away from the opposing peak 176.
The formation of spout 171 and opposing peak 176 are further schematically illustrated in
The inner flap 120 includes a dam tab 130 having a first portion 131 and a second portion 132, surrounding a “V” gap 133. The dam tab 130 is part of the inner flap 120, and extends from the portion of the inner flap 120 that is distal from the fold path 121. The dam tab 130 is delineated from remainder of the inner flap 120 by a corresponding folding path or crease 134. In some embodiments, wherein the inner flap 120 (including portions 131 and 132) is wider (width 301 in
When both flaps 120 and 140 are folded down, the dam tab 130 folds along the folding path 134 so as to lie between the inner flap 120 and the outer flap 140, as schematically illustrated in
The dam 290 inhibits or prohibits the flow of liquid (or non-liquid substances) from the interior volume 188 of the vessel 100 to the space 136 sandwiched between the flaps 120 and 140. Indeed, the dam 290 and the sidewall 185 of the base 101 form a channel 291 for liquid (or non-liquid substances) that escapes the interior volume 188 of the vessel. The channel 291 extends along the spout 171 to the aperture 172, as indicated in
When both of the flaps 140, 120 of the vessel 100 are unfolded, as illustrated in
Seam 110, as shown in
Under some circumstances the user of the vessel may desire to insert a straw. This could be accomplished by inserting the straw in the spout hole 172. To facilitate this insertion, some embodiments include serration 401 in the spout 171 as schematically illustrated in
Under some circumstances the user may wish to enhance the spill resistance properties of the vessel through the use of closure tabs 160. These tabs could secure the outer flap 140 to the body 101. In this embodiment, tab 160 is formed as an integral part of the sheet from which the vessel 100 is formed and protrudes from an edge of outer flap 140 (
Alternately, or in some embodiments, in addition, the adhesive 161 may be on the outer surface of the base 101, positioned to engage the tab 160 when the tab 160 is folded down alongside the base 101. The adhesive 161 is capable of repeatedly securing the tab 160 to the base 101 and repeatedly being removed from base 101. The tab 160 may therefore be described as “releasably” secured to the base 101, and adhesive 161 may thus be referred-to as a “multi-stick adhesive.”
In some embodiments, the vessel 100 may include a cover, folding tab, plug or clip for end of spout 171 to impede flow through the spout opening 172 when not in use. For example,
Alternatively, a cap or plug may serve to close the spout opening 172 when not in use. For example,
As mentioned above, a dam tab 120 may be one segment. An embodiment of a single-segment dam tab 130 is schematically illustrated in the embodiment schematically illustrated in
The width 301 of the inner flap 120, which includes the dam tab 130, is greater than the width 300 of the top 195 of the vessel 100, so that when the inner flap 120 is folded down, as schematically illustrated in
The dam 290 and the sidewall 185 of the base 101 form a channel 291 for liquid (or non-liquid substances) that escapes the interior volume 188 of the vessel 100. The channel 291 extends along the spout 171 to the aperture 172, as indicated in
In some embodiments, some edges and/or fold lines/creases/corel ines of the flaps and vessel may be waterproofed, or have an additional layer of waterproofing coating 114. For example, as schematically illustrated the in embodiment in
In the event that any content of vessel escapes the volume 188 of the vessel 100 and finds its way between the folded inner flap 120 and outer flap 140, the escaped content may flow back into the volume 188 of the vessel through the drain aperture 122. Several of the embodiments shown and described herein schematically illustrate a drain aperture 122 through an inner flap, but it should be noted that the drain aperture is optional in all embodiments, and may be included in, or omitted from, any inner flap.
Also schematically illustrated in
The adhesive strip 113 on the inner flap 120 is on the outer surface 126 of the inner flap 120; the surface that faces the outer flap 140 when the inner flap 120 and outer flap are folded. Stated alternately, the adhesive strip 113 on the inner flap 120 is on the outside surface of the vessel when the inner flap is not folded down, because that surface faces outwards from the vessel 100.
The embodiments described herein may generally be made of a flexible material such as paper. However, other embodiments may be provided in which the vessel is composed of other flexible materials that are suitable for forming into a vessel that is capable of containing liquids and has a structure similar to vessel 100, such as treated paper and plastics including polyethylene terephthalate, polypropylene, polystyrene, polylactic-acid-based compounds, etc.
The vessel may be fabricated by injection modeling, by thermoforming, or by rolling, scoring and forming from a sheet (e.g., sheet 193). A vessel 100 may also be manufactured with an insulating material made from plastic or paper based products such as extruded polystyrene foam (XPS) or cardboard respectively, so that the contents can be better insulated from the outside.
In embodiments where the vessel is composed of a material such as paper, the vessel may be coated on one or both sides with a waterproofing coating, such as wax, a polylactic-acid-based compound, or a polyethylene-based compound. Furthermore, the coating may be applied before or after the vessel is formed from a blank.
The embodiments described in all sections above are intended to be merely exemplary; numerous variations and modifications will be apparent to those skilled in the art. All such variations and modifications are intended to be within the scope of the present disclosure as defined in any appended claims.
The present application claims priority to U.S. provisional application 61/971,774, filed Mar. 28, 2014, titled “Vessel With Folded Dam,” naming Peter Herman and Robert J. D'Amato as inventors, and is related to U.S. Provisional Patent Application Ser. No. 61/186,458, filed Jun. 12, 2009; and is also related to U.S. non-provisional patent application Ser. No. 12/813,840, published Dec. 16, 2010 as US Published Patent Application No. US 2010/0314434 and issued as U.S. Pat. No. 8,505,807 on Aug. 13, 2013; and is also related to U.S. non-provisional patent application Ser. No. 13/942,916, filed Jul. 16, 2013 and published Nov. 14, 2013 as US Published Patent Application No. 2013/0299567. All of the foregoing applications, patents and publications are hereby incorporated by reference herein in their entirety for all purposes.
Number | Date | Country | |
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61971774 | Mar 2014 | US |