Multi-Walled Container with Mechanically Locking Outer Sleeve

None.

The present invention is generally directed to a multi-walled container which includes an inner receptacle, an outer sleeve, an intermediate space defined between the receptacle and outer sleeve for insulating the container, and a mechanical locking mechanism adapted for securing the outer sleeve to the inner receptacle.

Multi-walled containers suitable for holding hot and cold liquids are well known in the food and beverage packaging industry. Various solutions have been developed to enhance user comfort, improve thermal insulation and prevent spills. Historically, single-wall cups have been a widespread choice for their simplicity; however, they tend to be poor insulators and often require additional sleeves or layers to protect the user from extreme temperatures. The development of multi-walled containers with inner cups and outer cups, sleeves, or sidewalls marked a significant improvement in thermal insulation capabilities, providing an air gap between the walls that reduced heat transfer and the need for additional hand protection.

Despite their advantages, conventional multi-walled containers possess inherent limitations. Currently known containers in the industry typically require the use of chemical bonding or adhesive to attach the outer insulating sleeve to the inner base cup, which may introduce additional manufacturing complexity and costs. Additionally, these currently known containers typically utilize non-compostable materials to construct the outer insulating sleeve, inner base cup, and particularly the connection or insulating layer therebetween. This prevents the cups from decomposing and contributes to landfill waste and pollution. Further negative environmental impacts are created by the non-compostable adhesives used to attach the outer sleeve and inner base cup because these adhesives may not decompose for long periods of time.

Accordingly, a need exists for a compostable, insulated container that does not require the use of any chemical bonding or adhesive to interlock the insulating outer sleeve with the inner cup.

The present invention introduces a novel enhancement in the form of a compostable container comprised of an inner base cup with a mechanical locking sleeve, which decisively addresses the aforementioned deficiencies. This double-wall cup with a mechanical locking sleeve streamlines the manufacturing process by eliminating the reliance on adhesives or complex machinery for joining the inner cup with the outer sleeve. Instead, the mechanical locking mechanism securely joins the exterior of the inner cup with the outer insulating sleeve while maintaining the insulating intermediate space. Further, both components of the container may be constructed of completely compostable materials. Such a design not only simplifies the assembly but also permits disassembly, which is advantageous for the cup's compostable and recyclable qualities. These innovations present a clear departure from traditional approaches and signify a meaningful contribution to the field of beverage containers.

One embodiment of the present invention is generally directed to a multi-walled container comprising a receptacle, an outer sleeve, and an intermediate space defined therebetween. The receptacle comprises a circumferential sidewall and bottom wall, wherein the sidewall includes at least one outwardly projecting embossment spaced below the upper edge of the receptacle sidewall. The at least one receptacle embossment may be a continuous embossment extending circumferentially around the entire perimeter of the receptacle sidewall, or the embossment may be a plurality of spaced apart embossments formed around at least a portion of the perimeter of the receptacle. The outer sleeve includes a circumferential sidewall with an inwardly projecting upper lip at the top end thereof. The receptacle and outer sleeve may both be constructed of a paperboard material, and the receptacle may include an outwardly rolled upper lip at the top edge thereof. The intermediate space is defined between the receptacle sidewall and the outer sleeve sidewall, wherein the inwardly projecting upper lip of the outer sleeve is positioned above and engages the at least one outwardly projecting embossment of the receptacle. The intermediate space may preferably be formed of an air gap, but alternatively may also be composed from paper or other compostable material.

In one embodiment, the inner receptacle may further comprise an outwardly rolled upper lip at the top edge thereof, and the outer sleeve may include an outwardly projecting embossment positioned below the inwardly projecting outer lip. The outer sleeve embossment may be positioned to engage with the receptacle upper lip of a second container when the container is nested within the second container to allow for nesting in storage in shipping. The outer sleeve embossment may be a continuous embossment extending circumferentially around the entire perimeter of the sleeve sidewall, or the embossments may be a plurality of spaced apart embossments formed around at least a portion of the perimeter of the sleeve sidewall.

In another embodiment, the receptacle includes a first outwardly projecting embossment and a second outwardly projecting embossment located above the first outwardly projecting embossment, with both embossments being spaced below an upper edge of the receptacle. The inwardly projecting upper lip of the outer sleeve may be positioned above at least one outwardly projecting embossment, or the outer sleeve upper lip may be positioned between the first outwardly projecting embossment and second outwardly projecting embossment. The receptacle embossments may each be a continuous embossment extending circumferentially around the entire perimeter of the receptacle sidewall, or the first and second embossments may each be a plurality of spaced apart embossments formed around at least a portion of the perimeter of the receptacle Other and further objects of the invention, together with the features of novelty appurtenant thereto, will appear in the course of the following description.

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 generally to, one embodiment of the present invention is directed to a containerwhich includes a receptacle, an outer sleeve, and an intermediate spacedefined between the receptacleand outer sleeve. While the containermay be adapted for holding hot and cold liquids, it will be appreciated that it can also be used in connection with the storage and transportation of other items. Further, it will be appreciated that the outer sleevemay be manufactured independently from the receptacleand later applied to the receptacle.

As illustrated in, the receptaclemay be formed of a bottom walland a circumferential sidewall, with the exterior receptacle sidewallincluding at least one outwardly projecting embossmentin the upper portionbelow an upper edge of the receptacle, although other constructions are within the scope of the present invention. In a second embodiment, as illustrated in, the exterior receptacle sidewallmay further comprise a second outwardly projecting embossmentlocated above the first outwardly projecting embossment, both embossmentsandbeing spaced below an upper edge of the receptacle. The at least one outwardly projecting embossment(s)may be in the form of a protuberance, deformation, distortion, bend, bulge, bump, lump, hump, knob, swelling, protrusion or the like extending outwardly from a sidewall forming the receptacle sidewall. The at least one outwardly projecting embossmentmay be formed substantially continuously around the entire perimeter of the receptacle sidewall, or multiple embossmentsmay be a plurality of spaced apart embossments, formed generally intermittently for example, around at least a portion of the perimeter of the receptacle sidewall.

In one embodiment, the receptacleis constructed of paperboard material, and preferably coated paperboard, in order to resist the migration of liquids contained within the storage chamber. However, it will be appreciated that the receptaclemay be constructed of other materials, including but not limited to, polyethylene, polypropylene, polyethylene terephthalate (PET), or other materials suitable for use as a receptacle. The bottom walland receptacle sidewallmay be die cut from a larger sheet or roll (not shown) of material. As shown in, the bottom wallincludes a depending skirtsecured to the receptacle sidewallby a reverse bendportion of the receptacle sidewall. Securement of the bottom wallto the receptacle sidewallmay be achieved by use of a compostable, biopolymer-based adhesive such as, but not limited to, cellulose-based, starch-based, lignin-based, protein-based, and vegetable oil-based adhesives. Securement may also be achieved by other methods, including but not limited to, adhesive, hot melt, sonic welding, sealants, or the like. The reverse bendforms a footing upon which the containermay sit when in use. Construction of the receptacleas just described is well known in the art.

The receptaclepreferably has a generally frustoconical shape with a generally circular transverse cross sectional shape of varying diameter that increases in size from a bottom end of the receptacleto the top edge of the receptacle. In one embodiment, the top edge of the receptacle includes an outwardly rolled upper lipat the top edge thereof, which allows for nesting in storage and shipping. The receptacle sidewallmay be formed from a blank and wrapped around a mandrel. The receptacle sidewallmay include an overlapping seam (not shown) extending generally longitudinally between the top and bottom ends of the receptacle.

The seam (not shown) can be formed by adhering the overlapping margin portions of the receptacle sidewalltogether with a compostable, biopolymer-based adhesive such as, but not limited to, cellulose-based, starch-based, lignin-based, protein-based, and vegetable oil-based adhesives, so that all features of the containerremain completely compostable. The seam may also be formed by other methods, including but not limited to, adhesive, hot melt, sonic welding, or the like. The exposed edges at the seam of the receptacle sidewallmay be sealed to prevent the migration of liquids into the material comprising the receptacle sidewall. The containerof the present invention may have a storage chambervolume on the order of, for example, about four (4) fluid ounces to about thirty-two (32) fluid ounces, although larger or smaller containersmay be made and are within the scope of the present invention.

As illustrated in, an outer sleevesurrounds and overlies a substantial portion of the receptacle sidewall. The outer sleevemay be constructed from a suitable flat blank material and includes a circumferential sleeve sidewall, and an inwardly projecting upper lipat the top end thereof. The outer sleevemay also include an optional inwardly projecting fold, roll, lip, protuberance, deformation, distortion, bend, bulge, bump, lump, hump, knob, swelling, protrusion or the like at the bottom end thereof to create a generally uniform spacealong the entire height of the sleeve. The exterior of sleeve sidewallmay be suitable for having advertising, logos, and other graphics printed thereon.

In one embodiment, the sleeve sidewallmay include an outwardly projecting embossmentpositioned below the inwardly projecting upper lip. The embossmentmay be in the form of a protuberance, deformation, distortion, bend, bulge, bump, lump, hump, knob, swelling, protrusion or the like extending outwardly from a sidewall forming the outer sleeve. In one embodiment, the embossmentis formed substantially continuously around the entire perimeter of the sleeve sidewall, while another embodiment comprises multiple embossments, formed generally intermittently for example, around the perimeter of the sleeve sidewall. The embossmentmay be formed by an embossing roller, press plate, pins, or die plate, and may be embossed while the sleeve is still in flat form prior to being formed into a circumferential outer sleeve. In one embodiment, the embossmentmay be formed while the outer sleeveis on a printing press or die cutter. The embossmentmay be pressed, stamped, or rolled into the sleeve simultaneously, or in close temporal and spatial proximity with, with the die cutting or printing of the outer sleeve. In another embodiment, the embossmentis formed by applying, adding, or forming additional material along the outer surface of the sleeve sidewall. The embossmentmay also be formed by swelling or expanding the material forming the sleeve sidewallin the area of the embossmentthrough, for example, causing moisture to be absorbed or adsorbed, in the paperboard or other material forming the sleeve.

In one embodiment, the outer sleeveis preferably constructed of paperboard material; however, other materials including, but not limited to, polyethylene, polypropylene, PET, or other materials suitable for use as a receptacleare within the scope of the invention. The outer sleevepreferably has a generally frustoconical shape with a generally circular transverse cross sectional shape of varying diameter that increases in size generally in accordance with a corresponding receptacle. The sleeve sidewallmay be formed from a blank and wrapped around a mandrel. The sleeve sidewallmay include an overlapping seam (not shown) extending generally longitudinally between the top and bottom ends of the outer sleeve. The outer sleeve seam (not shown) can be formed by adhering the overlapping margin portions of the sleeve sidewalltogether with a compostable, biopolymer based adhesive such as, but not limited to, cellulose-based, starch-based, lignin-based, protein-based, and vegetable oil-based adhesives, so that all features of the containerremain completely compostable. The seam may also be formed by other methods, including but not limited to, adhesive, hot melt, sonic welding, or the like.

An intermediate spacemay be defined between the exterior receptacle sidewalland the outer sleevein order to protect a user's fingers and palm from the discomfort usually associated with holding a hot or cold beverage. In one embodiment, the intermediate spacemay be formed of an air gap defined between the exterior receptacle sidewalland the outer sleeve. This air gap can be formed, for example, by a standoff between the receptacle sidewalland the outer sleevein the upper portion, created by an interaction between the inwardly projecting upper lipof the outer sleevepositioned above and engaging with the at least one outwardly projecting embossmenton the exterior sleeve sidewall. The interaction between the inwardly projecting upper lipof the outer sleeveand the outwardly projecting embossmentcreates a locking mechanism to secure the outer sleevein place without the use of any additional adhesive. In one embodiment, the locking mechanism may be created by an interaction between the inwardly projecting upper lipof the outer sleevepositioned above the outwardly projecting embossmentand below the outwardly projecting embossment. In another embodiment, the locking mechanism may be achieved by the inwardly projecting upper lipbeing positioned above and engaging with the at least one embossment of any number of embossments.

In another embodiment, the intermediate spacemay also be composed from a paper material of various forms, including corrugated paper, paper with dimpled surfaces, low density paper, recycled paper, deformed paper, or the like. It may also be within the scope of the invention that the intermediate spacemay be composed of a thermoplastic resin, including but not limited to, polyethylene, polyolefin, polyvinylchloride, polystyrene, polyester, nylon, or materials suitable for use as an insulating layer. The intermediate spacemay be between about five (5) to thirty (30) mils in one embodiment and between ten (10) and twenty (20) mils in another embodiment, although other sized spacing gaps are also within the scope of the present invention. The insulating layermay be secured or fixedly attached to the exterior receptacle sidewallto prevent unraveling and to prevent relative movement in a longitudinal or axial direction.

The outer sleevemay be disposed around and engaged with the receptacle sidewallthrough a locking engagement in the upper portionwithout the use of any adhesive, glue, sealant, melt, or the like required. In one embodiment, as demonstrated in, the outer sleeveis attached to the receptaclethrough a locking engagement in the upper portionof the exterior receptacle sidewallsuch that the inwardly projecting upper lipof the outer sleeveengages with and is positioned above the outwardly projecting embossment. In another embodiment, as shown inthe outer sleeveis attached to the receptaclethrough a locking engagement in the upper portionof the exterior receptacle sidewallsuch that the inwardly projecting upper lipof the outer sleeveengages with and is positioned between the outwardly projecting embossmentsand. In other embodiments, the vertical placement of the outer sleevemay be adjusted depending on the location(s) of the outwardly projecting embossment(s), which consequently shall adjust the location of the interaction between the inwardly projecting upper lipand the exterior sleeve sidewall. It will be appreciated that, in other embodiments, the containermay not include an intermediate space, and securement of the outer sleeve to the receptacle sidewallmay also be adhesively attached to the exterior receptacle sidewall

As demonstrated in, the embossmentof a first containercontacts or engages with the outwardly rolled upper lipof a second containerto control the degree of nesting between the two containers. In that regard, the embossmentmay have a diameter De that is larger than a diameter Do of an opening defined by the outwardly rolled upper lip. The inner containeris held up by its embossmentand not permitted to fall so far into the outer containerso as to become wedged therein. The embossmentcauses a slight gapbetween the containersand. Specifically, the gapis defined between the outer surface of the sleeve sidewallof the inner containerand the inner surface of the receptacle sidewallof the outer container. The gapbetween two nested containersandcan permit the void space beneath the inner containerto be in fluid communication with the atmosphere so as not to create a vacuum in the void space between the two containersandwhich may impede their separation from one another. Such resistance may result in multiple containerssticking together when the user intends to grab only one from the stack. The gapalso prevents the two containersandfrom becoming wedged together in an interference fit. The height of the gapand degree of nesting between stacked containersis dependent upon the vertical placement of the embossment. For a greater height of the gap, the embossmentmay be placed a greater distance from the inwardly projecting upper lip.

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 inherent to the structure and method. 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 terms “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.