Abstract:
A nestable beverage cup is preferably formed of two tapered sections. A lower section is sized to fit a cup holder such as used in a vehicle, while an upper section which is not held in the cup holder is provided with a larger diameter than the lower section, and is more broadly tapered to hold a greater volume of fluid. The lower section has a flattened rim which is ultrasonically sealed to the bottom of the upper section. A recessed bottom of the upper section provides an air gap which will insulate the user from the surface of the lower section. The two stage cup contemplates designs with various sidewalls, angles, shapes and raw materials.

Description:
FIELD OF THE INVENTION 
     This invention relates generally to an improved container such as a food and beverage cup of the type commonly supported in automobiles, trucks and other vehicles. More particularly, the invention pertains to a two stage cup, preferably formed of paperboard, wherein an upper portion of a lower cup is uniquely joined to a lower portion of a substantially bottomless upper cup to provide enhanced integrity, insulation and other qualities. 
     BACKGROUND OF THE INVENTION 
     It is known that today&#39;s vehicles are equipped with one or more receptacles for holding generally cylindrical, food and beverage containers, such as cups and cans, so as to prevent their spillage while the vehicle is in transit. In order to accommodate containers of larger volumes, it has been necessary to consider cups designed with a base proportioned to fit the standard vehicle container receptacle having a main portion of a size larger than the base so as to address the problem of top heaviness of the filled container. 
     One such design is disclosed in U.S. Pat. No. 5,769,266, issued Jun. 23, 1998, to Willbrandt. In this patent, a one-piece container is comprised of a base and a lower body portion extending substantially upward from the base. A shoulder extends radially outward from the lower body portion and an upper body portion extends substantially upward from the shoulder. The upper body portion is open at the top to create an opening. The lower body portion has a size to fit in the standard vehicle container receptacle. The shoulder aids the container in securely nesting in the vehicle container receptacle. The upper body portion is of a size such that the container holds the desired amount of a beverage. In order to strengthen the sidewalls of the lower body portion and to facilitate material flow in the manufacture of the upper body portion, the lower body portion of the container is formed of a series of fluted sides that provide support to the lower body portion. The sides of the lower body portion increase in thickness as they extend upward from the base to the shoulder. 
     While the Willbrandt container has been generally satisfactory for use with cold beverages, its thermoplastic construction present several drawbacks, the first of which deals with its inability to provide satisfactory insulation for the holder of a hot beverage such as coffee or hot food product such as soup. As more and more people continue to ingest their meals in their vehicles, it is important to provide adequately insulated containers capable of comfortably handling a full temperature range of consumable products. As travelers may desire to reheat their food and beverages, the thermoplastic container is susceptible to deformation upon placement in a microwave oven. Once the thermoplastic container has been discarded, it does not exhibit the desirable biodegradability most favorable to the environment. Another disadvantage is recognized in the restricted ability and more expensive cost to print on the thermoplastic container. Because of the manner in which plastic is molded, printing is generally applied only to an upper portion of the container after it is formed. 
     Accordingly, there is a need for a different style, two stage container which can be securely accommodated in a standard vehicle container holder, mass produced at a reasonable cost and which otherwise overcomes the deficiencies in prior art containers as set forth above. 
     SUMMARY OF THE INVENTION 
     It is a general object of the present invention to provide a two stage cup preferably formed of paperboard having a lower section sized to fit a standard vehicle cup holder, and an upper section with a larger volume than the lower section. 
     It is one object of the present invention to provide a two stage cup which can be used with hot and cold beverages and foodstuffs. 
     It is also an object of the present invention to provide a two stage cup wherein the joinder of an upper cup and a lower cup provides improved insulative qualities and structural integrity. 
     It is a further object of the present invention to provide a two stage cup which is capable of being microwaved. 
     It is an additional object of the present invention to provide a two stage cup which is environmentally desirable. 
     It is a further object of the present invention to provide a two stage cup which offers greater flexibility in printing its outside surface. 
     Another object of the present invention is to provide a two stage cup wherein an upper cup section and a lower cup section have different sidewalls, angles, shapes, thicknesses, etc. 
     Still another object of the present invention is to provide a two stage cup which is easily nested and denested with one or more similar cups. 
     Yet another object of the present invention is to provide a two stage cup which fits into standard food and beverage dispensers. 
     A similar object of the present invention is to provide a two stage cup which is capable of mass production with existing cup producing equipment. 
     In one aspect of the invention, a two stage cup includes an upper cup having an upper cup sidewall disposed about a central axis and an upper cup bottom wall disposed generally transversely to the upper cup sidewall and punched out to define a bottom wall annular border extending radially inwardly from the upper cup sidewall. The upper cup sidewall has a top edge curled outwardly from the central axis and a lower cup has a lower cup sidewall and a lower cup bottom wall disposed generally transversely to the lower cup sidewall. The lower cup sidewall has a curled and flattened top edge lying in overlapping, sealed relationship with the upper cup bottom wall annular border, wherein a lower portion of the upper cup sidewall is spaced from an upper portion of the lower cup sidewall to create an insulative air gap, and the upper cup and the lower cup comprise paperboard. The upper cup sidewall is spaced from the lower cup sidewall 360° degrees about a circumference of the upper cup. The upper cup curled top edge is generally circular in cross section and is curled through 360° degrees. The upper cup top edge is curled in a direction generally outwardly of the central axis. The upper cup bottom wall annular border is spaced from the lower cup bottom wall by substantially the entire height of the lower cup sidewall. The lower cup sidewall and the lower cup bottom wall cooperate to form a recessed bottom. The upper cup has a volume larger than the lower cup. The upper cup sidewall tapers upwardly from the upper cup bottom wall annular border to the upper cup top edge, and the lower cup sidewall tapers upwardly from the lower cup bottom wall to the lower cup flattened top edge. The thickness of the upper cup sidewall is constant throughout its height, and the thickness of the lower cup sidewall is constant throughout its height. 
     In another aspect of the invention, a two stage container includes a lower cup comprised of paperboard and including a central axis, a lower cup sidewall and a lower cup bottom w all generally perpendicular to the central axis . An upper cup is comprised of paperboard and includes an upper cup sidewall and an upper cup bottom wall annular border extending generally perpendicular to the central axis and extending radially inwardly from the upper cup sidewall. The upper cup bottom wall annular border includes a first outer lip folded downwardly, generally transversely to the border, and the upper cup sidewall includes a first bottom flap folded upwardly over the first outer lip. The lower cup bottom wall includes a second outer lip folded downwardly, generally transversely to the bottom wall, and the lower cup sidewall includes a second bottom flap folded upwardly over the second outer lip to form a recessed bottom. The lower cup sidewall also has a flattened top edge which is disposed on top of the upper cup bottom wall annular border and is ultrasonically sealed thereto to join the upper cup above the lower cup. The first bottom flap on the upper cup sidewall is spaced from an upper portion of the lower cup sidewall to create an insulative air gap. The lower cup has a bottom region adapted to fit a cylindrically-shaped, vehicle container holder. The upper cup has an overall greater diameter than the lower cup. 
     Various other features, objects and advantages of the invention will be made apparent from the following description taken together with the drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The drawings illustrate the best mode presently contemplated of carrying out the invention. 
     In the drawings: 
     FIG. 1 is a perspective view of a two stage cup embodying the present invention; 
     FIG. 2 is an exploded view of the sidewall blank and the bottom blank of the upper cup used in the container shown in FIG. 1; 
     FIG. 3 is an exploded view of the sidewall blank and the bottom blank of the lower cup used in, the container illustrated in FIG. 1; 
     FIG. 4 is an exploded, inverted, perspective view of the assembly of the upper cup and the lower cup; 
     FIG. 5 is a cross-sectional view of the finished cup shown in FIG. 1; and 
     FIG. 6 is a cross-sectional view of two nested cups of the type shown in FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring generally to FIGS. 1-3, a two stage container  10  having an upper cup  12  and a lower cup  14  is shown. Upper cup  12  includes a sidewall blank  16  that forms its sidewall and a bottom blank  18  that forms its bottom wall, as best illustrated in FIG.  2 . However, as will be further discussed below, a central portion  18   a  of bottom blank  18  is removed leaving a radially inwardly extending, annular border  18   b . Lower cup  14  includes a sidewall blank  20  that forms its sidewall and a bottom blank  22  that forms its bottom wall, as best illustrated in FIG.  3 . Unlike punched out bottom blank  18 , bottom blank  22  remains solid. 
     As shown in FIGS. 4 and 5, an exemplary upper cup  12  includes an upper region  24  having a curled top edge  26  and a bottom region  28 . Sidewall blank  16  is wrapped around punched out bottom blank  18  and disposed generally transversely thereto. Bottom blank  18  is typically bent or folded over in proximity to its outer edge to form a lip  30 . The sidewall blank  16  is located with respect to punched out bottom blank  18  so a flap portion  32  of sidewall blank  16  extends beyond lip  30 . Flap portion  32  is bent or folded around lip  30  so lip  30  may be squeezed between flap portion  32  and a lower portion  34  of sidewall blank  16 . By forming upper cup  12  as illustrated in FIG. 4, a recessed bottom area  36  is created at the bottom of upper cup  12  on a lower side of bottom blank border  18   b.    
     As shown in FIGS. 4 and 5, lower cup  14  includes an upper region  38  preferably having a top edge  40  (which is later flattened) and a bottom region  42 . Lower sidewall blank  20  is wrapped around bottom blank  22  and disposed generally transversely thereto. Lower cup bottom blank  22  is typically bent or folded over in proximity to its outer edge to form a lip  44 . The sidewall blank  20  is located with respect to bottom blank  22  so a flap portion  46  of sidewall blank  20  extends beyond lip  44 . Flap portion  46  is bent or folded around  44  so lip  44  may be sandwiched between flap portion  46  and a lower region  48  of sidewall  20 . By forming lower cup  14  as illustrated in FIG. 5, a recessed bottom area  50  is created in the bottom of lower cup  14  on an opposite side of bottom  22  from the main container of lower cup  14 . Bottom region  42  is sized so as to provide a secure fit in a standard vehicle container receptacle. 
     Upper cup  12  and lower cup  14  are preferably fabricated from paperboard blanks which may be preprinted and have a thermoplastic coating, such as polyethylene. The thermoplastic material permits heating and sealing of adjacent components. For example, when upper cup sidewall blank  16  is wrapped around upper cup  12 , punched out, bottom blank  18 , the adjacent edges of sidewall blank  16  are heated and pressed together to form a seal  52 . Similarly, lip  30 , flap portion  32 , and lower region  34  may be heated and pressed together to form a strong, leak-proof bottom region  28 . This same approach may be used in the assembly of lower cup  14  so as to form a sidewall seal  53 . 
     Upper cup  12  and lower cup  14  may be made from the same grades of paperboard. Typically, the sidewall blank and bottom blank of each cup are made from similar grades of paperboard, although differing grades could also be used for these elements as well. 
     Upper cup  12  is disposed about a central axis  54  that extends generally perpendicularly through the center of bottom blank  18 . Preferably, when sidewall blank  16  is wrapped around bottom blank  18 , sidewall  16  has a tapering section which is disposed at an acute angle  56  with respect to central axis  54  (see FIG.  5 ). Angle  56  can be increased or decreased for a specific application. 
     Upper cup  12  also includes curled top edge  26  that is formed by rolling or curling the top of sidewall blank  16  initially away from central axis  54  and then around and back towards the remaining portion of sidewall blank  16 . Preferably, the curl extends through 180° degrees or more, and as illustrated, can curl through 360° degrees back to the remaining portion of sidewall blank  16  to form a generally circular cross section as illustrated in FIG.  5 . It is an important method step that before the bottom blank  18  is joined to the sidewall blank  16 , the central, preferably circular, portion  18   a  (FIG. 2) of bottom blank  18  is punched out and removed to facilitate assembly between the upper cup  12  and the lower cup  14 . 
     Lower cup  14  includes curled top edge  40  which is radially flattened at  40   a  when upper cup  12  is combined with lower cup  14  as illustrated in FIGS. 4 and 5. Additionally, the sidewall  20  of lower cup  14  includes a tapered section that forms an acute angle  58  with central axis  54  when upper cup  12  and lower cup  14  are combined. In a preferred embodiment, both the upper and lower cups have frustroconical contours. Each cup preferably has its own constant sidewall thickness throughout its height. The volume of the upper cup  12  is generally larger than that of the lower cup  14 . 
     Once the substantially bottomless upper cup  12  and the bottomed lower cup  14  have been formed, the upper cup  12  is passed over the lower cup  14  (as represented in FIG. 4) until the curled top edge  40  of lower cup  14  lies on top of the formed border  18   b  of lower cup. At this position, the edge  40  is radially flattened and then ultrasonically sealed to the border  18   b  to form a two stage container  10 . When upper cup  12  and lower cup  14  are fastened together, leakage of food and beverage is prevented and the structural integrity of the container  10  is enhanced by the sealed and flattened edge  40   a  of the lower cup  14  as it is fused to the upper cup  12 . Simultaneously, there is provided an air gap  60  between the recessed bottom of the upper cup  12  and the upper region of the lower cup  14  which will insulate the user from any hot contents in the container  10 . Air gap  60  extends for  3600  degrees around the circumference of lower cup  14  and over a significant vertical height h (typically one-half inch) so as to provide container  10  with substantial insulating ability. The hand can hold the cup comfortably without excessive heat or burning. 
     The resulting versatile cup is thus capable of holding varying volumes of both hot and cold beverages and foodstuffs. It is also possible that the lower portion of cup  10  could be filled with a granular or powdered soup or cereal mix and fitted with a temporary seal which could be removed to enable the user to add a hot water diluent in the upper portion of the cup  10 . Advantageously, cup  10  is designed to retain its sealing and strength features while being microwaved. Because of its paperboard construction, the cup has a reasonable degree of biodegradability which will not harm the environment. 
     One of the benefits of utilizing paperboard in the fabrication of container  10  is the ability to preprint the respective, flattened sidewall blanks  16 ,  20  of both the upper cup  12  and the lower cup  14  before the sidewall blanks are formed and sealed with their respective bottom blanks  18 ,  22 . Consequently, the upper cup  12  and the lower cup  14  may carry similar or different logos, graphics, indicia, etc. of high printing quality. This is contrast to the prior art thermoplastic cup which is generally partially printed by a different, more expensive method after the cup has been molded. That is, the upper surface of the plastic cup is printed as the cup is turned which can effect the quality of the ink transfer. 
     FIG. 6 illustrates a pair of formed two stage cups  10  which are in nesting relationship with one another. It should be understood that denesting can be controlled by the shape of the upper cup  12  or the lower cup  14 . The cups  10  are thus formed to permit their vertical or horizontal stacking when they are also used in conjunction with beverage or food dispensing equipment such as found in fast food establishments. 
     It will be understood that the foregoing description is of a preferred exemplary embodiment of this invention and that the invention is not limited to the specific forms shown. For example, various grades of paperboard and other materials may be used in the construction of either the upper cup or the lower cup; the upper cup and lower cups may each be provided with recessed bottoms or bottoms of other configurations; the curled top edge of the upper cup can have a variety of configurations, the lower cup can have either straight or tapered sidewall or sidewall sections; the lower cup can have varying degrees tapered to its sidewall; and the cups can have circular, elliptical, rectangular or other cross-sectional shapes depending on the overall shape of the container. For example, the lower cup may be conical, while the upper cup may be rectangular. These and other modifications may be made in the design and arrangement of the elements without departing from the scope of the invention as expressed in the appended claims.