Abstract:
This invention relates to a cup carrier and method of distribution and application whereby a flexible plastic carrier is applied around sidewall of one or more cups resulting in an easily portable unit with a flexible plastic handle extending therefrom.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/902,657, filed 22 Feb. 2007. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    This invention relates to a cup carrier that is separable from a spool of cup carriers and adapted to easily carry one or more cups. 
         [0004]    2. Description of Prior Art 
         [0005]    Cup carriers are used to unitize individual cups into a single portable package. Cup carriers enable a user to carry several cups while freeing the user&#39;s hands or other space to carry additional objects. Traditionally, cup carriers are rigid cardboard boxes or formed board carriers which generally contain four rigid openings, each for receiving a base of a cup. 
         [0006]    More recently, cup carriers may comprise flexible ring carriers. Flexible ring carriers are generally constructed of a thin lightweight sheet of thermoplastic material and are usually designed to carry between one and four cups. 
         [0007]    Marvin, U.S. Pat. No. 5,098,144, and Slomski, U.S. Pat. No. 5,755,474, disclose generally planar sheets of polymeric material for carrying a predetermined number of cups. The sheet includes cup engaging portions and an integral handle. A cup is inserted into a cup engaging portion until a tapered sidewall of the cup is firmly seated against an inner circumference of the cup engaging portion. The cup carriers are ostensibly dispensed in single units at the point of sale. 
       SUMMARY OF THE INVENTION 
       [0008]    The cup carrier of this invention comprises a sheet of flat flexible sheet which forms at least one cup aperture and a handle. Each cup aperture is surrounded by a cup engaging portion of the flexible material that engages a sidewall of a cup when the cup is inserted into the cup aperture. 
         [0009]    Multiple cup carriers are preferably wound onto a spool for distribution and application at the point of purchase. Individual cup carriers may be separated from the spool and applied without any additional steps beyond simple separation. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The above-mentioned and other features and objects of this invention will be better understood from the following detailed description taken in conjunction with the drawings wherein: 
           [0011]      FIG. 1  is a side elevational view of a cup carrier according to one preferred embodiment of this invention; 
           [0012]      FIG. 2  is a front view of a string of cup carriers according to one preferred embodiment of this invention; 
           [0013]      FIG. 3  is a front view of a cup carrier base according to one preferred embodiment of this invention; 
           [0014]      FIG. 4  is a front view of a cup carrier holding two cups according to one preferred embodiment of this invention; 
           [0015]      FIG. 5  is a front view of two adjacent cup carriers holding four cups according to one preferred embodiment of this invention; 
           [0016]      FIG. 6  is a front view of a cup carrier holding two cups according to one preferred embodiment of this invention; and 
           [0017]      FIG. 7  is a side elevational view of a cup carrier according to one preferred embodiment of this invention. 
       
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0018]      FIGS. 1-7  show various preferred embodiments of a cup carrier  10 . As described, cup carrier  10  is preferably used to transport one or more cups  80  in a convenient and portable manner thereby freeing up the user&#39;s hands to carry other objects and/or permit the user to hang the cups in a convenient manner. 
         [0019]      FIGS. 1-6  show cup carrier  10  for carrying one or more and preferably two cups  80 , for instance soft drink cups, according to various preferred embodiments of this invention. Cups  80 , such as those shown in  FIGS. 4-6 , are preferably beverage cups, such as those accommodating sixteen ounces, twenty-four ounces or other suitable quantities of soft drinks, beer, or other beverages or food products, such as popcorn and/or any similar product suitable for use with such cups. Although beverage cups are shown in  FIGS. 4-6 , similar cups  80  maybe used with cup carrier  10  according to this invention. 
         [0020]    Cup carrier  10  comprises a flexible plastic sheet  15  preferably constructed from a flexible, resilient material such as, in one preferable embodiment, low density polyethylene. For most applications, the flexible plastic sheet  15  may have a thickness of about 3-50 mils, suitably about 5-30 mils, commonly about 8-20 mils. 
         [0021]    According to a preferred embodiment of this invention, the flexible plastic sheet  15  used to form cup carrier  10  is formed using a polymer composition which includes a high pressure low density polyethylene polymer. The composition provides the cup carrier  10  with improved recovery after stretch, improved elongation and strength at break, and improved resistance to tearing when the carrier is notched or scratched. The low density polyethylene polymer should have a density of about 0.910-0.950, grams/cm 3 , suitably about 0.920-0.940 grams/cm 3 , desirably about 0.925-0.935 grams/cm 3 . In other words, the term “low density polyethylene polymer” includes polyethylene polymers commonly considered as having medium density, as well as polyethylene polymers commonly considered as having low density. 
         [0022]    Plastic sheet  15  of material is preferably cut, using means known to those skilled in the art, such as a stamping die, to form one or more suitable cup apertures  30  and preferably two cup apertures  30  in plastic sheet  15 . Cup apertures  30  are preferably formed in a desired shape to sufficiently engage and retain a respective cup  80 . Preferably cup apertures  30  and adjacent cup engaging portions  20  are generally round although elliptical, triangular and/or a rectangular shapes may be used for specialty applications. Plastic sheet  15  may include other configurations of cup aperture  30  depending on the size and/or configuration of cups  80  desired. 
         [0023]    Cup aperture  30  is preferably applied to cup  80  by sliding the cup aperture  30  up the sidewall of cup  80  from the bottom. As shown in  FIGS. 1-7 , each cup carrier  10  preferably includes two cup apertures  30 , although it is contemplated that one, three, four or any other suitable number of cup apertures  30  may be positioned within cup carrier  10 . 
         [0024]      FIG. 1  shows one preferred embodiment of cup carrier  10 . As described above, cup carrier  10  is constructed of a flat flexible sheet  15 . Cup carrier  10  is preferably cut, using means known to those skilled in the art, such as a stamping die, to form a plurality of cup apertures  30  and handle  40 . Handle  40  is designed to be wide enough to clear the top of the largest diameter cup  80 , in order to pivot handle  40  from the position shown in  FIG. 1  to the position shown in  FIGS. 4-6 . 
         [0025]    As shown in  FIGS. 1-7 , handle  40  is positioned within cup carrier  10  adjacent to the cup apertures  30 . Handle  40  is preferably positioned within cup carrier  10  to provide an ample area for a user to grab by inserting his hand or fingers through and still maintain the integrity of cup carrier  10 . As shown in the figures, handle  40  is preferably extends lengthwise along cup carrier  10  such that it is generally parallel to the two wide direction of cup apertures  30 . 
         [0026]    Handle  20  is connected with respect to one or more cup engaging portions  20  of flexible sheet  15  which form cup apertures  30 . Each cup aperture  30  preferably accepts a single cup  80 . 
         [0027]    According to a preferred embodiment of this invention, handle  40  preferably extends between two bails  45 , each bail positioned over a respective cup aperture  30  such as shown in  FIGS. 1 ,  4  and  7 . Each bail  45  preferably extends between handle  40  and one or more and preferably two struts  50 . Struts  50  are preferably positioned on either side of each cup aperture  30 . As shown in  FIG. 7 , each of two central struts  50  may share a single band in bail  45 . In one preferred embodiment of this invention, shown in  FIG. 1 , each cup engaging portion  20  is connected to each bail  45  through two struts  50 , spaced equidistantly on either side of cup engaging portion  20 . Each bail  45  is then preferably joined to each other bail  45  by handle  40 . Specifically, as shown in  FIG. 4 , two bails  45  are joined together by single handle  40 . As a result of the described embodiments, handle  40  is preferably connected at a total of three places to cup engaging portions  20 . 
         [0028]    Each bail  45  and/or handle  40  may additionally comprise one or more separable sections  55  that may be broken to open up an area for the purchaser to grab handle  50  and create a sufficient distance between cups  80  and the user&#39;s hand. As shown in  FIGS. 1 and 7 , and according to one embodiment of this invention, a total of two separable sections  55  are included on each cup carrier  10 . In addition, such separable sections  55  maintain the string of cup carriers  10  relative to each other during the punching and winding process described above. As described in more detail below, such separable sections  55  separate with less force than the force required to separate adjacent cup carriers  10 . 
         [0029]    As shown in  FIG. 1 , each bail  45  is preferably generally squared around each cup aperture  30 . Such an arrangement preferably maximizes length of bail  45  following separation from cup engaging portion  20 . In addition, each bail  45  preferably is connected to a bail  45  on an adjacent cup carrier  10  along line of weakness  60 . Line of weakness  60  may additionally extend between adjacent tabs  65  that extend from a portion of cup engaging portion  20  opposite a handle  40  side of cup carrier  10 . These attachment points along adjacent bails  45  and tabs  65  assist in the winding and unwinding of cup carriers  10  on spool  70 . 
         [0030]    Following engagement with a suitable cup  80 , cup engaging portion  20  surround a circumference of cup aperture  30  and permit, upon insertion of cup  80  into cup aperture  30 , frictional contact between cup engaging portion  20  and cup  80  as shown in  FIGS. 4-6 . 
         [0031]    As best shown in  FIG. 6 , cup engaging portion  20  preferably engages a generally tapered sidewall of cup  80  preferably above an approximate midpoint of the sidewall such that a center of gravity of filled cup  80  is below cup engaging portion  80 . When cup  80  is fully nested within cup aperture  30 , cup engaging portion  20  frictionally engages the tapered sidewall of cup  80 . Alternatively, or in addition, cup engaging portion  20  may nest against a lip or upper flange of cup  80  thereby preventing disengagement of cup aperture  30  from cup  80 . 
         [0032]    According to an additional preferred embodiment of this invention, shown in  FIG. 7 , cup carrier  10  may include one or more removable rings  75  that at least partially line one or more cup engaging portions  20 . As shown, removable rings  75  preferably are severable from cup engaging portion  20  along a perforated or similarly weakened division from cup engaging portion  20 . In use, removable rings  75  may be grasped along finger hold  85  and pulled to remove removable ring  75  thereby opening a diameter within cup carrier  10  to permit insertion of a larger diameter cup  80  or container. For instance, a nominally sized cup engaging portion  20  may be used to engage a  16  ounce cup or one or more removable rings  75  may be removed to result in a larger cup engaging portion  20 ′ thereby permitting insertion of a larger cup  80 , such as a  32  ounce cup. 
         [0033]    As shown in  FIG. 2 , cup carrier  10  is preferably manufactured so that raw carrier stock includes a generally continuous roll of plastic sheet  15  having a plurality of adjacent cup carriers  10  that are punched and then wound onto a spool  70  having a generally continuous string of cup carriers  10 , each cup carrier  10  attached to each adjacent cup carrier  10 , as described in more detail below. According to one preferred embodiment of this invention, spool  70  is applied to fixture  90  for unwinding spool  70  of cup carriers  10  as needed. 
         [0034]    Cup carriers  10  are then applied to cups  80  as needed, preferably from a vendor, counter, stand, etc. where the cups of product are dispensed and sold. Cup carriers  10  are preferably unwound from spool  70  as needed and individually separated from each other to form individual cup carriers  10 . Empty spools  70  may be replaced at point of purchase as they are used either with or without use of fixture  90 . 
         [0035]    According to a preferred embodiment of this invention, between each cup carrier  10  in the generally continuous roll of cup carriers is line of weakness  60 . Prior to, or during, the process of applying cup carrier  10  to cups  80 , each cup carrier  10  may be separated from each adjacent carrier along line of weakness  60 . As each cup carrier  10  is removed from spool  70 , a user preferably separates line of weakness  60  to free cup carrier  10  while at the same time breaking separable sections  55  of cup carrier  10 . As such, line of weakness  60  preferably requires more breaking force than separable sections  55 . The resulting cup carrier  10  therefore is ready for application to cups  80  without any additional manipulation or separation of components within cup carrier  10 . 
         [0036]    Spools  70  may be positioned for separation of cup carriers  10  and use by the seller or the buyer. An additional fixture, such as recessed cup holders, not shown, may be used for placement of cups  80  as cup carrier  10  is applied to cups  80 . 
         [0037]    Lines of weakness  60  may comprise perforations, serrations, slits or combination thereof formed in plastic sheet  15  and are preferably tearable or frangible to permit separation of plastic sheet  15  along a defined line. In addition, lines of weakness  60  preferably do not extend directly into any edge or aperture of plastic sheet  15  but instead are preferably positioned within interior portions of plastic sheet  15 . 
         [0038]    According to embodiments of the invention best shown in  FIGS. 1-6 , a method of distributing cup carriers  10  and carrying cups  80  preferably includes providing a generally continuous plastic sheet  15  having a plurality of cup carriers  10  each having one or more and preferably two cup apertures  30 . The generally continuous string of cup carriers  10  is preferably provided on a spool  70  which may in turn be positioned on fixture  90  or may be configured to provide self-contained rotation to facilitate unwinding of cup carriers  10 . Such carriers  10  optimally form a single carrying handle for carrying one or more cups  80 , as described herein. 
         [0039]    As filled cups  80  are purchased from a vending station, counter or similar point of purchase, an individual cup carrier  10  is separated from the continuous string of cup carriers  10  on spool  70  along line of weakness  60 . As line of weakness is separated, one or more addition separable sections  55  are pulled apart by the force of such separation. The resulting cup carrier  10  may then be placed underneath one or more cups  80  and lifted up thereby engaging each cup engaging portion  20  with a respective cup  80 . Following application, each cup  80  therefore includes a cup aperture  30  positioned about its sidewall that enables convenient carrying of cup  80  using handle  40 . The resulting package of one or more cups  80  and one cup carrier  10  may then be lifted and carried using handle  40 . A consumer may then carry, hang and/or pour cup  80  as desired and appropriately dispose of the empty cup  80  and cup carrier  10 . According to one preferred embodiment of this invention, one or more severable sections may be positioned within cup carrier  10  to permit the user to break apart cup carrier  10  prior to disposal. 
         [0040]    According to a preferred embodiment of this invention, and as shown in  FIG. 6 , hook  100  may be available or provided for placement in an automobile or other suitable location to facilitate hanging cup carrier  10  for storage, transport or accessibility of cup  80 . In addition, straw apertures  35  may be positioned within cup carrier  10  to facilitate placement of straws for use with cups  80  as needed. 
         [0041]    While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that cup carrier  10  and the related method of manufacture are susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.