MULTI-WALLED CONTAINER WITH MECHANICALLY LOCKING OUTER SLEEVE

A multi-walled container comprising a receptacle, an outer sleeve, and an intermediate space defined therebetween for insulating the container is provided. The receptacle includes a bottom wall and circumferential sidewall, the receptacle sidewall including at least one outwardly projecting embossment spaced below an upper edge of the receptacle. The outer sleeve has a circumferential sidewall including an inwardly projecting upper lip at the top end thereof. The inwardly projecting upper lip is positioned above and engages the at least one outwardly projecting embossment of the receptacle to define an intermediate space between the receptacle sidewall and outer sleeve sidewall and couple the outer sleeve to the receptacle.

CROSS-REFERENCE TO RELATED APPLICATIONS

FIELD OF THE INVENTION

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.

BACKGROUND

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.

SUMMARY OF THE INVENTION

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.

DESCRIPTION OF THE INVENTION

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.

Referring generally to FIGS. 1-5, one embodiment of the present invention is directed to a container 10 which includes a receptacle 12, an outer sleeve 40, and an intermediate space 14 defined between the receptacle 12 and outer sleeve 40. While the container 10 may 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 sleeve 40 may be manufactured independently from the receptacle 12 and later applied to the receptacle 12.

As illustrated in FIG. 2, the receptacle 12 may be formed of a bottom wall 16 and a circumferential sidewall 18, with the exterior receptacle sidewall 18a including at least one outwardly projecting embossment 24 in the upper portion 22 below an upper edge of the receptacle 12, although other constructions are within the scope of the present invention. In a second embodiment, as illustrated in FIG. 7, the exterior receptacle sidewall 18a may further comprise a second outwardly projecting embossment 26 located above the first outwardly projecting embossment 24, both embossments 24 and 26 being spaced below an upper edge of the receptacle 12. The at least one outwardly projecting embossment(s) 24 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 18. The at least one outwardly projecting embossment 24 may be formed substantially continuously around the entire perimeter of the receptacle sidewall 18a, or multiple embossments 24 may be a plurality of spaced apart embossments, formed generally intermittently for example, around at least a portion of the perimeter of the receptacle sidewall 18.

In one embodiment, the receptacle 12 is constructed of paperboard material, and preferably coated paperboard, in order to resist the migration of liquids contained within the storage chamber 28. However, it will be appreciated that the receptacle 12 may be constructed of other materials, including but not limited to, polyethylene, polypropylene, polyethylene terephthalate (PET), or other materials suitable for use as a receptacle 12. The bottom wall 16 and receptacle sidewall 18 may be die cut from a larger sheet or roll (not shown) of material. As shown in FIGS. 2 and 7, the bottom wall 16 includes a depending skirt 30 secured to the receptacle sidewall 18 by a reverse bend 32 portion of the receptacle sidewall 18. Securement of the bottom wall 16 to the receptacle sidewall 18 may 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 bend 32 forms a footing upon which the container 10 may sit when in use. Construction of the receptacle 12 as just described is well known in the art.

The receptacle 12 preferably 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 receptacle 12 to the top edge of the receptacle 12. In one embodiment, the top edge of the receptacle includes an outwardly rolled upper lip 20 at the top edge thereof, which allows for nesting in storage and shipping. The receptacle sidewall 18 may be formed from a blank and wrapped around a mandrel. The receptacle sidewall 18 may include an overlapping seam (not shown) extending generally longitudinally between the top and bottom ends of the receptacle 12.

The seam (not shown) can be formed by adhering the overlapping margin portions of the receptacle sidewall 18 together 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 container 10 remain 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 sidewall 18 may be sealed to prevent the migration of liquids into the material comprising the receptacle sidewall 18. The container 10 of the present invention may have a storage chamber 28 volume on the order of, for example, about four (4) fluid ounces to about thirty-two (32) fluid ounces, although larger or smaller containers 10 may be made and are within the scope of the present invention.

As illustrated in FIGS. 1 and 5, an outer sleeve 40 surrounds and overlies a substantial portion of the receptacle sidewall 18. The outer sleeve 40 may be constructed from a suitable flat blank material and includes a circumferential sleeve sidewall 42, and an inwardly projecting upper lip 44 at the top end thereof. The outer sleeve 40 may also include an optional inwardly projecting fold 48, 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 space 14 along the entire height of the sleeve 40. The exterior of sleeve sidewall 42 may be suitable for having advertising, logos, and other graphics printed thereon.

In one embodiment, the sleeve sidewall 42 may include an outwardly projecting embossment 46 positioned below the inwardly projecting upper lip 44. The embossment 46 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 outer sleeve 40. In one embodiment, the embossment 46 is formed substantially continuously around the entire perimeter of the sleeve sidewall 42, while another embodiment comprises multiple embossments 46, formed generally intermittently for example, around the perimeter of the sleeve sidewall 42. The embossment 46 may 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 40. In one embodiment, the embossment 46 may be formed while the outer sleeve 40 is on a printing press or die cutter. The embossment 46 may 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 40. In another embodiment, the embossment 46 is formed by applying, adding, or forming additional material along the outer surface of the sleeve sidewall 42. The embossment 46 may also be formed by swelling or expanding the material forming the sleeve sidewall 42 in the area of the embossment 46 through, for example, causing moisture to be absorbed or adsorbed, in the paperboard or other material forming the sleeve 16.

In one embodiment, the outer sleeve 40 is preferably constructed of paperboard material; however, other materials including, but not limited to, polyethylene, polypropylene, PET, or other materials suitable for use as a receptacle 12 are within the scope of the invention. The outer sleeve 40 preferably 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 12. The sleeve sidewall 42 may be formed from a blank and wrapped around a mandrel. The sleeve sidewall 42 may include an overlapping seam (not shown) extending generally longitudinally between the top and bottom ends of the outer sleeve 40. The outer sleeve seam (not shown) can be formed by adhering the overlapping margin portions of the sleeve sidewall 42 together 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 container 10 remain 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 space 14 may be defined between the exterior receptacle sidewall 18a and the outer sleeve 40 in 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 space 14 may be formed of an air gap defined between the exterior receptacle sidewall 18a and the outer sleeve 40. This air gap can be formed, for example, by a standoff between the receptacle sidewall 18 and the outer sleeve 40 in the upper portion 22, created by an interaction between the inwardly projecting upper lip 44 of the outer sleeve 40 positioned above and engaging with the at least one outwardly projecting embossment 24 on the exterior sleeve sidewall 18a. The interaction between the inwardly projecting upper lip 44 of the outer sleeve 40 and the outwardly projecting embossment 24 creates a locking mechanism to secure the outer sleeve 40 in 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 lip 44 of the outer sleeve 40 positioned above the outwardly projecting embossment 24 and below the outwardly projecting embossment 26. In another embodiment, the locking mechanism may be achieved by the inwardly projecting upper lip 44 being positioned above and engaging with the at least one embossment of any number of embossments.

In another embodiment, the intermediate space 14 may 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 space 14 may 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 space 14 may 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 layer 14 may be secured or fixedly attached to the exterior receptacle sidewall 18a to prevent unraveling and to prevent relative movement in a longitudinal or axial direction.

The outer sleeve 40 may be disposed around and engaged with the receptacle sidewall 18 through a locking engagement in the upper portion 22 without the use of any adhesive, glue, sealant, melt, or the like required. In one embodiment, as demonstrated in FIGS. 2 and 3, the outer sleeve 40 is attached to the receptacle 12 through a locking engagement in the upper portion 22 of the exterior receptacle sidewall 18a such that the inwardly projecting upper lip 44 of the outer sleeve 40 engages with and is positioned above the outwardly projecting embossment 24. In another embodiment, as shown in FIGS. 7 and 8 the outer sleeve 40 is attached to the receptacle 12 through a locking engagement in the upper portion 22 of the exterior receptacle sidewall 18a such that the inwardly projecting upper lip 44 of the outer sleeve 40 engages with and is positioned between the outwardly projecting embossments 24 and 26. In other embodiments, the vertical placement of the outer sleeve 40 may be adjusted depending on the location(s) of the outwardly projecting embossment(s) 24, which consequently shall adjust the location of the interaction between the inwardly projecting upper lip 44 and the exterior sleeve sidewall 18a. It will be appreciated that, in other embodiments, the container 10 may not include an intermediate space 14, and securement of the outer sleeve to the receptacle sidewall 18 may also be adhesively attached to the exterior receptacle sidewall 18a.

As demonstrated in FIGS. 5 and 10, the embossment 46 of a first container 10a contacts or engages with the outwardly rolled upper lip 20 of a second container 10b to control the degree of nesting between the two containers. In that regard, the embossment 46 may have a diameter De that is larger than a diameter Do of an opening defined by the outwardly rolled upper lip 20. The inner container 10a is held up by its embossment 46 and not permitted to fall so far into the outer container 10b so as to become wedged therein. The embossment 46 causes a slight gap 34 between the containers 10a and 10b. Specifically, the gap 34 is defined between the outer surface of the sleeve sidewall 42 of the inner container 10a and the inner surface of the receptacle sidewall 18 of the outer container 10b. The gap 34 between two nested containers 10a and 10b can permit the void space beneath the inner container 10a to be in fluid communication with the atmosphere so as not to create a vacuum in the void space between the two containers 10a and 10b which may impede their separation from one another. Such resistance may result in multiple containers 10 sticking together when the user intends to grab only one from the stack. The gap 34 also prevents the two containers 10a and 10b from becoming wedged together in an interference fit. The height of the gap 34 and degree of nesting between stacked containers 10 is dependent upon the vertical placement of the embossment. For a greater height of the gap 34, the embossment 46 may be placed a greater distance from the inwardly projecting upper lip 44.