Spout unit, lid assembly comprising the spout unit, beverage container and method for manufacturing the spout unit

The present invention provides a spout unit for dispensing beverage in a beverage container, including a spout and a reinforcement unit overmolded with the spout. The reinforcement unit includes a device for reinforcing interlocking of the reinforcement unit with the spout, for example shut off holes and/or depressions, at least a pair of tabs, and one or more outwardly facing longitudinal grooves. This invention also relates to a lid assembly including the spout unit, and a beverage container assembly including such a lid assembly. Furthermore, this invention provides a method for manufacturing the spout unit.

FIELD OF THE INVENTION

This invention relates generally to a spout unit for dispensing beverage in a beverage container, and in particular a spout unit comprising a mouthpiece that is prevented from releasing from the spout unit. This invention also relates to a lid assembly comprising the spout unit, and a beverage container assembly comprising such a lid assembly. Furthermore, this invention provides a method for manufacturing the spout unit.

BACKGROUND OF THE INVENTION

Beverage containers with a spout unit facilitate a user to drink any time beverages held in the container. Given a variety of beverages, such as water, soup, milk, juice, soft drinks, coffee, tea or shakes, are commonly consumed, a high tolerance of the spout unit under various temperature, pH value is required. While repeated washing is required for beverage containers, in particular sterilization with hot water, steam or microwave, durability is an important aspect for consumers of such products. For beverage container designated for infants or kids, abused use of the spout unit of the beverage container shall be considered.

Presently, the spout unit comprises a soft spout having a mouthpiece and a base coupled with the spout. The soft spout protrudes beyond a body of the lid for dispensing of the contents inside the beverage container and for better comfort. Generally, a bonder is applied to bond the base and the spout in surface contact manner. There is no interlocking structure or feature to permanently adhere the base and the spout together. Therefore, the spout can be easily released from the base subject to the repeated and/or abused use of the beverage container assembly.

Accordingly, there is a need for designing a spout unit with higher strength and increased twisting torque to prevent releasing or separation of the spout from the base.

SUMMARY OF THE INVENTION

The present invention has a principle object of providing a spout unit use in conjunction with a lid for a beverage container, comprising a device for reinforcing to achieve higher strength and resistance to twisting and tearing.

This and other objects are satisfied by a first aspect of the present invention, which provides a spout unit for dispensing beverage in a beverage container, comprising:

a spout comprising a mouthpiece having a dispensing orifice, and a neck extending downwardly from the mouthpiece,

a reinforcement unit overmolded with the spout, wherein the reinforcement unit comprises:

a main body having a top wall and a receiving chamber,

a linking portion extending from the main body to protrude beyond the top wall of the main body for engaging the spout, the linking portion having a bore which extends through the linking portion and is in fluid communication with the dispensing orifice of the spout, and

a device for reinforcing structurally interlocking of the reinforcement unit with the spout.

The essence of the invention is to reinforce the interlocking of the reinforcement unit with the spout in the structural sense. In one embodiment, the device for reinforcing may include one or more shut off holes and/or depressions adapted to receive flow of material from the spout in the overmolding process, and the flow of material forms one or more ridges on an outer side surface of the neck of the spout, thereby generating interlocking of the spout and the reinforcement unit. Preferably, the shut off holes and/or depressions are distributed circumferentially on the top wall. In order to improve the interlocking of the spout and the reinforcement unit, the device for reinforcing may include at least a pair of tabs extending transversely from opposite outer side wall surfaces of the linking portion, the pair of tabs being positioned to engage a pair of inwardly facing grooves opposite to and facing each other on the two opposite inner side walls of the spout. In one preferred embodiment of the invention, two pairs of tabs extend transversely from opposite outer side wall surfaces of the linking portion, respectively, each of the pairs of tabs being positioned to engage a pair of inwardly facing grooves opposite to and facing each other on the two opposite inner side walls of the spout.

In some cases, one or more outwardly facing longitudinal grooves may be formed axially in each of the tabs, the one or more longitudinal grooves adapted to receive flow of material from the spout in the overmolding process, and the flow of material forms one or more ribs on an inner side wall of the mouthpiece of the spout. Such features can provide additional structure for interlocking of the spout and the reinforcement unit.

In one embodiment of the invention, the reinforcement unit may comprise a first bulge and a second bulge provided on opposite side walls of the main body thereof, the first and second bulges configured as a first pivot and a second pivot for pivotably mounting the spout unit on the lid body.

In one embodiment of the invention, the receiving chamber may comprise a pair of lateral slots opposite to and facing each other on two opposite inner sides of the receiving chamber.

Preferably, the spout and the reinforcement unit are overmolded as a unitary structure. The spout may be made of a flexible material, and the reinforcement unit may be made of a rigid material. In one embodiment of the invention, the spout comprises silicon material, and the reinforcement unit comprises nylon material.

A second aspect of this invention provides a lid assembly coupled to a beverage container for covering an opening of the beverage container, comprising a lid comprising a lid body adapted to be placed over and coupled to the opening of the container, and a spout unit according to this invention.

In one particular embodiment of the invention, the lid assembly may further comprise a drinking straw having one end portion received in the receiving chamber of the main body of the reinforcement unit and in fluid communication with the mouthpiece of the spout. The receiving chamber comprises a pair of lateral slots opposite to and facing each other on two opposite inner sides of the receiving chamber, and the pair of slots are adapted to engage the end portion of the drinking straw.

In one preferred embodiment of the invention, the lid assembly may further comprise a cover member pivotably mounted on the lid body and pivotal between a locked position where the spout unit is allowed to fold into a stowed configuration, and an unlocked position where the cover member pivots upwardly, thereby allowing the spout unit to unfold into a dispensing configuration for dispensing the beverage. A locking unit may be pivotally mounted on the lid body for locking the cover member in the locked position when the locking unit is engaged with the cover member and unlocking the cover member when the locking unit is disengaged from the cover member.

A third aspect of the present invention provides a beverage container assembly comprising a beverage container having an opening, and a lid assembly according to this invention for coupling to the opening of the container.

A fourth aspect of the present invention relates to a method for manufacturing a spout unit according to this invention, comprising the steps of:(a) injection-molding the reinforcement unit,(b) heating the injection-molded reinforcement unit at a predetermined temperature for a period of time,(c) placing the heated reinforcement unit in an overmolding mold,(d) applying a material of the spout into the overmolding mold for overmolding the spout around the linking portion of the reinforcement unit, and(e) demolding the overmolded spout unit.

In one embodiment, the method further comprises a step of applying a primer onto at least a part of the reinforcement unit intended to come into contact with the spout prior to the step (b) of heating. The part of the reinforcement unit to be in contact with the spout may be selected from the group consisting of the top wall, the tabs, the shut off holes or depressions, the grooves and any combination thereof.

Step (b) of heating may be conducted at a temperature between 120° and 200°, preferably between 130° and 180° for 10 to 30 minutes, preferably for 20 minutes.

The method may further comprises a step of trimming and inspecting the overmolded spout unit.

DETAILED DESCRIPTION OF THE INVENTION

While the present invention is illustrated and described in preferred embodiments, the spout unit of the present invention may be produced in many different configurations, sizes, forms and materials to assemble with the lid assembly for dispensing beverage in a beverage container.

Referring now to the drawings,FIGS. 1 to 5Cillustrate a beverage container assembly1comprising a spout unit of the invention. As illustrated, the container assembly1comprises a container2having a top opening, and a lid assembly3connected to the container2for covering the top opening. The container2is used to contain or store contents such as liquid and may be of any type known in the art. The lid assembly3comprises a lid body31, a spout unit5mounted in the lid body31, and a cover member32pivotally mounted on the lid body31.

The lid body31is adapted to be removably attached to the opening of the container. As shown inFIG. 1, the lid body31has a window formed therethrough and is molded integrally from, for example, a plastic material. The window is provided to receive and engage with the spout unit5, which will be discussed hereinbelow. The lid body31has internal threads for mating engagement with corresponding threads formed on an outside of the opening of the container2.

Now turning toFIGS. 2A to 5C, there is illustrated the spout unit5constructed consistent with a first embodiment of the invention. The spout unit5comprises a spout51and a reinforcement unit52coupled with the spout51. In this embodiment, the spout51and the reinforcement unit52are overmolded as a unitary structure. The spout51may be made of a flexible material, e. g. silicon material; and the reinforcement unit52may be made of a rigid material, e. g. nylon material.

The reinforcement unit52comprises a main body527of a substantially rectangular frame having a top wall526and a receiving chamber54inside the main body527. The receiving chamber54comprises a pair of lateral slots541opposite to and facing each other on two opposite inner sides of the receiving chamber. The reinforcement unit52further comprises a linking portion523extending from the main body527to protrude beyond the top wall526of the main body527for engaging the spout51. As shown inFIGS. 3A and 3B, the linking portion523has a bore5232which extends through the linking portion526.

One of the features of the invention is that the reinforcement unit52comprises device for reinforcing interlocking of the reinforcement unit with the spout51to increase twist and pull strength for the spout51, and thereby prevention of separation of the spout51from the reinforcement unit52. As illustrated inFIGS. 3A and 3B, device for reinforcing in this embodiment comprises four shut off holes525adapted to receive flow of silicon material from the spout in the process of overmolding the spout51with the reinforcement unit52. The shut off holes525are distributed circumferentially at an equal angular interval on the top wall526. The device for reinforcing further comprises a pair of tabs5231extending transversely from opposite outer side wall surfaces of the linking portion523adjacent to a top surface of the linking potion523.

Turning toFIGS. 4A to 4C, there is illustrated the spout51engageable with the reinforcement unit. As illustrated, the spout51comprises a mouthpiece511having a dispensing orifice53and a neck512extending downwardly from the mouthpiece511. The dispensing orifice53of the mouthpiece is in fluid communication with the bore5232of the linking portion523. The neck512may extend into the receiving chamber54of the reinforcement unit52. The spout unit5is mounted in the lid body such that the mouthpiece511protrudes beyond the lid body31, and the reinforcement unit52is pivotally mounted in the lid body31to enable pivotable movement of the spout51between a dispensing configuration and a stowed configuration, which will be discussed herein below.

In this embodiment, the spout51is formed by overmolding with the reinforcement unit52. In the overmolding process, the silicon material of the spout51flows into the four shut off holes525of the reinforcement unit52and form, respectively, four ridges513on the outer side surface of the neck512of the spout51. The ridges513create respectively four circumferential seals on the top between the reinforcement unit52and the spout51. The spout51further comprises a pair of inwardly facing grooves514opposite to and facing each other on the two opposite inner side walls thereof. The pair of grooves514are positioned to be engageable with the pair of tabs5231of the linking portion523. The engagement of the two tabs5231with the grooves514further enhances the interlocking between the reinforcement unit52and the spout51. It would be within the ability of a person skilled in the art that, in order for further strengthen the interlocking of the spout51and the reinforcement unit, a second pair of inwardly facing grooves opposite to and facing each other on the two other opposite inner side walls of the spout51may be provided and positioned to be engageable with a second pair of tabs of the linking portion523.

FIGS. 5A to 5Cshow respective cross-sectional views of the spout51, and the reinforcement unit52, and their interlocking assembly. As illustrated, the silicon material of the spout51flows into the shut off holes525extending through the top wall526of the reinforcement unit52to establish a first interlocking feature, that is, the silicon flow forms the ridges513. The pair of opposite tabs5231of the linking portion523of the reinforcement unit52engage the grooves514of the spout51, which establishes a second interlocking feature. These two interlocking features can improve the strength onto the spout51and the twisting torque between the spout51and the reinforcement unit52.

The reinforcement unit52comprises a first bulge521and a second bulge522provided on opposite side walls of the main body527thereof. The first and second bulges521,522are configured as a first pivot and a second pivot for pivotably mounting the spout unit5on the lid body31(seeFIGS. 6A and 6B). Because of the two pivots, the spout unit5is able to pivot relative to the lid body31.

FIGS. 6A to 7Cillustrate a spout unit constructed consistent with a second preferred embodiment of the present invention. The spout unit of this embodiment is structurally same as the one shown in the first embodiment above, except the following:the linking portion524has an increased height compared with the linking portion523of the first embodiment discussed above, the increased height of the linking portion may further enhance the pull strength of the spout; andone or more outwardly facing longitudinal grooves5244are formed axially in each of the tabs514of the linking portion524, the one or more longitudinal grooves5244adapted to receive flow of material from the spout in the overmolding process to form ribs on an inner side wall of the mouthpiece of the spout; and the ribs may further enhance the pull strength and the twisting torque of the spout unit of this embodiment.

Now turning toFIGS. 6A to 6C and 7A, the linking portion524has a greater length in an axial direction, and two pairs of tabs5241extend transversely from opposite outer side wall surfaces of the linking portion524, respectively. Each pair of tabs5241is positioned to engage a pair of inwardly facing grooves514opposite to and facing each other on the two opposite inner side walls of the spout51. As shown clearly inFIGS. 6A, 6B and 6C, one pair of the tabs5241each has an outwardly facing longitudinal grooves5244formed axially in the tab, and the longitudinal grooves5244are adapted to receive flow of silicon material from the spout51in the overmolding process. The flow of silicon material forms ribs on an inner side wall of the mouthpiece511of the spout51. The engagement of the ribs and the longitudinal grooves provides an additional improvement related to the interlocking between the spout51and the reinforcement unit52.

These kinds of interlocking features in the second embodiment help to further strengthen the interlocking between the spout51and the reinforcement unit52to prevent the spout from detachment from the reinforcement unit52.

As shown inFIGS. 8A and 8B, the lid assembly3further comprises a drinking straw56having one end portion coupled with the spout unit5and in fluid communication with the mouthpiece511of the spout51. With reference toFIGS. 8A and 8B, the end portion of the drinking straw56is snugly received in the pair of inwardly facing lateral slots541of the receiving chamber54of the reinforcement unit52. A retaining ring55is arranged between the inner wall of the main body527of reinforcement unit52and the drinking straw56to secure the drinking straw56inside the receiving chamber54and prevent displacement of the end portion of drinking straw56received in the spout unit.

To implement the locking and the unlocking of the cover member32, a locking unit60is provided on the lid body31. With reference toFIG. 1, the locking unit60is mounted on the lid body31on an opposite side to the pivotal point about which the cover member32pivots. The locking unit60comprises a push button61mounted on the lid body31and having a locking block64engageable with a locking seat321arranged on the cover member32. The locking unit60further comprises a linkage62operably connected with the push button61, and a compression spring63mounted between the linkage62and the lid body31, as can be seen inFIGS. 8A and 8B. The linkage62has a hook65engageable with a recess57formed on the main body of the reinforcement unit52. When an inward pressure is applied onto the push button61, it would cause the locking block64to move inwardly, with a result of the locking block64disengaging from the locking seat321of the cover member32and at the same time of the hook of the linkage62disengaging from the recess57of the main body of the reinforcement unit52, so that the cover member32is switched to the unlocked position accompanied with the unfolding of the spout unit into the dispensing configuration where the drinking straw56is unfolded to allow fluid communication between the mouthpiece511of the spout unit and the interior of the container2(seeFIG. 8A). To close the container assembly1, the spout unit5is pressed to fold downwardly into the stowed configuration where the drinking straw56is caused to bend to block the fluid pathway between the mouthpiece511of the spout unit and the interior of the container2(seeFIG. 8B). The cover member32is then pressed down so that the locking seat321pivots downwardly to engage the locking block64.

FIG. 10illustrates a method for fabricating the overmolding structure of the spout unit5, the method comprising injection-molding the reinforcement unit of predefined structure and dimension (step101). After the injection-molding of the reinforcement unit is finished, the reinforcement unit is released from the injection mold, and a primer is applied onto at least a part of the reinforcement unit intended to come into contact with the spout, including the top wall, the tabs, the shut off holes, the grooves or any combination thereof. The primer may include glues or adhesives. The reinforcement unit with the applied primer is then put in an oven and heated at a temperature between 130° C. and 180° C., preferably 150° C. for about 15 to 25 minutes (step103). The heated reinforcement unit is placed in an overmolding mold (step104), and a silicon material is applied into the overmolding mold for overmolding the spout around the linking portion of the reinforcement unit (steps105and106). After the overmolding is finished, the unitary structure of the reinforcement unit and the spout is demolded from the overmolding mold (step107), followed by the step of trimming and inspecting the overmolded spout unit (step108).

The primer is applied to at least part of the reinforcement unit to enhance the coupling between the reinforcement unit52and the spout51, such that the twisting and tearing strength can be further increased. The primers that are known in the art, for example YB-SS-7510, can be employed to the molded reinforcement unit.

Assays

Assays were carried out for testing and verifying the twist and pull strength of the spout units with different variations according to the invention. Some of the variations of the spout units are shown inFIG. 9and include the following:Variation B1: the neck512of the spout51is configured to extend downward further.Variation B2: the length of the linking portion523,524is increased with increased thickness of the mouthpiece.Variation B3: the top wall of the linking portion523,524is configured to move closer towards the top edge of the main body527.Variation B4: additional pair of tabs5231,5241is provided.Variation B5: longitudinal grooves5244are formed in the tabs of the linking portion523,524.Variation B6: the diameter of shut off holes525is increased.

Variations B1-B3 and B6 are devised to accommodate more material of the spout51, and variation B4-B5 are devised to increase interlocking feature and interlocking surface area.

A series of samples of spout units were prepared for use in the following tests by the method of the invention discussed above, using ASCEND Vydyne 21 SPC PA66 resin as the nylon material for the reinforcement unit, POLYSIL LIM-9050D as the silicon material for the spout51. The reinforcement units of these samples were fabricated to have four shut off holes comprising a first pair of front-back shut off hole and a second pair of left-right shut off holes shown in table 1.

TABLE 1Dimensions of shut off holesPosition of the holesWidth (mm)Length (mm)Front-Back shut off holes2.187.0Left-Right shut off holes3.96.4

In the assays, a mixture of YB-SS-7510A and YB-SS-7510B is used as the primer. The pulling test, twisting test and/or tearing test methods were employed in accord with industrial standard of CFR requirements.

Spout units having variation B5 were tested for their tearing strength. Six samples of spout units of identical structure were fabricated, with a same reinforcement unit in which the longitudinal grooves5244are provided on the front-back tabs of the linking portion. No primer was applied to these six samples.

The results are shown in table 2.

TABLE 2Tearing Test results of spout unitsSampleCW* (Nm)CCW* (Nm)Tear off positionA1.010.92Front side edge minor tearB1.010.89Front edge tearC0.970.89Back side edgeD0.990.84Back side edge minor tearE1.011Front side edge minor tearF0.991Front edge tear*CW—clockwise; CCW—counter clockwise

The above results reveal that improved tearing strength was conferred on the spouts in the spout units by the features of the shut off holes and the longitudinal grooves.

Spout units having variations B2, B4 and B5 were tested for their twist torque and pulling strength. Some samples of spout units of identical structure were fabricated, with a same reinforcement unit which comprises the same elongated linking portion524. The elongated linking portion524is provided with the same longitudinal grooves5244provided on the front-back tabs of the linking portion and an additional pair of tabs5241on the outer side wall surfaces of the elongated linking portion524.

Tests were performed on the samples of spout units with and without primer.

The results are shown in tables 3 and 4.

The data shown in tables 3 and 4 reveals that the spout units5having the features of the elongated linking portion524with additional tabs5241and longitudinal grooves5244exhibit a substantially increased performance in terms of twist torque and pulling strength. Application of the primer is found to further increase the interlocking strength and the twisting torque between the reinforcement unit and the spout.

While the above described are preferred embodiments of the spout unit of the present invention with what is presently considered to be the most practical and preferred arrangement, it should be appreciated that the invention is not limited to the disclosed embodiments, and is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the claims. Modifications and variations in the present invention may be made without departing from the novel aspects of the invention as defined in the claims, and this application is limited only by the scope of the claims.