Abstract:
An insulation sleeve for a heated beverage cup. The sleeve is formed from spathes of a raw husk material, such as corn husk. The spathes are attached such that end portions of the spathes overlap to form a generally circular form sized to fit about and vertically support a typical frustoconical beverage cup. The sleeve may be further formed to have a generally frustoconical shape to fit the corresponding frustoconical shape of the beverage cup. The spathes may be dampened to assist in forming the sleeve into the circular or frustoconical shape.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application No. 61/421,783 filed Dec. 10, 2010, which is hereby incorporated by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present disclosure relates generally to beverage containers, and more specifically, to an insulation sleeve for a heated beverage cup. 
       BACKGROUND 
       [0003]    Various types of disposable cups are known in the art for use with beverages. In order to reduce manufacturing costs and shipping weight, such cups are typically thin and do not provide sufficient insulation to protect a user&#39;s hand when holding a hot beverage, such as coffee or tea. To combat this problem, insulating sleeves are typically made available at the place of purchase for use with the cup. However, the sleeves have a detrimental impact on the environment due to the increased energy and environmentally harmful processes required to manufacture the sleeve material, which typically consists of cardboard or polystyrene. Furthermore, even paper-based sleeve materials such as cardboard are not fully biodegradable and require costly procedures in order to be safely recycled or disposed of. Improved cup sleeves are therefore needed which provide sufficient insulation and, at the same time, have a reduced environmental impact in relation to both manufacturing and disposal. 
       SUMMARY 
       [0004]    According to one aspect, an insulation sleeve for holding a frustoconical beverage cup is disclosed. The insulation sleeve comprises a first husk spathe and a second husk spathe, the first and second spathes having an elongated shape. The end portions of the first and second spathes are attached together in a partially overlapping arrangement to form a substantially circular shape. An interior diameter of the sleeve is sized to fit about an exterior diameter of the frustoconical beverage cup such that the sleeve vertically supports the frustoconical beverage cup when held by a user. The insulation sleeve may be configured in a frustoconical shape to substantially correspond to the frustoconical beverage cup. The insulation sleeve may be pressed upon a frustoconical molding device to achieve the frustoconical shape. To assist in the forming process, the spathes may be dampened before or during assembly of the insulation sleeve. The spathes may be attached together using thread or adhesive, or other fasteners known in the art. A graphic may be applied to an exterior surface of the sleeve. 
         [0005]    According to another aspect, a method of manufacturing an insulation sleeve for a beverage cup is disclosed, comprising attaching a first end of a first corn husk spathe and a second end of a second corn husk spathe in a partially overlapping fashion, and attaching a third end of the first corn husk spathe to a fourth end of the second corn husk spathe in a partially overlapping fashion to form a substantially circular shape. An interior diameter of the sleeve is sized to fit about an exterior diameter of the frustoconical beverage cup such that the sleeve vertically supports the beverage cup when held by a user. The method may also include pressing the first and second spathe onto a frustoconical molding device to form the sleeve into a substantially frustoconical shape and/or dampening the first and second corn husk spathes to assist in the forming process. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  depicts a front view of an insulation sleeve installed about a beverage cup according to one embodiment of the present disclosure. 
           [0007]      FIG. 2  depicts a front view of two spathes of a husk material in a first stage of assembly of the insulation sleeve of  FIG. 1 . 
           [0008]      FIG. 3  depicts a front view the two spathes of a husk material in a second stage of assembly of the insulation sleeve of  FIG. 1 . 
           [0009]      FIG. 4  depicts a front view of two spathes of a husk material in a third stage of assembly of the insulation sleeve of  FIG. 1 . 
           [0010]      FIG. 5  depicts a front view of two spathes of a husk material in a fourth stage of assembly of the insulation sleeve of  FIG. 1 . 
           [0011]      FIG. 6  depicts a perspective view of the insulation sleeve of  FIG. 1  in a fifth stage of assembly. 
           [0012]      FIG. 7  depicts a front view of the insulation sleeve of  FIG. 1  being molded upon an inverted frustoconical molding device. 
           [0013]      FIG. 8  depicts a top view of an insulation sleeve according to a further embodiment of the present disclosure. 
           [0014]      FIG. 9  depicts a perspective view of an insulation sleeve according to a further embodiment of the present disclosure. 
           [0015]      FIG. 10  depicts a top view of an insulation sleeve which has been collapsed to a substantially flat form. 
           [0016]      FIG. 11  depicts a perspective view of a plurality of insulation sleeves stacked in a nested column arrangement. 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0017]    For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, and alterations and modifications in the illustrated device, and further applications of the principles of the invention as illustrated therein are herein contemplated as would normally occur to one skilled in the art to which the invention relates. 
         [0018]    Referring to  FIG. 1 , there is shown a front view of an insulated sleeve  10  for a beverage cup  15  according to a preferred embodiment of the present disclosure. The sleeve  10  is formed from a raw husk material, such as a corn husk. Because the husk material is completely non-toxic, biodegradable, and typically considered a waste product from existing farming operations, it has very little impact on the environment from both a manufacturing and disposal perspective. As discussed further below, the sleeve  10  is formed in a generally circular form to fit around a typical frustoconical beverage cup, such as those used in many fast food restaurants and coffee shops. The sleeve  10  may further be formed in a generally frustoconical or downwardly-tapering shape and sized to correspond to the frustoconical beverage cup. 
         [0019]    The sleeve  10  is preferably formed by stacking a first husk spathe  20  and a second husk spathe  25  in an opposing partially overlapping fashion as shown in  FIG. 2 , with the naturally narrowing end portions  22  and  27  of the spathes overlapping. The spathes  20  and  25  may preferably be dampened with water or steam in order to allow greater flexibility and prevent cracking during the assembly process. Additional spathes may be used to form layers within the sleeve and increase the insulative effect. 
         [0020]    Next, the upper edges  30  and  35  and lower edges  40  and  45  are folded inward to form flaps  50 ,  55 ,  60 , and  65  as shown in  FIG. 3 . The desired height of the sleeve  10  may be achieved by adjusting the amount of material used to form the flaps. The flaps  50 ,  55 ,  60 , and  65  serve to provide reinforced edges  51 ,  56 ,  61 , and  66  which are less prone to tearing and less likely to irritate or cut a user&#39;s fingers. The flaps also create additional air pockets which contribute to the insulating effect of the sleeve  10 . 
         [0021]    Stitching  70  and  75  may be applied as shown to hold the flaps  50 ,  55 ,  60 , and  65  flat against the central body portions  23  and  28  of spathes  20  and  25  and maintain the relative arrangement of the spathes  20  and  25 . The stitching  70  and  75  is preferably made of cotton thread, although other types of thread material may be used. The stitching  70  and  75  is preferably done in a zigzag pattern to provide additional protection against tearing of the husk material. Other types of stitching may also be used, such as chain stitching and lock stitching. In certain embodiments, the stitching is applied in vertical strips as shown in  FIG. 3 . In other embodiments, stitching  71  and  76  is applied in an overall horizontal or angled direction, following the edges of the spathe material, as shown in  FIG. 4 . 
         [0022]    In other embodiments, an adhesive may be applied to an interior surface of the flaps  50 ,  55 ,  60 , and  65  to secure the flaps to the body portions  23  and  28 . The adhesive is preferably a water-based food-grade adhesive having suitable flexibility to maintain adhesion as the sleeve  10  flexes during assembly, shipping and use. The adhesive may also be applied between the overlapping portions  29  of the spathes  20  and  25  to secure the spathes  20  and  25  together. It still further embodiments, the adhesive may be applied to the entire spathes  20  and  25  to provide a smooth and more comfortable coating when handled. The adhesive may also be used to soften the spathes  20  and  25  instead of or in addition to water. 
         [0023]    Turning to  FIG. 5 , the spathes  20  and  25  are formed into a generally circular shape, with the end portions  80  and  85  in close proximity to one another. The end portion  85  is then tucked into the end portion  80  such that the flaps  50  and  60  partially enclose the end portion  85 . Stitching  90  may then be applied through the spathes  20  and  25  as shown to secure the end portion  85  within the end portion  80  as shown in  FIG. 6 . In other embodiments, an adhesive may be applied to the end portion  85  to secure the end portions  80  and  85  together. The end portions  80  and  85  may be held together using sufficient pressure for a sufficient time to allow the adhesive to set up and maintain the bond between the end portions  80  and  85 . 
         [0024]    Turning to  FIG. 7 , the sleeve  10  may be formed into a frustoconical shape by placing the dampened sleeve  10  onto a frustoconical molding device  95  with sufficient pressure to stretch the husk material and allow it to partially dry. The molding device  95  may be sized to match the size and shape of the drinking cups which will eventually be used with the sleeve  10 . In one embodiment, the molding device  95  may comprise a frustoconical drinking glass placed upside down. Drying time may be decreased by applying hot air to the sleeve  10  while still mounted on the molding device  95 . In certain embodiments, the sleeve  10  may be removed from the molding device before drying in order to increase production speed. In such cases, the overall diameter of the dampened sleeve  10  and molding device  95  may be optionally increased to account for shrinkage that can occur as the spathes  20  and  25  dry out. In certain embodiments, stitching  90  may be applied after forming the sleeve  10  onto the molding device  95  in order to further encourage the sleeve to maintain the frustoconical shape once the stitching  90  is applied. If adhesive is used, the sleeve  10  may be placed onto the frustoconical molding device  95  before the adhesive is set up or cured, allowing the adhesive to develop its bond while the sleeve  10  is held in the frustoconical shape. It shall be understood that molding devices having shapes other than a frustoconical shape may also be used, such as cylinders or other suitable sleeve shapes. 
         [0025]    In other embodiments, instead of tucking the end portion  85  into the flaps  50  and  60 , the end portions  80  and  85  may simply be overlapped as shown in  FIG. 8 . Adhesive may then be applied to the mating surfaces  81  and  86  in the overlap area  87  before or while the sleeve  10  is being applied to the frustoconical molding device  95  to secure and maintain the frustoconical shape of the sleeve  10 . 
         [0026]    Once dry, the sleeve  10  will tend to retain its circular and frustoconical shape. In addition, the dried husk material will provide increased insulative properties, due to the air gaps formed between the cup and the naturally-uneven splined surface of the husk. The sleeve  10  is durable enough to be reused multiple times, although eventual disposal of the sleeve has very little impact on the environment, as the husk material will naturally decompose once exposed to soil or other natural waste environment. 
         [0027]    The rigidity and texture of the dried sleeve  10  also provides a suitable surface to apply a graphic, logo, or other advertising material using ink. Various types of ink or dye may be used, including solvent-based and water-based inks In a preferred embodiment, pad printing may be used to apply the graphic to the sleeve  10 . In addition to ink-based processes, the graphic may be applied using laser etching, heat branding (burning), dry film, decals, or other processes known in the art. The graphic or logo may also be embroidered or sewn into the husk material. 
         [0028]      FIG. 9  shows another embodiment wherein the end portions  80  and  85  are not tucked or overlapped, but rather are gathered against one another by contacting the interior end surfaces of both spathes  20  and  25  as shown. This allows stitching  100  to be easily applied across the gathered portions of the spathes, since the sewing apparatus does not need to be inserted through the interior cavity of the sleeve  10 . Once the stitching  100  has been applied, the excess portion  105  which is outside of the stitching  100  may be trimmed off to provide a more uniform circular shape if desired. Alternatively, the excess portion  105  may be left in place in order to form the basis for a handle or an additional area to place a graphic or advertising message. 
         [0029]    In certain embodiments, the sleeve  10  may be collapsed into a fully or partially flattened arrangement while still damp in order to allow for more compact shipping and storage as shown from a top view in  FIG. 9 . When ready for use, the collapsed sleeve  10  may be expanded and restored to its circular or frustoconical shape. In other embodiments, the sleeve  10  may be left in a frustoconical shape during shipping with multiple sleeves  10  nested into columns  103  as shown in  FIG. 10 , or simply placed loosely within a container, such as a biodegradable burlap bag. 
         [0030]    While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiment has been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.