Patent Publication Number: US-2022212838-A1

Title: Fibrous Lid With High Polymer Mating Region

Description:
PRIORITY CLAIM 
     This application claims priority to international application no. PCT/US2020/033643 filed May 19, 2020, U.S. provisional application Ser. No. 62/850,312 filed May 20, 2019, GB1907921.9 filed Jun. 4, 2019 and issued as GB2584640, and U.S. Utility application Ser. No. 16/694,795, filed Nov. 25, 2019, the disclosures of each of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The field of the invention is lids for drinking cups. 
     BACKGROUND 
     The following description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art. 
     Many people enjoy having coffee, tea, or other beverages, and it is well known to imbibe such drinks from a disposable paper cup. Such cups are typically constructed from paper having a thin inner plastic coating. One example is shown in U.S. Pat. No. 6,926,197. Such cups can also be made entirely of plastic, but paper is more environmentally friendly than plastic. 
     The U.S. Pat. No. 6,926,197 patent, and all other extrinsic materials discussed herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. 
     Paper-based cups have several disadvantages. For example, paper tends to absorb liquid, resulting in deformation of the cup. Wax-coated paper cups are advantageous in that they tend to resist deformation, however, their popularity diminished because wax can melt with hot liquids, and wax coatings tend to be too thick. 
     It is well known to make paper coffee cups with very thin plastic coatings. For example, US20070170236A1 teaches a cup made of a plastic-coated paper. Such cups provide several advantages. First, the plastic does not melt. Second, the plastic protects paper-based cups from liquid exposure. 
     Regarding lids, it is known in some instances to use a paper lid for a paper container. For example, U.S. Pat. No. 1,952,401 teaches a paper lid for an ice cream container. This paper lid is satisfactory for its intended purpose, but would not work well for a paper coffee cup because it provides an inadequate seal. A lid for the coffee cup must be closed tightly to provide a secure seal, because liquid would press against the lid when a person tilts the cup for drinking. A paper lid for an ice cream container works sufficiently well because one does not normally tilt the ice cream container with its lid attached. And also ice cream is solid, not liquid. A second reason that a paper lid is dysfunctional for a coffee cup is that as the lid absorbs liquid, even to a small extent, such absorption might well weaken the lid sufficiently to negatively impact the seal. For these and probably other reasons, the vast majority of lids for paper drinking cups are made entirely of plastic. 
     U.S. Pat. No. 4,589,569 teaches a plastic lid. Such lids work well with typical paper drinking cups, but are unsatisfactory with respect to environmental effects. Plastic pollution is currently one of the greatest environmental concerns, harming all manner of plants, oceans, animals, and humans. It can take hundreds or even thousands of years for plastic to break down, so the damage to the environment is long-lasting. It has been reported that about 16 billion plastic lids are used on disposable coffee cups each year. The European Union is moving forward on banning single-use plastic stirrers and plates by 2021. It is time for us to seriously consider how to reduce the amount of single-use plastic and maintain our environment clean and safe. 
     Recognizing that paper or mostly paper lids provide inadequate seals, Japanese patent application JPH09301394A and Korean patent application KR20070025299A each teach lids for drinking cups that have paper or mostly paper tops, and entirely plastic sides. Although adequate to reduce the amount of plastic in the lids, those designs introduce significant additional costs and complexity to mate the paper tops with the plastic sides, and even so fail to adequately reduce the amount of plastic utilized. 
     The basic problem is that “the perfect is the enemy of the good”. People keep trying to make a lid that is entirely fibrous material, i.e., with no plastic whatsoever. That may happen in the future, but in the meantime an awful lot of plastic is thrown away in plastic lids. What is needed right now is a lid made mostly of paper or other fiber-based material, but has sufficient plastic to provide an adequate seal for a coffee cup or other paper (or mostly paper) container. 
     SUMMARY OF THE INVENTION 
     The inventive subject matter provides apparatus, systems, and methods in which a lid is made mostly of paper or other fiber-based material, both in the body and side portions, both potentially having a polymer coating, but with an extra coating or layer of polymer about the side portion to provide an improved seal. 
     As used herein, the side portion of the lid refers to that part of the lid which descends from the body of the lid, and which is sized and dimensioned to mate with an upper rim bead of a cup. The side portion preferably has an annular indentation or bump, with a depth or protrusion of at least 0.5 mm, more preferably at least 1.0 mm, and most preferably at least 1.5 mm. The side portion is preferably flared to assist a user in positioning the lid onto the top upper rim bead of a cup. 
     Preferred lids contain no more than 10 wt % of polymer material, more preferably no more than 5 wt % polymer, and still more preferably no more than 1 wt % polymer. 
     As technical improvements, the extra coating or layer of polymer about the mating portion provides additional stiffness, and in some cases additional fluid resistance, to the lid, all while reducing the total polymer percentage used in the lid. The extra coating or layer of polymer is at least 0.1 mm thick, more preferably at least 0.2 mm thick, and most preferably at least 0.3 mm thick. The extra coating or layer of polymer can be positioned medially, laterally, in a sandwich manner, or in any combination thereof, relative to the paper or other fibrous material contained in the mating portion. 
     Contemplated polymer materials include polyethylene, polydiketoenamine, polypropylene, polyethylene terephthalate, high-density polyethylene, polyvinyl chloride, low-density polyethylene, ultra-high-molecular-weight polyethylene, and any combination thereof. In some embodiments, the polymer is a natural polymer (e.g., cellulose), a biodegradable polymer, or a compostable polymer, and is preferably water resistant or water impermeable. In some embodiments, the polymer is heat resistant up to 100° C. 
     Preferred lids have a drinking hole disposed in a raised portion of the body, towards its radial edge, and in some cases a separate air hole. A polymer coating is preferably disposed on an upper surface of the body, either about its entire upper surface, or at least about least 5 mm about the drinking hole. Preferred lids also have a polymer coating disposed about the entire underside or interior surface of the body, or at least 90%, 80%, 70%, 60%, 50%, 40%, or 30% of the underside or interior surface, preferably extending from the radial edges inward toward the center of the body, or extending from the radial edge proximal to the drinking hole and extending toward the opposite radial edge of the body. 
     As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously. 
     As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. 
     All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention. 
     Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a lid. 
         FIG. 2  is a vertical cross-sectional view of the lid of  FIG. 1 , and also showing a cup with which the lid is configured to mate. 
         FIG. 3  is a vertical cross-sectional view of an alternative embodiment of a lid. 
         FIG. 4  is a vertical cross-sectional view of another alternative embodiment of a lid. 
         FIG. 5  is a vertical cross-sectional view of another alternative embodiment of a lid. 
         FIG. 6  is a vertical cross-sectional view of another alternative embodiment of a lid. 
         FIG. 7  is a vertical cross-sectional view of yet another alternative embodiment of a lid. 
         FIG. 8  is a vertical cross-sectional view of still another alternative embodiment of a lid. 
         FIG. 9  is a ventral view of another alternative embodiment of a lid. 
         FIG. 10  is a ventral view of yet another alternative embodiment of a lid. 
     
    
    
     DETAILED DESCRIPTION 
     The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed. 
     The present invention relates to apparatus, methods, and systems for a lid having paper or other fiber-containing material in both (a) its body and (b) its descending side, and where the side is polymer reinforced with a higher weight percentage of a polymer than the body, thereby providing increased rigidity to the side. The principles and operations for such methods and systems, according to the present invention, may be better understood with reference to the accompanying description and drawings. 
       FIG. 1  generally depicts a fiber-containing lid  100  generally comprising a body  110  and a side  122  that depends from the body  110 . Side  122  flares outwardly at  123 . The lid  100  comprises at least two materials, a fibrous material and a polymer coating. 
     All suitable fibrous materials are contemplated, including wood and vegetable fibers (as for example utilized in papers and cardboards). Biodegradable paper is especially preferred to reduce negative environmental impact when the lids are disposed. 
     All suitable polymer materials are contemplated, especially including polymers typically used to coat inside surfaces of paper coffee cups. This includes polyethylene, polypropylene, polyethylene terephthalate, high-density polyethylene, polyvinyl chloride, low-density polyethylene, ultra-high-molecular-weight polyethylene, and any combination thereof. 
     To reduce the environmental impact, preferred embodiments of the entirely of the lid  100  have no more than 10 wt % the total polymer material(s), more preferably no more than 10 wt % or even 5 wt % polymer, and most preferrably no more than 1 wt % polymer. 
     The body  110  has a drinking hole  130 . It is contemplated that a polymer coating can be disposed on an upper surface of the lid, about at least a region  140  adjacent the drinking hole  130 . A coating in that region is thought to provide an improved mouth feel relative to embodiments where the region is not coated, or otherwise provide water resistance or proofing, or thermal insulation. In some embodiments, the polymer coating of the body extends at least 5 mm around the drinking hole  130 . To aid with disposal, the polymer coating about drinking hole  130  is peel-able or removable in some embodiments so that the paper or fibrous content of lid  100  can be composted or recycled separately. However, in some embodiments the polymer is bound to the upper surface of the lid, and cannot be peeled off or removed. 
     In  FIG. 2 , lid  200  generally has a body  201  and a side  220 . The lid  200  is configured to be removably coupled with a cup  250 , allowing repeated closing and opening the lid. 
     Lid  200  includes one or more fibrous materials  221   a ,  221   b  extending along both the body  210  and the mating portion, respectively. Fibrous materials  221   a  and  221   b  could be the same or different from each other. 
     In this embodiment, the body  210  has a raised portion  211  that surrounds a depressed portion  212 . The raised portion  211  can be of constant height, or of varying heights. Typically, a drinking hole  230  is positioned in the raised portion  211 . 
     Body  210  has a polymer coating  213  on its entire underside, although it is contemplated that there might be embodiments in which there is no overall underside coating. Polymer coating  213  might or might not extend to the medial surface of the side  220 . Instead of, or in addition to any polymer coating  213  on its medial surface, side  220  has a thickened coating or layer of polymer  214 . Polymers  213 ,  214  might or might not comprise the same chemical compositions. To aid with disposal, polymer coating  213  or  214  is peel-able or removable in some embodiments so that the paper or fibrous content of lid  200  can be composted or recycled separately. However, in some embodiments polymer coating  213  or  214  is bound to the underside of the lid, and cannot be peeled off or removed. 
     Side  220  extends circumferentially and downwardly from the body  210 . Side  220  is substantially planar. A mating region  222  includes a negative depression in the substantially planar interior surface of side  220  is sized and dimensioned to securely mate with the upper rim bead  251  of the cup  250 . For a typical paper coffee cup, the negative depression is preferably an indentation, groove, or channel with a depth of at least 1.5 mm. In some embodiments, the indentation, groove, or channel is continuous about the circumference of the rim, but alternatively can be intermittent. Having a secure seal is desirable because it protects the user from spilling hot liquid such as coffee, tea, or soup over himself or herself. 
     Side  220  has a flared region  223 , sized and dimensioned to assist a user in positioning the lid onto the top upper rim bead of a cup, thereby helping to prevent significant deformation of the lid  200 . 
     In  FIG. 3 , an alternative lid  300  has a body  310  and a side  320  with a mating region. Lid  300  includes one or more fibrous materials  321  continuously extending along the body  310  and the side  320 . 
     There is a polymer coating  313  that extends along the entirety of the underside of the body  310  and the medial surface of side  320 . The mating portion of side  320  includes an indented region  322  and a flared region  323 . There is an extra coating of polymer  314  and  315  on the medial and lateral surfaces, respectively, of the mating region of side  320 . 
     Side  320  has a flared region  323 , sized and dimensioned to assist a user in positioning the lid onto the top upper rim bead of a cup, thereby helping to prevent significant deformation of the lid  300 . 
     In  FIG. 4 , an alternative lid  400  has a body  410  and a side  420 , with mating region  422 . Lid  400  includes one or more fibrous materials  421  continuously extending along the body  410  and the side  420 . There is a polymer coating  413  that extends along the entirety of the underside of the body  410  and the medial surface of side  420 . There is an additional layer of polymer  414  positioned within the fibrous material(s)  421  about the mating region  422 . 
     Side  420  has a flared region  423 , sized and dimensioned to assist a user in positioning the lid onto the top upper rim bead of a cup, thereby helping to prevent significant deformation of the lid  400 . 
     In  FIG. 5 , an alternative lid  500  has a body  510  and a side  520 . A mating bump or ridge  522  of polymer cooperates with region  551  and the upper rim bead of cup  250  to attach the lid to the cup. In some embodiments, mating bump or ridge  522  is continuous about the interior circumference of side  520 . However, mating bump or ridge can also be a plurality of intermittent bumps or ridges along the interior circumference of side  520 , for example to provide less resistance or easier attachment of lid  500  to containers. Lid  500  includes one or more fibrous materials  521  continuously extending along the body  510  and the side  520 . There is a polymer coating  513  that extends along the entirety of the underside of the body  510 , and a thickened coating  514  of the same or different polymer on the medial surface of side  520 . 
     Side  520  has a flared region  523 , sized and dimensioned to assist a user in positioning the lid onto the top upper rim bead of a cup, thereby helping to prevent significant deformation of the lid  500 . 
       FIG. 6  shows a cross-sectional view of a lid of the inventive subject matter, including body  621  and mating portion  620 . There is polymer coating  605  on the underside of the body  621 . The mating portion  620  includes an indented region  622  and a flared region  623 . There is an extra coating  624  of polymer on part of the medial side of the body  621 , and the medial sides of the indented  622  and flared  623  regions. 
       FIG. 7  shows a cross-sectional view of an alternative lid, including a body  721  and a mating portion  720 . There is a polymer coating  705  on the underside of the body  721 . The mating portion  720  includes an indented region  722  and a flared region  723 . There is an extra coating  725  of polymer on the lateral side of the indented region  722 . 
     It is also contemplated that one could use magnetic coupling so that the cup and lid would “click” together, magnetically, and thereby remain “mated” without the need for any mechanical coupling as in  FIGS. 2-7 . To that end, in  FIG. 8  is similar to  FIGS. 2-7 , with embedded magnets, metal, or other material attracted by magnetic force, for example upper rim bead  851 A is magnetic or includes magnetic material  852 , and the stiffening member  827 A is a metal or other material attracted by magnetic force. 
     For example,  FIG. 8  shows lid  800  generally has a body  801  and a side  820 . The lid  800  is configured to be removably coupled with a cup or container  850 , allowing repeated closing and opening of the lid. Lid  800  includes one or more fibrous material  821  extending along both the body  810  and the mating portion. Fibrous materials could be the same or different from each other. 
     In this embodiment, the body  810  has a raised portion  811  that surrounds a depressed portion  812 . The raised portion  811  can be of constant height, or of varying heights. Typically, a drinking hole  830  is positioned in the raised portion  811 . Body  810  has a polymer coating  813  on its entire underside, although it is contemplated that there might be embodiments in which there is no overall underside coating. Polymer coating  813  might or might not extend to the medial surface of the side  820 . Instead of, or in addition to any polymer coating  813  on its medial surface, side  820  has a thickened coating or layer of polymer. 
     Side  820  extends circumferentially and downwardly from the body  810 . A mating region  822  is sized and dimensioned to securely mate with the upper rim bead  851 A of the cup  850 . For a typical paper coffee cup, the mating portion would preferably have an indentation with a depth of at least 1.5 mm. Having a secure seal is desirable because it protects the user from spilling of hot liquid such as coffee, tea, and soup over himself or herself. 
     Side  820  has a flared region  823 , sized and dimensioned to assist a user in positioning the lid onto the top upper rim bead of a cup, thereby helping to prevent significant deformation of the lid  800 . 
     In should be understood all of the various embodiments show in the figures herein should be interpreted such that the additional coating or layer of polymer at the mating portion is preferably at least 0.1 mm, more preferably at least 0.2 mm, and most preferably at least 0.3 mm in thickness, and the polymer on the bottom surface of the body covers the entirety of that surface. Also, all of the embodiments depicted herein should be interpreted such that the one or more fibrous materials in the body of the lid can be the same as, or different from, the one or more fibrous materials in the side. Also, all of the embodiments depicted herein should be interpreted as having a drinking hole similar to hole  130  in  FIG. 1 . Still further, all of the embodiments depicted herein should be interpreted as having at least 20 wt % of fibrous material in their respective sides, more preferably at least 40 wt % of fibrous material in their respective sides, and even more preferably at least 60 wt % of fibrous material in their respective sides. 
     There are at least two reasons for adding the polymer material to the mating portions of the various embodiments. First, if the polymer is disposed on a medial side of the mating portion, the polymer can protect the mating portion from deformation caused by the liquid or a vapor evaporating from the liquid. Second, including a polymer in the mating portion can significantly enhance stiffness of the mating portion, thereby providing a secure seal with a cup or other vessel. 
     It is also contemplated that the mating portion could be entirely polymeric, i.e., with no fibrous content. In such instances the polymeric mating portion could have a thin extension that extends up into the body of the lid, or is glued or otherwise adhered to a medial or lateral side of the body. 
       FIG. 9  depicts the ventral side of lid  900  of the inventive subject matter. Lid  900  is comprised of paper or fibrous material and includes radial edge  902 , polymer coated surface  904  extending from radial edge  902  to border  906 , and exposed surface  908 . In most embodiments, the polymer coating of  904  is coextensive with a polymer layer on the interior surface of the sides of the lid, not pictured from this angle (e.g., see side  220  of  FIG. 2 ). Drinking hole  910  is disposed proximal to radial edge  902  and bounded by polymer coated surface  904  Polymer coated surface  904  is a portion of the ventral surface of lid  900  that is coated with a protective polymer, adding structural integrity to lid  900  at the coated surface, as well as water resistance or proofing, heat resistance, or thermal insulation. Exposed surface  908  is simply the exposed paper or fibrous material lid  900  is comprised of. 
     In preferred embodiments, border  906  includes perforations to provide easy detachment of exposed surface  908  from polymer coated surface  904 . Such a feature is useful for disposing of the lid. The user can separate the paper or fibrous portion of lid  900  for composting, biodegrading, or recycling. The polymer coated portion of lid  900  is then disposed of separately as regular trash, recycled, biodegraded, or composted as appropriate based on the composition of the polymer (e.g., recyclable polymer, biodegradable, compostable, etc.). 
       FIG. 10  depicts the ventral side of lid  1000  of the inventive subject matter. Lid  1000  is comprised of paper or fibrous material and includes radial edge  1002 , polymer coated surface  1004  extending from radial edge  1002  proximal to drinking hole  1010  to border  1006 , and exposed surface  1008 . In most embodiments, the polymer coating of  1004  is coextensive with a polymer layer on the interior surface of the sides of the lid, not pictured from this angle (e.g., see side  220  of  FIG. 2 ). Drinking hole  1010  is bounded by polymer coated surface  1004  Polymer coated surface  1004  is a portion of the ventral surface of lid  1000  that is coated with a protective polymer, adding structural integrity to lid  1000  at the coated surface, as well as water resistance or proofing, heat resistance, or thermal insulation. Exposed surface  1008  is simply the exposed paper or fibrous material lid  1000  is comprised of. 
     In preferred embodiments, border  1006  includes perforations to provide easy detachment of exposed surface  1008  from polymer coated surface  1004 . Such a feature is useful for disposing of the lid. The user can separate the paper or fibrous portion of lid  1000  for composting, biodegrading, or recycling. The polymer coated portion of lid  1000  is then disposed of separately as regular trash, recycled, biodegraded, or composted as appropriate based on the composition of the polymer (e.g., recyclable polymer, biodegradable, compostable, etc.). 
     Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary. 
     Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims. 
     It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.