Patent Publication Number: US-2012037654-A1

Title: Container lid

Description:
RELATED APPLICATIONS 
     The present application is a continuation-in-part of application Ser. No. 12/291,700, filed Nov. 26, 2009, which claims the filing priority of U.S. Provisional Application No. 61/128,723 filed on Jun. 23, 2008. Each application is incorporated by reference herein. 
    
    
     TECHNICAL FIELD 
     The present device relates to a container assembly including a container and a container lid. Specifically, the present device relates to a flexible container lid coated with a flexible material which secures container contents by forming a seal between the container and the periphery of the container lid while allowing for ease of access to the contents upon activation of the lid by a user. 
     BACKGROUND 
     Container lids are common devices designed to enclose containers, preserving freshness of foodstuffs, hiding contents from view, or preventing spillage of contents. Unfortunately, however, many container lids—by virtue of their ability to form a seal with the containers—are difficult to remove. Such container lids require the user to separate the container and lid with two hands, or even pry the lid from the container, potentially jeopardizing the structural integrity of the container and lid. 
     Alternatively, a container lid which fails to successfully form a seal with the container may too easily become detached, even upon a user&#39;s inadvertent contact with the lid. Such detachability can cause frustration when the container&#39;s contents spill. Further, a dislodged container lid can cause spoilage of edible contents, or allow impurities to enter the container and contaminate contents. In some instances, even where a container lid is properly in place but no seal is formed with the container, air, moisture, dust, or other impurities may seep into the container—the presence of which may significantly degrade the quality of the container&#39;s contents. 
     The present invention is intended to address these and other possible problems associated with existing container lids. 
     SUMMARY OF THE INVENTION 
     There is disclosed herein an improved container lid which avoids the disadvantages of prior devices while affording additional structural and operating advantages. Generally speaking, the lid includes a flexible material held to a flexible substrate, such as a flexible steel or plastic, having first and second opposing surfaces and a peripheral lip. When fitted to a container, the coated flexible substrate forms a seal between a sidewall of the container and the periphery of the container lid. 
     In an embodiment of the container lid, the flexible substrate is formed in such a way that it is bi-stable, thus capable of achieving and existing in either a convex or concave state. It is an aspect of at least one embodiment of the container lid that the flexible substrate, being manufactured of a flexible steel, comprises a plurality of flexing or grasping sections distributed about the periphery of the flexible substrate. Such sections may range in quantity, with as few as three providing the necessary outward flex for the peripheral lip. 
     In an embodiment of the invention, the flexible material is molded to the substrate using a flow through process for encapsulating the substrate. Such a substrate comprises a plurality of holes, allowing material to flow from one opposing surface to the other. 
     It is an alternative embodiment of the container lid, a primer is applied to the flexible substrate prior to application of the flexible material. The flexible material adhered to the flexible substrate preferably comprises silicone rubber, but may include any such flexible material which may be secured to the substrate to provide a peripheral seal. 
     These and other aspects of the invention may be understood more readily from the following description and the appended drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated. 
         FIG. 1  is a cross-section of one embodiment of a lid and container assembly; 
         FIG. 2  is a partial view of the cross-section of the lid and container assembly shown in  FIG. 1 ; 
         FIG. 3  is a cross section of another embodiment of a lid and container assembly; 
         FIG. 4  is a partial view of the cross-section of the lid and container assembly shown in  FIG. 4 ; 
         FIG. 5  is a top view of another embodiment of a lid and container assembly; 
         FIG. 6  is a cross section along line  6 - 6  of  FIG. 5  with the lid being in a convex state; 
         FIG. 7  is an enlarged view of the section indicated in  FIG. 6  illustrating the formed seal between the present container lid and a container; 
         FIG. 8  is a top view of another embodiment of the flexible substrate of the present container lid in a convex state; 
         FIG. 9  is a cross section along the line  9 - 9  of the embodiment of  FIG. 8  of the present flexible substrate in a convex state; 
         FIG. 10  is a top view of an embodiment similar to that of  FIG. 5  showing the present container lid in a concave state; 
         FIG. 11  is a cross section along line  11 - 11  of the embodiment of  FIG. 10  of the present container lid enclosing a container, the lid being in a concave state; 
         FIG. 12  is an enlarged view of the section indicated in  FIG. 11  illustrating the broken seal between the present container lid and a container; 
         FIG. 13  is a top view of an embodiment similar to that of  FIG. 11  showing the flexible substrate in a concave state; 
         FIG. 14  is a cross section along the line  14 - 14  of the embodiment of  FIG. 13  of the flexible substrate of the present container lid in a concave state; 
         FIG. 15  is a top perspective view of an embodiment of the flexible substrate including through holes at the periphery and center area for molding; 
         FIG. 16  is a cross-section of a lid including the flexible substrate of  FIG. 15 ; 
         FIGS. 17 and 17A  are cross-sectional views the lid of  FIG. 15  including through holes for molding. 
     
    
    
     DETAILED DESCRIPTION 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to embodiments illustrated. 
     To the extent additional or alternative embodiments are disclosed herein, such additional or alternative components are consistently referenced using the same two digit number or, in some cases, by adding a leading third digit to the corresponding reference number. Otherwise, like components are consistently numbered in the following description and in each of the appended drawing figures. 
     Referring to  FIGS. 1-17 , there is illustrated several embodiments of a container lid  10 . Generally speaking, the container lid  10  is comprised of a thin, flexible, substrate  12  having a first (outer) surface  14  and a second (inner) surface  16 . The flexible substrate  12 , or at least a part of the substrate  12  including the periphery, is preferably encapsulated by a flexible material  18 . In the embodiment of  FIGS. 1 and 2 , only the peripheral lip  13  is encapsulated by the flexible material  18 . In this embodiment, the flexible, or resilient, material contacts the inner surface  16  and the outer surface  14  of the peripheral lip  18  providing a similar resilient material on the inner surface and the outer surface of the peripheral lip, as is evident in  FIGS. 1 and 2 .  FIGS. 3 and 4  have the entire substrate  12  encapsulated. In both embodiments, when used with a container  20 , the container lid  10  friction fits to the container  20  at a periphery to thereby form a seal along the periphery. As shown in  FIGS. 2 and 4 , small projections  23  may be formed as part of the flexible material to facilitate the formation of a seal between the lid  10  and the container  20 . 
     As shown in  FIGS. 6 and 11 , the flexible substrate  12  is comprised of a slightly cupped surface with a peripheral lip  13  extending substantially perpendicularly downwardly from the periphery of a central section  22  the lid  10 . The flexible substrate  12  is preferably formed of a metal, such as spring steel. It may, however, be formed of stainless steel, aluminum, plated steel, or many other metals having the ability to be so formed. The substrate may also be formed of most any flexible plastic, including numerous thermoplastic and thermoform polymers, composites, and laminate material capable of being flexed and formed while retaining a certain amount of rigidity, as is known by persons having ordinary skill in the art. 
     A flexible or resilient material  18  may be applied directly to the flexible substrate  12 , such as preferably through compression molding, but including such processes as over-molding, bonded assembly and other processes known in the art. Regardless of how the material is attached to the substrate, it is more the placement of the material to form a seal which is of importance. 
     In a preferred compression-molding process, for example, the flexible substrate  112  may be formed with a plurality of holes  17 ,  117 , as illustrated in  FIGS. 15 and 16 . The plurality of holes  17 ,  117  can include peripheral holes  17  in the central section  122  of the flexible substrate  112 . With the peripheral holes  17  being provided, the resulting lid may then include flexible material encapsulating only the lip  13 , similar to the embodiment depicted in  FIGS. 1 and 2 . Alternatively, additional areas of holes, e.g., central holes  117  located adjacent a center of the central section  22  of the flexible substrate  122 , may be provided as well (see  FIGS. 15 and 17 ). The flexible material  118  (see  FIG. 16 ) could then be applied to the substrate in a single step, as above, or in multiple steps, as necessary to achieve the desired encapsulation of the lid  110 . That is, the compression molded material would spread to fill the first and subsequent holes  17 ,  117  to thereby encapsulate the lip and the remainder of the substrate  112  with material  118 . When done in consecutive steps, the molding process is used to cover the lid periphery in a first step, and then the remaining bottom or under surface of the substrate  12  is covered in a second step. The two similar materials may bond to one another, for example, at an area where they interface on the lid under surface. As shown in  FIG. 17 , a central button section  132  of material at the center of the top or upper surface of the substrate  12  helps anchor the material to the substrate much like the holes  17  about the periphery. 
     The flexible substrate  112  includes the plurality of holes  17 ,  117  and the resilient material  118  extends through the holes from the outer surface  114  of the flexible substrate to the inner surface  116  of the flexible substrate as seen in  FIG. 17 . This provides the similar resilient material  18  on the inner surface  116  and the outer surface  114  of the flexible substrate  112  including the peripheral lip  113  and the central section  122 . The peripheral holes  17  are circumferentially spaced around the central section  122  of the flexible substrate (see  FIG. 15 ). An entirety of the lower surface  116  of the central section  122  of the flexible substrate  12  can be covered by the resilient material  118 . The resilient material  118  can include the central button section  32  formed on the outer surface  112  of the flexible substrate  12  covering the central holes  117  and a peripheral section  34  ( FIG. 16 ) formed on the outer surface of the flexible substrate covering the peripheral holes  17 . As seen in the embodiment depicted in  FIGS. 17 and 17A , the upper surface  114  of the central section  122  of the flexible substrate  12  is not covered by resilient material between the central button section  32  and the peripheral section  34 . 
     Similarly, the same embodiments can be achieved through the use of a bonding agent or primer in lieu of the through holes  17 ,  117 . The primer (not shown) would be applied to the desired area of coverage (e.g., the periphery) and the flexible material  18  could then be compression molded to that area. A primer may first be applied to the flexible substrate  12  so as to cause the flexible material  18  to bond more aggressively to the flexible substrate  12 . The primer is best used when the flexible material is to be applied to the entirety of the flexible substrate  12  (see  FIG. 11 ), including the peripheral lip  13 , as careful metering of the primer is less critical. That is, where only a portion of the lid  10  is to be coated and primer “overspray”—the accidental application of primer to any area which is not being coated—is unsightly and, therefore, undesirable, application of primer to such a small area exclusively may be difficult. Thicker (i.e., more viscous) primer coatings which can be more accurately applied by, for example, a brush may help alleviate this application problem. 
     Where “overspray” is of no concern, the primer and flexible material may be applied to less than the entire lid  10 . As several alternative examples, primer may be applied to (1) the second container-facing surface  16  and the container-facing portion of the peripheral lip  13  of the flexible substrate  12 , (2) the periphery and peripheral lip  13  of the first and second surfaces  14 ,  16  of the flexible substrate  12 , or (3) the contact points of the flexible substrate  12  between the container lid  10  and the container  20 . 
     In an alternative process, the flexible material  18  may be molded separately, in one or several pieces, and then chemically or heat bonded to the substrate  12 . 
     Combinations of these manufacturing processes are also possible and may be effective for certain applications. 
     The flexible material  18  itself may be comprised of any number of polymers, copolymers, polymer blends and the like. Suitable materials include, but are not limited to, silicone rubber, thermoplastic elastomers, waxes, resins or any other resilient and malleable material capable of being flexed, formed, and attached to or about the flexible substrate  12  in any of the manners described above. 
     In a preferred embodiment of the present invention, the flexible substrate  12  is formed such that it is bi-stable. That is, the substrate  12  is capable of existing in either a stable convex ( FIGS. 5-9 ) or a stable concave ( FIGS. 10-14 ) state. The central section  22 ,  122  is movable between a convex configuration and a concave configuration. The flexible substrate  12 ,  112  is made from a bi-stable material configured to maintain the central section  22  in the convex configuration or the concave configuration until acted on by a force applied to the central section normal to a central axis of the flexible substrate. A user causes the flexible substrate  12  of the container lid  10  to alternate from a convex to a concave state by applying an inward force at the center (C) of the container lid  10 . The peripheral lip  13  includes a plurality of notches  19  to create flexing sections  15  which allow outward and inward flexing of the lip  13 . There can be at least three, but preferably four or more flexing sections  15 , and as many as 30 (or even greater than 30) sections, to allow the lid  10  to properly function. The flexing sections  15  press the encapsulating flexible material  18  against the container  20  to effect a seal when the flexible substrate  12  exists in its convex state, as depicted in  FIG. 7 . Similarly, a user causes the flexible substrate  12  of the container lid  10  to alternate from a concave to a convex state by applying force to at least two points along the peripheral lip  13  of the container lid  10  or by applying an upward force at the center of the container lid. The flexing sections  15  of the peripheral lip  13  release pressure on the container  20  when the flexible substrate  12  exists in its concave state, as depicted in  FIG. 12 . The flexing sections  15 ,  115  are movable between an inwardly disposed position (shown in  FIGS. 2 ,  4 ,  7 ) and an outwardly disposed position (shown in  FIG. 12 ) in response to the central section  22 ,  122  moving between the convex configuration and the concave configuration. As seen in the figures, the resilient material moves between a first position where the resilient material  18  is engaged with the container  20  to facilitate a seal between the container lid  10  and the container  20  (see  FIG. 7 ) to a second position where the resilient material  18  is disengaged from the container (see  FIG. 12 ). The resilient material  18  is configured such that the flexing sections  15  maintain the outwardly disposed position and the resilient material maintains the second position when the central section  22  is in the concave position until acted on by a generally outward (upward per the orientation shown in  FIG. 12 ) force applied to the central section generally normal to a central axis of the flexible substrate or by a generally inward force applied along the peripheral lip  13 . Stated another way, the flexible substrate  12  and the resilient material  18  configured in a manner such that the resilient material does not impart an inward force on the flexing sections great enough to move the flexing sections from the outwardly disposed position to the inwardly disposed position when the central section is in the concave configuration (such as shown in  FIG. 12 ). 
     The flexing sections  15  may be formed to more aggressively grasp the periphery of the container  20  by adding, for example, a slight bend at the section end. The bend may create a different pressure point for forming a seal against the container  20  than the straight flexing sections  15 , which may be preferable for certain applications. In most other respects, the flexing sections  115  are functionally equivalent to the flexing sections  15  of the previous embodiment, though for purposes of this disclosure the flexing sections  115  are typically greater in number. The flexing sections  115  preferably number from about 10 to an amount which achieves the desired and intended peripheral seal. 
     Section width and the gap between adjacent flexing sections  115  may be varied to achieve the desired peripheral sealing. When provided in a greater number, the flexing sections  115  may have the effect of increasing flexibility and durability of the container lid  110 . As noted, the embodiment of the container lid  110  including the flexing sections  115  operates similarly to the embodiment of the container lid  10  comprising the flexing sections  15 . For example, as depicted in  FIGS. 8 and 9 , the flexing sections  115  grasp the container  20  when the flexible substrate  12  exists in its convex state, and release the container  20  when the flexible substrate  12  exists in its concave state, as depicted in  FIGS. 13 and 14 . The resilient material spans circumferentially between adjacent flexing sections  15 ,  115  filling the respective notch  19 , (see  FIG. 17A ) between the adjacent flexing sections with resilient material  18 . The cross section in  FIG. 17A  was taken through a notch  119  between adjacent flexing sections  115 —notice how the flexible material fills the notch (depicted by the flexing section not being visible in  FIG. 17A ). Also, a thickness through the resilient material  118  between an internal surface  42  of the resilient material  18  and an external surface  44  of the resilient material measured through a respective flexing section  15 ,  115  is the same as the thickness measured through a respective notch  19 . This can obscure the flexing sections from the consumer since the resilient material will cover the flexing sections  15 ,  115  without providing an indication that the flexing sections are encapsulated by the resilient material. 
     Additionally, as detailed above, a primer, flexible material, or both may be solely applied to the flexing sections  115 , to the flexing sections  115  and the rest of the flexible substrate  12 , or to any combination of the flexing sections  115 , the first and second surfaces of the flexible substrate  12 , and the container-facing and container-reversing portions of the grasping sections  115 . The primer, when used, could be applied in any of the noted processes previously described. 
     The container lid  10  illustrated in  FIGS. 1-17  is shown to be circular. However, persons having ordinary skill in the art will understand that the container lid  10 , including the flexible substrate  12 ,  112  and the associated flexible material  18 ,  118  can be formed to accommodate containers of a variety of shapes and sizes. In one embodiment of the present container lid  10 , a circular flexible substrate is formed of stainless steel to be bi-stable, coated entirely with a primer, and compression molded with a thin layer of a flexible silicone rubber material to entirely cover the flexible substrate. The resilient material can be provided to include a continuous circular lower edge  36  (i.e., the lower edge does not deviate from a plane normal to a central axis of the container lid  10 ), which also obscures the flexing sections from the consumer since the resilient material will cover the flexing sections  15 ,  115  without providing an indication that the flexing sections are encapsulated by the resilient material. 
     The container  20  onto which the container lid  10  fits may similarly be formed of a variety of materials (see list for container lid above) and in numerous shapes, as is known by persons having ordinary skill in the art. One embodiment of the container, as illustrated in  FIGS. 1 and 3 , is of cylindrical shape featuring a continuous cylindrical wall and a circular bottom. The container  20  may be formed of any material stated above, and need not be formed of the same material as the container lid. 
     With reference to  FIG. 16 , each flexing section  115  includes a distal edge  50  spaced from the central section  122 . The resilient material  118  wraps around and covers the distal edge  50  to provide the similar resilient material on the inner surface  116  and the outer surface  114  of the peripheral lip  113 . The resilient material  118  forms an inner upper terminal edge  52  adjacent the inner surface  116  of the peripheral lip  113 . The inner upper terminal edge  52  is spaced from resilient material attached with the lower surface of the central section  122 . Accordingly, as seen in  FIG. 16 , the inner surface  116  of the flexing sections  115  above the inner upper terminal edge  52  is not covered with resilient material  118 . This can facilitate the inward and outward movement of the flexing sections that is described above. 
     The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicant&#39;s contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.