Patent Description:
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.

<CIT> discloses a beverage container comprising a spout composed of a spout base and a spout tip having a dispensing orifice. The spout tip, which is constructed from a soft material felt comfortable on a user's lips, includes a tethered end portion configured to be coupled to a free end portion of the spout base, wherein the tethered end portion may have a friction fit with the free end portion of the spout base and may be configured to be removable therefrom. A locking portion of the spout base is configured to be received in between first and second stop walls that extend into an open-ended channel of the spot tip, and which help trap the free end portion of the spout base inside the open-ended channel. A notch formed at the spout base is configured to receive a ridge that extends into the open-ended channel between the first and second stop walls, such that the notch may function as a keyway with respect to the ridge, which functions as a key. Further, the tethered end portion has a key portion configured to mate with the corresponding keyway of the spout base.

<CIT> discloses a beverage container comprising a lid with a lid housing and a spout arranged at the lid. The spout, which may be made of silicone rubber or another elastomer, includes a dispensing portion, a mounting portion and an intermediate portion arranged in-between. The mounting portion defines a mounting end of the spout that is sized to be disposed in an upper portion of a flow opening by and between an annular wall and a flanged portion of the lid housing.

<CIT> discloses another beverage container comprising a container lid with an on-off-valve.

<CIT> discloses a beverage container comprising a lid that includes a spout or tube defining a conduit therein. The tube is formed or coupled with a nipple.

The present invention has a principle object of providing a spout unit use in conjunction with a lid for a beverage container, comprising means 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:.

The essence of the invention is to reinforce the interlocking of the reinforcement unit with the spout in the structural sense. According to the invention the means for reinforcing 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. 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 means 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:.

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 <NUM>° and <NUM>°, preferably between <NUM>° and <NUM>° for <NUM> to <NUM> minutes, preferably for <NUM> minutes.

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

To have a better understanding of the invention reference is made to the following detailed description of the invention and embodiments thereof in conjunction with the accompanying drawings. In the various figures of the drawings, like reference numbers are used to designate like parts.

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, <FIG> illustrate a beverage container assembly <NUM> comprising a spout unit of the invention. As illustrated, the container assembly <NUM> comprises a container <NUM> having a top opening, and a lid assembly <NUM> connected to the container <NUM> for covering the top opening. The container <NUM> is used to contain or store contents such as liquid and may be of any type known in the art. The lid assembly <NUM> comprises a lid body <NUM>, a spout unit <NUM> mounted in the lid body <NUM>, and a cover member <NUM> pivotally mounted on the lid body <NUM>.

The lid body <NUM> is adapted to be removably attached to the opening of the container. As shown in <FIG>, the lid body <NUM> has 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 unit <NUM>, which will be discussed hereinbelow. The lid body <NUM> has internal threads for mating engagement with corresponding threads formed on an outside of the opening of the container <NUM>.

Now turning to <FIG>, there is illustrated the spout unit <NUM> constructed consistent with a first embodiment of the invention. The spout unit <NUM> comprises a spout <NUM> and a reinforcement unit <NUM> coupled with the spout <NUM>. In this embodiment, the spout <NUM> and the reinforcement unit <NUM> are overmolded as a unitary structure. The spout <NUM> may be made of a flexible material, e. silicon material; and the reinforcement unit <NUM> may be made of a rigid material, e. nylon material.

The reinforcement unit <NUM> comprises a main body <NUM> of a substantially rectangular frame having a top wall <NUM> and a receiving chamber <NUM> inside the main body <NUM>. The receiving chamber <NUM> comprises a pair of lateral slots <NUM> opposite to and facing each other on two opposite inner sides of the receiving chamber. The reinforcement unit <NUM> further comprises a linking portion <NUM> extending from the main body <NUM> to protrude beyond the top wall <NUM> of the main body <NUM> for engaging the spout <NUM>. As shown in <FIG> and <FIG>, the linking portion <NUM> has a bore <NUM> which extends through the linking portion <NUM>.

One of the features of the invention is that the reinforcement unit <NUM> comprises means for reinforcing interlocking of the reinforcement unit with the spout <NUM> to increase twist and pull strength for the spout <NUM>, and thereby prevention of separation of the spout <NUM> from the reinforcement unit <NUM>. As illustrated in <FIG> and <FIG>, the means for reinforcing in this embodiment comprises four shut off holes <NUM> adapted to receive flow of silicon material from the spout in the process of overmolding the spout <NUM> with the reinforcement unit <NUM>. The shut off holes <NUM> are distributed circumferentially at an equal angular interval on the top wall <NUM>. The means for reinforcing further comprises a pair of tabs <NUM> extending transversely from opposite outer side wall surfaces of the linking portion <NUM> adjacent to a top surface of the linking potion <NUM>.

Turning to <FIG>, there is illustrated the spout <NUM> engageable with the reinforcement unit. As illustrated, the spout <NUM> comprises a mouthpiece <NUM> having a dispensing orifice <NUM> and a neck <NUM> extending downwardly from the mouthpiece <NUM>. The dispensing orifice <NUM> of the mouthpiece is in fluid communication with the bore <NUM> of the linking portion <NUM>. The neck <NUM> may extend into the receiving chamber <NUM> of the reinforcement unit <NUM>. The spout unit <NUM> is mounted in the lid body such that the mouthpiece <NUM> protrudes beyond the lid body <NUM>, and the reinforcement unit <NUM> is pivotally mounted in the lid body <NUM> to enable pivotable movement of the spout <NUM> between a dispensing configuration and a stowed configuration, which will be discussed herein below.

In this embodiment, the spout <NUM> is formed by overmolding with the reinforcement unit <NUM>. In the overmolding process, the silicon material of the spout <NUM> flows into the four shut off holes <NUM> of the reinforcement unit <NUM> and form, respectively, four ridges <NUM> on the outer side surface of the neck <NUM> of the spout <NUM>. The ridges <NUM> create respectively four circumferential seals on the top between the reinforcement unit <NUM> and the spout <NUM>. The spout <NUM> further comprises a pair of inwardly facing grooves <NUM> opposite to and facing each other on the two opposite inner side walls thereof. The pair of grooves <NUM> are positioned to be engageable with the pair of tabs <NUM> of the linking portion <NUM>. The engagement of the two tabs <NUM> with the grooves <NUM> further enhances the interlocking between the reinforcement unit <NUM> and the spout <NUM>. It would be within the ability of a person skilled in the art that, in order for further strengthen the interlocking of the spout <NUM> and 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 spout <NUM> may be provided and positioned to be engageable with a second pair of tabs of the linking portion <NUM>.

<FIG> show respective cross-sectional views of the spout <NUM>, and the reinforcement unit <NUM>, and their interlocking assembly. As illustrated, the silicon material of the spout <NUM> flows into the shut off holes <NUM> extending through the top wall <NUM> of the reinforcement unit <NUM> to establish a first interlocking feature, that is, the silicon flow forms the ridges <NUM>. The pair of opposite tabs <NUM> of the linking portion <NUM> of the reinforcement unit <NUM> engage the grooves <NUM> of the spout <NUM>, which establishes a second interlocking feature. These two interlocking features can improve the strength onto the spout <NUM> and the twisting torque between the spout <NUM> and the reinforcement unit <NUM>.

The reinforcement unit <NUM> comprises a first bulge <NUM> and a second bulge <NUM> provided on opposite side walls of the main body <NUM> thereof. The first and second bulges <NUM>, <NUM> are configured as a first pivot and a second pivot for pivotably mounting the spout unit <NUM> on the lid body <NUM> (see <FIG> and <FIG>). Because of the two pivots, the spout unit <NUM> is able to pivot relative to the lid body <NUM>.

<FIG> illustrate 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:.

Now turning to <FIG> and <FIG>, the linking portion <NUM> has a greater length in an axial direction, and two pairs of tabs <NUM> extend transversely from opposite outer side wall surfaces of the linking portion <NUM>, respectively. Each pair of tabs <NUM> is positioned to engage a pair of inwardly facing grooves <NUM> opposite to and facing each other on the two opposite inner side walls of the spout <NUM>. As shown clearly in <FIG>, <FIG> and <FIG>, one pair of the tabs <NUM> each has an outwardly facing longitudinal grooves <NUM> formed axially in the tab, and the longitudinal grooves <NUM> are adapted to receive flow of silicon material from the spout <NUM> in the overmolding process. The flow of silicon material forms ribs on an inner side wall of the mouthpiece <NUM> of the spout <NUM>. The engagement of the ribs and the longitudinal grooves provides an additional improvement related to the interlocking between the spout <NUM> and the reinforcement unit <NUM>.

These kinds of interlocking features in the second embodiment help to further strengthen the interlocking between the spout <NUM> and the reinforcement unit <NUM> to prevent the spout from detachment from the reinforcement unit <NUM>.

As shown in <FIG>, the lid assembly <NUM> further comprises a drinking straw <NUM> having one end portion coupled with the spout unit <NUM> and in fluid communication with the mouthpiece <NUM> of the spout <NUM>. With reference to <FIG>, the end portion of the drinking straw <NUM> is snugly received in the pair of inwardly facing lateral slots <NUM> of the receiving chamber <NUM> of the reinforcement unit <NUM>. A retaining ring <NUM> is arranged between the inner wall of the main body <NUM> of reinforcement unit <NUM> and the drinking straw <NUM> to secure the drinking straw <NUM> inside the receiving chamber <NUM> and prevent displacement of the end portion of drinking straw <NUM> received in the spout unit.

To implement the locking and the unlocking of the cover member <NUM>, a locking unit <NUM> is provided on the lid body <NUM>. With reference to <FIG>, the locking unit <NUM> is mounted on the lid body <NUM> on an opposite side to the pivotal point about which the cover member <NUM> pivots. The locking unit <NUM> comprises a push button <NUM> mounted on the lid body <NUM> and having a locking block <NUM> engageable with a locking seat <NUM> arranged on the cover member <NUM>. The locking unit <NUM> further comprises a linkage <NUM> operably connected with the push button <NUM>, and a compression spring <NUM> mounted between the linkage <NUM> and the lid body <NUM>, as can be seen in <FIG>. The linkage <NUM> has a hook <NUM> engageable with a recess <NUM> formed on the main body of the reinforcement unit <NUM>. When an inward pressure is applied onto the push button <NUM>, it would cause the locking block <NUM> to move inwardly, with a result of the locking block <NUM> disengaging from the locking seat <NUM> of the cover member <NUM> and at the same time of the hook of the linkage <NUM> disengaging from the recess <NUM> of the main body of the reinforcement unit <NUM>, so that the cover member <NUM> is switched to the unlocked position accompanied with the unfolding of the spout unit into the dispensing configuration where the drinking straw <NUM> is unfolded to allow fluid communication between the mouthpiece <NUM> of the spout unit and the interior of the container <NUM> (see <FIG>). To close the container assembly <NUM>, the spout unit <NUM> is pressed to fold downwardly into the stowed configuration where the drinking straw <NUM> is caused to bend to block the fluid pathway between the mouthpiece <NUM> of the spout unit and the interior of the container <NUM> (see <FIG>). The cover member <NUM> is then pressed down so that the locking seat <NUM> pivots downwardly to engage the locking block <NUM>.

<FIG> illustrates a method for fabricating the overmolding structure of the spout unit <NUM>, the method comprising injection-molding the reinforcement unit of predefined structure and dimension (step <NUM>). 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 <NUM> and <NUM>, preferably <NUM> for about <NUM> to <NUM> minutes (step <NUM>). The heated reinforcement unit is placed in an overmolding mold (step <NUM>), and a silicon material is applied into the overmoding mold for overmolding the spout around the linking portion of the reinforcement unit (steps <NUM> and <NUM>). After the overmolding is finished, the unitary structure of the reinforcement unit and the spout is demolded from the overmolding mold (step <NUM>), followed by the step of trimming and inspecting the overmolded spout unit (step <NUM>).

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

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 in <FIG> and include the following:.

Variations B1-B3 and B6 are devised to accommodate more material of the spout <NUM>, 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 <NUM> SPC PA66 resin as the nylon material for the reinforcement unit, POLYSIL LIM-9050D as the silicon material for the spout <NUM>. 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 <NUM>.

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 grooves <NUM> are provided on the front-back tabs of the linking portion. No primer was applied to these six samples.

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 portion <NUM>. The elongated linking portion <NUM> is provided with the same longitudinal grooves <NUM> provided on the front-back tabs of the linking portion and an additional pair of tabs <NUM> on the outer side wall surfaces of the elongated linking portion <NUM>.

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

The results are shown in tables <NUM> and <NUM>.

Claim 1:
A spout unit (<NUM>) for dispensing beverage in a beverage container (<NUM>), comprising:
a spout (<NUM>) comprising a mouthpiece (<NUM>) having a dispensing orifice (<NUM>), and a neck (<NUM>) extending downwardly from the mouthpiece (<NUM>), and
a reinforcement unit (<NUM>) overmolded with the spout (<NUM>), wherein the reinforcement unit (<NUM>) comprises:
a main body (<NUM>) having a top wall (<NUM>) and a receiving chamber (<NUM>),
a linking portion (<NUM>; <NUM>) extending from the main body (<NUM>) to protrude beyond the top wall (<NUM>) of the main body (<NUM>) for engaging the spout (<NUM>), the linking portion (<NUM>; <NUM>) having a bore (<NUM>) which extends through the linking portion (<NUM>; <NUM>) and is in fluid communication with the dispensing orifice (<NUM>) of the spout (<NUM>), and
means for reinforcing structurally interlocking of the reinforcement unit (<NUM>) with the spout (<NUM>)
characterized in that the means for reinforcing includes one or more shut off holes (<NUM>) adapted to receive flow of material from the spout (<NUM>) in the overmolding process, wherein the flow of material forms one or more ridges (<NUM>) on an outer side surface of the neck (<NUM>) of the spout (<NUM>), and the shut off holes (<NUM>) are distributed circumferentially on the top wall (<NUM>).