Note: Descriptions are shown in the official language in which they were submitted.
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THREE-LAYERED CONTAINERS AND METHODS OF MAKING THE SAME
FIELD OF THE INVENTION
[0001] The present invention relates generally to disposable containers and,
more
particularly, to insulated disposable containers and/or cups and methods of
manufacturing the
same.
BACKGROUND OF THE INVENTION
[0002] Some types of disposable cups that are typically used for holding
beverages
include those comprised of polystyrene, expanded polystyrene, and paper.
Although polystyrene cups are aesthetically pleasing, they provide little, if
any, insulation
and are, therefore, mainly used for holding cold drinks. Condensation may form
on the
outside of a polystyrene cup containing a cold drink, thereby making the cup
wet, cold,
and/or uncomfortable to use and/or hold for prolonged periods of time. The
condensation
may also make the polystyrene cup slippery, thus making the cup even more
difficult and/or
uncomfortable to hold. Another drawback of polystyrene cups is that they are
environmentally unfriendly because they are neither biodegradable nor easily
recyclable.
[0003] A second type of cup, comprised of expanded polystyrene, or EPS (e.g.,
a
Styrofoam(& cup), is an excellent thermal insulator and may, thus, maintain
the temperature
of a drink - whether hot or cold - for extended periods of time. Expanded
polystyrene cups
are generally inexpensive and comfortable to handle because their exteriors
stay close to
ambient temperature regardless of the temperature of the beverage inside the
cup. One
drawback of expanded polystyrene cups, however, is that they are
environmentally unfriendly
because expanded polystyrene is neither biodegradable nor easily recyclable.
As a result, the
use of expanded polystyrene cups has been banned in some municipalities.
Additionally,
because the expanded polystyrene cups must be printed after they have been
formed and their
rough surface does not allow high-resolution printing, a slow and costly
process must be used
for printing on expanded polystyrene cups.
[0004] Standard, single-wall paper cups are generally recyclable and
biodegradable
and are, therefore, considered environmentally sound. However, paper cups are
relatively
poor thermal insulators, and, thus, a beverage in a paper cup quickly warms
(if cold) or cools
(if hot). Paper cups are also generally uncomfortable to handle because a hot
or cold drink
may uncomfortably cool or heat a hand. Additionally, as with polystyrene cups,
a cold drink
CA 02598153 2007-08-20
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may cause condensation to appear on the outside of the paper cup, making the
cup slippery
and/or difficult to hold. Furthermore, the single-wall construction of paper
cups makes them
particularly fragile, and, thus, paper cups filled with liquid may crumble
after prolonged
handling.
[0005] Multi-layered paper cups have been designed to provide thermal
insulation
and increased strength, which are often lacking in single-layered paper cups.
Multi-layered
cups generally comprise several layers including an outer layer, a middle
insulating layer, and
an inner layer. Although generally strong and thermally efficient, multi-
layered cups may be
expensive and impractical to manufacture.
[0006] In some existing multi-layered cups, the inner layer and the outer
layer are
formed from a single sheet. The single sheet may then be folded over to form
the inner layer
and the outer layer. This approach may be undesirable because it may result in
a substantial
amount of wasted materials, particularly in embodiments where the height of
the outer layer
is less than the height of the inner layer. Furthermore, forming the inner
layer and the outer
layer from the same sheet necessitates that the inner layer and the outer
layer be comprised of
the same material and/or coating. This may be undesirable because the
materials and/or
thicknesses of the different layers may not be altered to achieve desired
properties of the cup
including insulating ability, weight, strength, percentage of recyclable
material, cost of
material, and the like. Furthermore, if a "legend" is to be printed on the
inner ring of the
bottom of the cup, the "fold-over" approach may require printability on both
sides of the
single sheet, which may further increase manufacturing costs of the multi-
layered cup.
[0007] It would be desirable to provide a multi-layered container or cup that
assists
in addressing one or more of the above disadvantages.
SUMMARY OF THE INVENTION
[0010] According to one embodiment of the present invention, a thermally
insulated
container is disclosed. The container comprises an inner layer having a bottom
portion with a
bottom closure attached to the bottom portion. The container further comprises
an outer layer
wrapped around the inner layer. The container further comprises an insulating
middle layer
sandwiched between the inner layer and the outer layer. The container further
comprises a
side seam including five or less layers. At least one of the layers of the
side seam is an end of
the middle layer.
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100111 According to one process of the present invention, a method of making a
thermally insulated container is disclosed. The method comprises the act of
providing a
bottom blank, an inner layer, an outer layer, and a middle layer. The middle
layer comprises
an insulating sheet material. The method further comprises the act of stacking
the inner
layer, the outer layer, and the middle layer such that the middle layer is
sandwiched between
the inner layer and the outer layer to form a layered arrangement. The layered
arrangement
has a first end and an opposing second end. The method further comprises the
act of
wrapping the layered arrangement such that the first end overlaps the second
end to form an
overlapping portion. The method further comprises the act of sealing at least
part of the
overlapping portion to form a side seam having five or less layers. At least
one of the layers
of the side seam is an end of the middle layer.
[0012] According to another embodiment of the present invention, a thermally
insulated container is disclosed. The container comprises an inner layer
having a bottom
portion with a bottom closure attached to said bottom portion. The container
further
comprises an outer layer wrapped around said inner layer. The container
further comprises
an insulating middle layer sandwiched between the inner layer and the outer
layer. The
container further comprises a side seam comprising five or less layers. At
least one end of
the outer layer is sealed with at least one end of the inner layer at the side
seam.
[00131 According to another embodiment of the present invention, a thermally
insulated container is disclosed. The container comprises an inner layer
having a bottom
portion with a bottom closure attached to the bottom portion. The container
further
comprises an outer layer wrapped around the inner layer. The container further
comprises an
insulating middle layer sandwiched between the inner layer and the outer
layer. The
container further comprises a side seam including six layers, the six layers
comprising a first
end and a second end of the inner layer, a first end and a second end of the
middle layer, and
a first end and a second end of the outer layer.
In one aspect, the invention provides a thermally insulated container,
comprising:
an inner layer having a first free end, an opposing second free end, a top
end, and an
opposing bottom end;
a bottom portion coupled to the bottom end of the inner layer;
an outer layer wrapped around the inner layer, the outer layer having a first
free end and
an opposing second free end;
an insulating middle layer sandwiched between the inner layer and the outer
layer; and
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a side seam including five or less layers, wherein at least one of the layers
of the side
seam is an end of the middle layer.
In one aspect, the invention provides a method of making a thermally insulated
container, the method comprising the acts of.
providing a bottom blank, an inner layer, an outer layer, and a middle layer,
the middle
layer comprising an insulating sheet material, the inner layer, the outer
layer, and the
middle layer being separated from one another;
stacking the inner layer, the outer layer, and the middle layer such that the
middle layer is
sandwiched between the inner layer and the outer layer to form a layered
arrangement, the
layered arrangement having a first end and an opposing second end;
wrapping the layered arrangement such that the first end overlaps the second
end to form
an overlapping portion; and
sealing at least part of the overlapping portion to form a side seam having
five or less
layers, wherein at least one of the layers of the side seam is an end of the
middle layer.
[00081 The above summary of the present invention is not intended to represent
each
embodiment or every aspect of the present invention. Additional features and
benefits of the
present invention are apparent from the detailed description and figures set
forth below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a cross-sectional, elevational view of a cup made according
to one
embodiment of the present invention.
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[0015] FIG. 2a is a top view of sheet blanks used for making a cup in
accordance with
an embodiment of the present invention.
[0016] FIG. 2b is a side view of a middle layer blank according to one
embodiment.
[0017] FIG. 2c is a top view of a three-layered arrangement formed using the
blanks
of FIG. 2a.
[0018] FIG. 3a is a top view of a three-layered arrangement of blanks
according to
another embodiment of the present invention.
[0019] FIG. 3b is a top, cross-sectional view of a cup formed using the three-
layered
arrangement of FIG. 3a.
[0020] FIG. 3c is a blown-up view generally of section A of FIG. 3b according
to one
embodiment.
[0021] FIG. 3d is a blown-up view generally of section A of FIG. 3b according
to
another embodiment.
[0022] FIG. 3e shows section A of FIGs. 3b and 3c after a side seam has been
sealed.
[0023] FIG. 3f shows section A of FIG. 3e having a waterproof coating applied
to
surfaces of several layers of the cup according to one embodiment.
[0024] FIG. 3g shows section A of FIG. 3e having a waterproof coating applied
to
surfaces of several layers of the cup according to another embodiment.
[0025] FIG. 4a is a top view of a three-layered arrangement of blanks
according to
another embodiment of the present invention.
[0026] FIG. 4b is a top, cross-sectional view of a cup formed using the three-
layered
arrangement of FIG. 4a.
[0027] FIG. 4c is a blown-up view generally of section B of FIG. 4b.
[0028] FIG. 4d shows section B of FIGs. 4a and 4b after a side seam has been
sealed
according to one embodiment.
[0029] FIG. 5a is a top view of a three-layered arrangement of blanks
according to
another embodiment of the present invention.
[0030] FIG. 5b is a top, cross-sectional view of a cup formed using the three-
layered
arrangement of FIG. 5a.
[0031] FIG. 5c is a blown-up view generally of section C of FIG. 5b.
[0032] FIG. 5d shows section C of FIGs. 5a and 5b after a side seam has been
sealed.
[0033] FIG. 6a is a top view of a three-layered arrangement of blanks
according to
another embodiment of the present invention.
CA 02598153 2007-08-20
[0034] FIG. 6b is a top, cross-sectional view of a cup formed using the three-
layered
arrangement of FIG. 6a.
[00351 FIG. 6c is a blown-up view generally of section D of FIG. 6b.
[0036] FIG. 6d shows section D of FIGs. 6a and 6b after a side seam has been
sealed.
100371 FIG. 7a is a top view of a three-layered arrangement of blanks
according to
another embodiment of the present invention.
(0038] FIG. 7b is a top, cross-sectional view of a cup formed using the three-
layered
arrangement of FIG. 7a.
[0039] FIG. 7c is a blown-up view generally of section E of FIG. 7b.
[0040] FIG. 7d shows section E of FIGs. 7a and 7b after a side seam has been
sealed.
[0041] FIG. 8a is a side view of a three-layered arrangement of blanks
according to
another embodiment of the present invention.
[0042] FIG. 8b is a top, cross-sectional view of a cup formed using the three-
layered
arrangement of FIG. 8a.
[0043] FIG. 8c is a blown-up view of section F of FIG. 8b according to one
embodiment.
[00441 FIG. 8d shows section F of FIGs. 8a and 8b after a side seam has been
sealed
according to one embodiment.
[0045] FIG. 8e shows section F of FIGs. 8a and 8b after a side seam has been
sealed
according to another embodiment.
[0046] FIG. 8f is a blown-up view of section F of FIG. 8b according to another
embodiment.
[0047] FIG. 8g shows section F of FIG. 8f after a side seam has been sealed.
[0048] While the invention is susceptible to various modifications and
alternative
forms, specific embodiments are shown by way of example in the drawings and
are described
in detail herein. It should be understood, however, that the invention is not
intended to be
limited to the particular forms disclosed. Rather, the invention is to cover
all modifications,
equivalents, and alternatives falling within the spirit and scope of the
invention.
DESCRIPTION OF ILLUSTRATED EMBODIMENTS
[0049] Referring to FIG. 1, a cup 10 is shown in accordance with one
embodiment of
the present invention. The cup 10 includes bottom 11 and a sidewall 12. The
sidewall 12
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comprises an inner layer 24, an insulating middle layer 25, and an outer layer
26. The bottom
11 is formed from a bottom blank 13, as shown in FIG. 2a.
[00501 The inner layer 24 may comprise various types of suitable materials.
Non-
limiting examples of materials that may be used to form the inner layer 24
include, flat,
unscored paperboard such as chipboard (plain chip or bending chip),
linerboard, virgin
paperboard, paperboard with recycled content, solid bleach sulfite (SBS)
board, solid
unbleached sulfite (SUS) board, polymeric solid sheets, combinations thereof,
or the like.
The inner layer 24 may further be comprised of foil or metalized film
laminated paperboard,
porous sheets, foam sheets (e.g., expanded polystyrene), combinations thereof,
or the like.
Although the thickness of the inner layer 24 generally depends on the type
and/or application
of the resulting cup 10, the thickness of the inner layer 24 is generally from
about 1 mil to
about 20 mils. More typically, the thickness of the inner layer 24 is
generally from about 5
mils to about 10 mils. It is contemplated that the inner layer 24 may also
have other
thicknesses.
[00511 Alternatively or additionally, a front side 29a, a back side 29b, or
both the
front side 29a and the back side 29b of the inner layer 24 may be coated with
a waterproof
material including, for example, plastic. It may be desirable for the back
side 29b of the inner
layer 24 to include the waterproof material to assist in preventing or
inhibiting a liquid held
inside of the cup 10 from seeping into or through the sidewall 12. One non-
limiting example
of such a waterproof material is polyethylene (low, medium, or high density),
which may
serve as both an adhesive and a waterproof coating. Furthermore, a
polyethylene coating
generally provides a printable surface. Although the embodiments of the
present invention
are generally described herein as having a polyethylene coating, it is
contemplated that other
suitable coatings may also be used with any of the embodiments of the present
invention. For
example, other types of waterproof and heat sealable coatings that may be used
include, but
are not limited to, polypropylene, foamed polyethylene, other foamed polymers,
polyester,
polyolefins, other types of biodegradable, recyclable, waterproof and/or heat
sealable
coatings, combinations thereof, or the like. The thickness of the waterproof
coating is
generally from about 0.5 mils to about 1.5 mils. It is contemplated that the
waterproof
coating may also have other thicknesses. The coating may have a matte finish,
a gloss finish,
or an intermediate, semi-gloss type finish. Any suitable method of applying
the coating may
be used including, but not limited to press applying the waterproof coating.
It is
contemplated that the inner layer 24 may comprise two-sided polyethylene
sheets such that
CA 02598153 2007-08-20
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the inside of the cup 10 is waterproofed and provides the outside of the cup
10 with a coated
printable surface on the front side 29a.
[0052] Similarly, the outer layer 26 may comprise various types of suitable
materials.
Non-limiting examples of materials that may be used to form the outer layer 26
include
unscored paperboard such as chipboard (plain chip or bending chip),
linerboard, virgin
paperboard, paperboard with recycled content, SBS board, SUS board, polymeric
solid
sheets, combinations thereof, or the like. The outer layer 26 may further be
comprised of foil
or metalized film laminated paperboard, porous sheets, foam sheets (e.g.,
expanded
polystyrene), combinations thereof, or the like. Alternatively or
additionally, a front side 30a,
a back side 30b, or both the front side 30a and the back side 30b of the outer
layer 26 may be
coated with a waterproof coating including, for example, polyethylene.
Although the
thickness of the outer layer 26 generally depends on the type and/or
application of the
resulting cup 10, the thickness of the outer layer 26 is generally from about
I mil to about 20
mils. More typically, the thickness of the outer layer 26 is generally from
about 5 mils to
about 10 mils. It is contemplated that the outer layer 26 may also have other
thicknesses.
Although not shown in the illustrated embodiments, the outer layer 26 may
include ribs, an
array of dimples, corrugations, scores, combinations thereof, or the like to
increase insulation
and/or to provide an enhanced surface for gripping.
[0053] The insulating middle layer 25 may comprise any suitable material. For
example, the insulating middle layer 25 may comprise flat, unscored paperboard
such as
chipboard (plain chip or bending chip), linerboard, virgin paperboard,
paperboard with
recycled content, SBS board, SUS board, polymeric sheets, combinations
thereof, or the like.
The middle layer 25 may further be comprised of scored foil or metalized film
laminated
paperboard, porous sheets, foam sheets (e.g., expanded polystyrene), fluted
paperboard sheet,
a water-soluble (e.g., starch-based) material, a paperboard sheet with a
foamed heat-
insulating layer coating (e.g., polyethylene, polyolefin, polyvinylchloride,
polystyrene,
polyester, or nylon), combinations thereof, or the like. The thickness of the
middle layer 25
is generally from about 2 mils to about 15 mils. More typically, the thickness
of the middle
layer 25 is generally from about 5 mils to about 10 mils. It is contemplated
that the middle
layer 25 may also have other thicknesses.
10054] The middle layer 25 generally includes spaced grooves, scores, or
corrugations
33 (see FIG. 2b) formed into its surface. The corrugations 33 provide air
space within the
sidewall 12 of the cup 10. The corrugations 33 of the illustrated embodiments
extend
CA 02598153 2007-08-20
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substantially from a top edge 34a to a bottom edge 34b of the middle layer 25.
The
corrugations 33 may be positioned from about 115 mils to about 515 mils apart
and may
range from about 5 mils to about 30 mils deep. It is contemplated that the
corrugations 33
may be positioned other distances apart and/or may have various other depths.
The
corrugations 33 may be formed by any suitable die operation(s). In one
embodiment, the
corrugations 33 are formed into a sheet while cutting the sheet from a larger
starting sheet.
The corrugations 33 may also be formed prior to or after cutting the sheet. In
an alternative
embodiment, instead of corrugations running from top to bottom, the
corrugations are
positioned to run sideways (i.e., from left to right), diagonally, or the
like. Furthermore,
instead of corrugations 33, it is contemplated that embossed dimples or any
other type of
integral deformities may be formed into the sheet.
[00551 The bottom 11 may comprise various types of suitable materials. Non-
limiting examples of materials that may be used to form the bottom 11 include
unscored
paperboard such as chipboard (plain chip or bending chip), linerboard, virgin
paperboard,
paperboard with recycled content, SBS board, SUS board, polymeric solid
sheets,
combinations thereof, or the like. The bottom 11 may further be comprised of
foil or
metalized film laminated paperboard, porous sheets, foam sheets (e.g.,
expanded
polystyrene), combinations thereof, or the like. The thickness of the bottom
11 is generally
from about 1 mil to about 20 mils. More typically, the thickness of the bottom
11 is generally
from about 5 mils to about 15 mils. It is contemplated that the bottom 11 may
also have other
thicknesses. It is further contemplated that the bottom 11 may be coated on at
least an inner
surface 35 with a waterproof material including those described above with
respect to the
inner layer 24.
[00561 Each of the inner layer 24, the middle layer 25, and the outer layer 26
is
formed from a corresponding inner layer blank 28, middle layer blank 30, and
outer layer
blank 32, as shown in FIG. 2a. Each of the blanks 28, 30, 32 may be die cut
from a separate,
corresponding larger sheet or roll (not shown) of paper or other suitable
sheet material.
[00571 The inner layer blank 28 and the outer layer blank 32 are generally
tapered to
form the corresponding inner layer 24 and outer layer 26 of the sidewall 12 of
the cup 10. In
general, when making straight-walled containers using techniques of the
present invention,
the sidewall blanks should be generally straight rather than tapered as in
FIG. 2a.
[00581 In the illustrated embodiment, the middle layer 25 is corrugated, thus
allowing
portions of the middle layer 25 to be stretched or compressed when wrapped to
form the cup
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10. Therefore, the middle layer blank 30 may have various shapes including
rectangular, as
shown in the embodiment of FIG. 2a.
[0059] The dimensions of the inner layer blank 28, the middle layer blank 30,
and the
outer layer blank 32 generally depend on the desired dimensions of the
resulting cup 10. The
width W of the blanks 28, 30, 32 may, for example, range from about 4 inches
to about 24
inches. It is also contemplated, however, that the blanks 28, 30, 32 may have
other widths.
Because the outer layer 26 of the cup 10 has a slightly larger circumference
than the middle
layer 25, the outer layer blank 32 is generally slightly wider than the middle
layer blank 30.
Similarly, because the middle layer 25 has a slightly larger circumference
than the inner layer
24, the middle layer blank 30 is generally slightly wider than the inner layer
blank 28.
[0060] The height H of each of the blanks 28, 30, 32 may generally range from
about
2 inches to about 10 inches. According to the illustrated embodiment of FIG.
2a, the inner
layer blank 28 has a greater height (i.e., is taller) than the middle layer
blank 30 and the outer
layer blank 32. This may be desirable so that less materials are used, thereby
decreasing the
cost of manufacturing the resulting cup 10. In embodiments where the outer
layer blank 32
and/or the middle layer blank 30 have smaller heights than the inner layer
blank 28, the
blanks 28, 30, 32 should be stacked such that at least the middle portion 25
is generally
located on an area of the sidewall 12 that is likely to be grasped by a user.
For example, the
middle portion 25 may be generally centrally located relative to the height of
the cup 10. It is
contemplated that the blanks and corresponding layers of the cups or
containers of the present
invention may also have other heights relative to one another.
[0061] After each of the inner layer blank 28, the middle layer blank 30, and
the outer
layer blank 32 are cut and formed, they are assembled to form the sidewall 12
(FIG. 1). To
form the sidewall 12, the outer layer blank 32, the middle layer blank 30, and
the inner layer
blank 28 are stacked to form a flat, three-layered arrangement 44, as shown in
FIG. 2c. The
middle layer blank 30 is sandwiched between the outer layer blank 32 and the
inner layer
blank 28 such that a front side 46a of the outer layer blank 32 forms an
outside surface 47 of
the cup 10 and the back side 46b of the inner layer blank 28 forms an inside
surface 50 of the
cup (FIG. 1).
[0062] The middle layer blank 30 may be glued, bonded, or otherwise fastened
to the
inner layer blank 28 and/or the outer layer blank 32. For example, the middle
layer blank 30
may be attached to the inner layer blank 28 and the outer layer blank 32 by
dabbing small
amounts of adhesive (e.g., hot melt adhesive) periodically along the length of
either or both
CA 02598153 2007-08-20
sides 49a,b of the middle layer blank 30. Alternatively or additionally, the
small amounts of
adhesive may be dabbed periodically along the length of a front side 36a of
the inner layer
blank 28 and/or along the back side 46b of the outer layer blank 32. Because
the outer layer
26 generally has a slightly larger circumference than the middle layer 25 and
the inner layer
24 (as described above), the outer layer blank 32 slides relative to the
middle layer blank 30
and the inner layer blank 28 when the three-layered arrangement 44 is wrapped
to form the
sidewall 12. Thus, dabbing the adhesive periodically along the length of the
blank(s) 28, 30,
32 fastens the blanks 28, 30, 32 such that the outer layer blank 32 may slide
relative to the
inner layer blank 28 to assist in preventing the resulting sidewall 12 from
becoming distorted.
In embodiments where the middle layer blank 30 is fastened to only one of the
inner layer
blank 28 or the outer layer blank 32, it may be desirable for the inner layer
blank 28 to be
fastened to the outer layer blank (e.g., at an end 47a, 47b) such that each
layer 28, 30, 32 is at
least indirectly attached to the other layers 28, 30, 32. The adhesive serves
to maintain the
blanks 28, 30, 32 in the flat, three-layered arrangement 44 of FIG. 2c prior
to assembling the
cup 10 and to assist in preventing shifting of the individual blanks 28, 30,
32. The adhesive
may also assist in maintaining the resulting cup 10 in an assembled state.
[0063] After the three-layered assembly 44 is formed, it may then be wrapped
to form
the sidewall 12 of the cup. According to one embodiment, the three-layered
arrangement 44
is wrapped or bent around a known tapered mandrel (not shown) to form the
sidewall 12,
which includes the inner layer 24, the middle layer 25, and the outer layer
26. It is
contemplated that other methods of wrapping the three-layered assembly 44 may
also be
used. A first end 47a of the three-layered arrangement 44 is then sealed with
a second end
47b at a side seam area (not shown).
[0064] FIG. 3a shows a flat three-layered arrangement 48 according to one
embodiment of the present invention. The three-layered arrangement 48 of FIG.
3a is similar
to that of FIG. 2c. However, the three-layered arrangement 48 of FIG. 3a
includes a middle
layer blank 52 having a shorter length than an inner layer blank 54 and an
outer layer blank
56. The blanks 52, 54, 56 are stacked such that respective first edges 58, 60,
62 of the blanks
52, 54, 56 are generally aligned at a first end 64 of the three-layered
arrangement 48.
[0065] The middle layer blank 52 may be glued, bonded, or otherwise fastened
to
either or both the inner layer blank 54 and the outer layer blank 56 as
described above with
respect to the embodiment of FIGs. 2a-c. Alternatively or additionally, the
middle layer
blank 52, the inner layer blank 54, and the outer layer blank 56 may be
attached at or near the
CA 02598153 2007-08-20
11
first end 64 (i.e., at or near the respective first edges 58, 60, 62) such
that each blank 52, 54,
56 is at least indirectly attached to the other blanks 52, 54, 56.
[00661 The three-layered arrangement 48 of FIG. 3a may then be wrapped and
assembled into a cup 66 having an inner layer 68 (formed from the inner layer
blank 54), a
middle layer 69 (formed from the middle layer blank 52), and an outer layer 70
(formed from
the outer layer blank 56), as shown in FIGs. 3b, 3c. The wrapping is performed
such that the
first end 64 (i.e., the first edges 58, 60, 62) is on the outside of the cup
66 and an opposing
second end 67 is on the inside of the cup 66. It is contemplated, however,
that the wrapping
may also be performed such that the first end 64 is on the inside of the cup
66 and the second
end 67 is on the outside of the cup 66. Marginal portions of the outer layer
70, the middle
layer 69, and the inner layer 68 of the first end 64 overlap marginal portions
of the outer layer
70 and the inner layer 68 of the second end 67. Although in the illustrated
embodiment, the
middle layer 69 does not overlap the first end 64, it is contemplated that a
marginal portion of
the middle layer 69 may overlap the first end 64, as shown in FIG. 3d. It is
contemplated
that any suitable wrapping technique may be used.
[00671 After the three-layer arrangement 48 has been wrapped, a back side 80b
of the
outer layer 70 is attached to a front side 78a of the inner layer 68 at a
first attachment site 72
located at the second end 67, as shown in FIG. 3e. Additionally, a back side
78b of the inner
layer 68 of the first end 64 and a front side 80a of the outer layer 70 at the
second end 67 are
attached at a second attachment site 74, as shown in FIG. 3e. Thus, a
resulting side seam 76
of the embodiment of FIGs. 3a-e generally includes five layers: three layers
of the first end
64 (outer layer 70, middle layer 69, and inner layer 68) and two layers of the
second end 67
(outer layer 70 and inner layer 68). Therefore, shortening the length of the
middle layer
blank 52 with respect to the inner layer blank 54 and the outer layer blank
56, as illustrated in
FIGs. 3a-e, reduces the thickness of the side seam 76 such that only five
layers are present at
the side seam 76, instead of six layers, as would be the case if the middle
layer blank 52
extended to the second end 67 (see FIGs. 2a-c).
[00681 It is contemplated that any suitable attachment method may be used at
the first
and second attachment sites 72, 74 and the resulting side seam 76 including,
but not limited
to, adhesive, heat sealing, combinations thereof, or the like. At least one of
the surfaces at
each of the attachment sites 72, 74 has an adhesive or a coating applied
thereon such that a
seal may be formed. Coating less than all of the sides of the inner layer 68
and/or the outer
layer 70 may be desirable to reduce costs of manufacturing and also to make
the cup 66 more
CA 02598153 2007-08-20
12
environmentally friendly. For example, each of the inner layer 68 and the
outer layer 70 may
include a polyethylene coating on only one of the front side 78a, 80a or the
back side 78b,
80b. Because it may be desirable for the back side 78b of the inner layer 68
to include a
waterproof coating (because the back side 78b may contact liquid within the
cup 66), the
back side 78b of the inner layer 68 and the back side 80b of the outer layer
70 may include a
polyethylene coating 75, as illustrated in FIG. 3f. Alternatively, only one of
the inner layer
68 and the outer layer 70 may include a polyethylene coating on both the front
side 78a, 80a
and the back side 78b, 80b. It is also contemplated that the inner layer 68
and the outer layer
70 may include a polyethylene coating 75 on both the front sides 78a, 80a and
the back sides
78b, 80b, as shown in FIG. 3g.
[0069] Referring now to the embodiments of FIGs. 4a-d, a flat, three-layered
arrangement 82 is shown according to another embodiment of the present
invention. The
three-layered arrangement 82 is similar in structure to the three-layered
arrangement 48 of
FIG. 3a in that the three-layered arrangement 82 includes a middle layer blank
84 that is
shorter in length than an inner layer blank 86 and an outer layer blank 88. In
the embodiment
of FIG. 4a, however, the middle layer blank 84 is generally positioned a
marginal distance d
away from a first end 90 and a marginal distance d' away from a second end 92.
It is
contemplated that the distance d may be substantially the same as or different
than the
distance d'. Although in the embodiments of FIGs. 4a-d, the inner layer blank
84 and the
outer layer blank 88 are substantially the same length, it is contemplated
that the inner layer
blank 84 and the outer layer blank 88 may have different lengths.
[0070] The three-layered arrangement 82 may then be attached and wrapped using
any suitable techniques, including those described above with respect to FIGs.
2a-c, to form a
resulting cup 94, as shown in FIG. 4b. The cup 94 includes an outer layer 95
(formed from
the outer layer blank 88), a middle layer 98 (formed from the middle layer
blank 84), and an
inner layer 99 (formed from the inner layer blank 86).
[0071] Referring to FIG. 4c, after the three-layered arrangement 82 is
wrapped, a
marginal portion of the first end 90 overlaps a marginal portion of the second
end 92. The
overlapping portion includes four layers: two layers of the first end 90
(i.e., the outer layer 95
and the inner layer 99) and two layers of the second end 92 (i.e., the outer
layer 95 and the
inner layer 99).
[0072] FIG. 4d illustrates one possible way of forming a side seam using the
wrapped
three-layered arrangement 82 of FIGs. 4a-c. In the embodiment of FIG. 4d, the
outer layer 95
CA 02598153 2007-08-20
13
and the inner layer 99 of the first end 90 are attached to one another at a
first attachment site
96a, and the outer layer 95 and the inner layer 99 of the second end 92 are
attached to one
another at a second attachment site 96b. The layers 95, 99 of the first end 90
are then
attached to the layers 95, 99 of the second end 92 at a third attachment site
96c. It is
contemplated that each of the attachment sites 96a-c may be formed
simultaneously or
separately (in any order).
[00731 Referring now to FIG. 5a, a flat, three-layered arrangement 103 is
shown
according to another embodiment of the present invention. The three-layered
arrangement
103 includes an inner layer blank 104, a middle layer blank 105, and an outer
layer blank
106. In the embodiment of FIGs. 5a-d, the length of the outer layer blank 106
is greater than
the length of the inner layer blank 104 and the middle layer blank 105. In the
illustrated
embodiment, the length of the inner layer blank 104 is substantially the same
as the length of
the middle layer blank 105. It is also contemplated that the inner layer blank
104 may have a
different length than the middle layer blank 105. The blanks 104, 105, 106 are
stacked to
form the three-layered arrangement 103 such that respective first edges 108,
110, 112 of the
blanks 104, 105, 106 are generally aligned at a first end 114 of the three-
layered arrangement
103. The blanks 104, 105, 106 may be attached to one another using any
suitable method
including those described with respect to FIGs. 2a-c.
[00741 The three-layered arrangement 103 of FIG. 5a may then be wrapped and
assembled into a cup 116 (FIG. 5b) having an inner layer 118 (formed from the
inner layer
blank 104), a middle layer 120 (formed from the middle layer blank 105), and
an outer layer
122 (formed from the outer layer blank 106), as shown in FIG. 5b. The wrapping
is
performed such that the first end 114 (i.e., the first edges 108, 110, 112) is
on the inside of the
cup 116 and an opposing second end 124 is on the outside of the cup 116. It is
contemplated,
however, that the wrapping may also be performed such that the first end 114
is on the
outside of the cup 116 and the second end 124 is on the inside of the cup 116.
After the
three-layered arrangement 103 is wrapped, a marginal portion of the outer
layer 122 of the
second end 124 overlaps a marginal portion of the layers 118, 120, 122 of the
first end 114,
as shown in greater detail in FIG. 5c. Thus, the overlapping portion includes
four layers: the
outer layer 122 of the second end 124 and the outer layer 122, the middle
layer 120, and the
inner layer 118 of the first end 114. It is contemplated that any suitable
wrapping technique
may be used, including those described above with respect to FIGs. 2a-c.
CA 02598153 2007-08-20
14
[0075] The four layers may then be attached to form a side seam 126, as shown
in
FIG. 5d. More specifically, a back side 132b of the outer layer 122 of the
second end 124
may be attached to a front side 132a of the outer layer 122 of the first end
114 at an
attachment site 134. The layers may be attached using any suitable method,
including the
methods described above with respect to FIGs. 2a-e.
[0076] Because there is only one attachment site 134 involving both sides
132a,b of
the outer layer 122 in the embodiment of FIGs. 5a-d, it would be sufficient
for either the front
side 132a or the back side 132b of the outer layer 122 to include an adhesive
or a coating to
form the side seam 126. According to another embodiment, the front side 132a
of the outer
layer 122 and a back side 135b of the inner layer 118 include, for example, a
polyethylene
coating. It is contemplated that other surfaces or combinations of surfaces of
the inner layer
118 and/or the outer layer 122 may be coated with polyethylene.
[0077] Referring now to FIGs. 6a-d, a flat, three-layered arrangement 150 is
shown
according to another embodiment of the present invention. The three-layered
arrangement
150 includes an inner layer blank 152, a middle layer blank 154, and an outer
layer blank
156. In the embodiment of FIGs. 6a-d, the length of the inner layer blank 152
is generally
greater than the length of the outer layer blank 156 and the middle layer
blank 154. Although
in the illustrated embodiment, the middle layer blank 154 and the outer layer
blank 156 are
substantially the same length, it is contemplated that the middle layer blank
154 and the outer
layer blank 156 may have different lengths. The blanks 152, 154, 156 are
stacked to form the
three-layered arrangement 150 such that respective first edges 158, 160, 162
of the blanks
152, 154, 156 are generally aligned at a first end 164 of the three-layered
arrangement 150.
The blanks 152, 154, 156 of the three-layered arrangement 150 may be attached
using any
suitable method including those described with reference to FIGs. 2a-c.
[0078] The three-layered arrangement 150 of FIG. 6a may then be wrapped and
assembled into a cup 170 (FIG. 6b) having an inner layer 174 (formed from the
inner layer
blank 152), a middle layer 176 (formed from the middle layer blank 154), and
an outer layer
178 (formed from the outer layer blank 156), as shown in FIG. 6b. The wrapping
is
performed such that the first end 164 (i.e., the first edges 158, 160, 162) is
on the outside of
the cup 170 and an opposing second end 172 is on the inside of the cup 170. It
is
contemplated, however, that the wrapping may also be performed such that the
first end 164
is on the inside of the cup 170 and the second end 172 is on the outside of
the cup 170. It is
CA 02598153 2007-08-20
contemplated that any suitable wrapping technique may be used including those
described
above with respect to FIGs. 2a-c.
[0079] After the three-layered arrangement 150 is wrapped, marginal portions
of the
layers 174, 176, 178 of the first end 164 overlap a marginal portion of the
inner layer 174 of
the second end 172. Thus, the overlapping portion includes four layers: the
outer layer 178,
the middle layer 176, and the inner layer 174 of the first end 164 and the
inner layer 174 of
the second end 172. The four layers may then be attached to form a side seam
180, as shown
in FIG. 6d. More specifically, a back side 175b of the inner layer 174 of the
first end 164 is
attached to a front side 175a of the inner layer 174 of the second end 172 at
an attachment
site 186 (FIG. 6d). The layers may be attached using any suitable methods
including the
methods described above with respect to FIGs. 2a-e.
[0080] Because there is only one attachment site 186 in the embodiment of
FIGs. 6a-
d, it would be sufficient for either the front side 175a or the back side 175b
of the inner layer
174 to include an adhesive or a coating to form the side seam 180. It may be
desirable, for
example, for a polyethylene coating to be located on the back side 175a of the
inner layer 174
to waterproof the interior surface of the cup 170. It is contemplated that
other surfaces or
combinations of surfaces of the inner layer 174 and/or the outer layer 178 may
be coated with
polyethylene.
[0081] Referring now to FIGs. 7a-d, a flat, three-layered arrangement 200 is
shown
according to another embodiment of the present invention. The three-layered
arrangement
200 includes an inner layer blank 202, a middle layer blank 204, and an outer
layer blank
206. In the embodiment of FIGs. 7a-d, the length of the inner layer blank 202
is generally
greater than the length of the outer layer blank 206 and the middle layer
blank 204.
Furthermore, the outer layer blank 206 is longer than the middle layer blank
204. The inner
layer blank 202 and the outer layer blank 206 are stacked such that a first
edge 208 of the
inner layer blank 202 is generally aligned with a first edge 210 of the outer
layer blank 206 at
a first end 211 of the three-layered arrangement 200. The middle layer blank
204 is stacked
such that a first edge 212 of the middle layer blank 204 is offset from the
first edges 208, 210
of the inner layer blank 202 and the outer layer blank 206. An opposing second
edge 214 of
the middle layer blank 204 is generally aligned with a second edge 216 of the
outer layer
blank 206. The blanks 202, 204, 206 of the three-layered arrangement 200 may
be attached
using any suitable method including those described with reference to FIGs. 2a-
c.
CA 02598153 2007-08-20
t.
16
[0082] The three-layered arrangement 200 of FIG. 7a may then be wrapped and
assembled into a cup 220 (FIG. 7b) having an inner layer 222 (formed from the
inner layer
blank 202), a middle layer 224 (formed from the middle layer blank 204), and
an outer layer
226 (formed from the outer layer blank 206), as shown in FIG. 7b. The wrapping
is
performed such that the first end 211 (i.e., the first edges 208, 210, 212) is
on the outside of
the cup 220 and an opposing second end 228 is on the inside of the cup 220. It
is
contemplated, however, that the wrapping may also be performed such that the
first end 211
is on the inside of the cup 220 and the second end 228 is on the outside of
the cup 220. It is
contemplated that any suitable wrapping techniques may be used including those
described
above with respect to FIGs. 2a-c.
[0083] After the three-layered arrangement 200 of FIG. 7a is wrapped, marginal
portions of the outer layer 226 and the inner layer 222 of the first end 211
overlap a marginal
portion of the inner layer 222 of the second end 228, as shown in FIG. 7c.
Thus, the
overlapping portion includes three layers: the outer layer 226 and the inner
layer 222 of the
first end 211 and the inner layer 222 of the second end 228. The three layers
may then be
attached to form a side seam 230, as shown in FIG. 7d. More specifically, a
back side 231b
of the outer layer 226 of the first end 211 is attached to a front side 232a
of the inner layer
222 of the first end 211 at a first attachment site 233a. A back side 232b of
the inner layer
222 of the first end 211 is attached to a front side 232a of the inner layer
222 of the second
end 228 at a second attachment site 233b. The layers may be attached using any
suitable
methods including the methods described above with respect to FIGs. 2a-e.
Depending on
the distance D" of the middle layer 226 from the first end 211 of the cup 220,
the slope of the
outer layer 226 at the first end 211 after being sealed may be small and/or
gradual.
Furthermore, the outer layer 226 of the first end 211 is in generally the same
plane as the
outer layer 226 of the second end 228, which may be desirable to create a
smooth surface at
or near the side seam 230.
[0084] As described above, at least one of the surfaces at each of the
attachment sites
233a, 233b includes an adhesive or a coating applied thereon such that a
generally leak-proof
seal may be formed. Thus, each of the inner layer 222 and the outer layer 226
of FIGs. 7a-d
may include a polyethylene coating on both the front sides 231 a, 232a and the
back sides
231b, 232b. Alternatively, each of the inner layer 222 and the outer layer 226
may be coated
with polyethylene on only one side 231 a, 232a, 231b, 232b. According to one
non-limiting
example, a back side 231 b of the outer layer 226 and a back side 232b of the
inner layer 222
CA 02598153 2007-08-20
t . = ,
17
are coated with polyethylene. It is contemplated that other surfaces or
combinations of
surfaces of the inner layer 222 and/or the outer layer 226 may be coated with
polyethylene.
[0085] Referring now to FIGs. 8a-f, a flat, three-layered arrangement 292 is
shown
according to another embodiment of the present invention. The three-layered
arrangement
292 includes an inner layer blank 294, a middle layer blank 296, and an outer
layer blank
298. In the embodiment of FIGs. 8a-f, the length of the middle layer blank 296
is generally
smaller than the length of the inner layer blank 294 and the outer layer blank
298. Although
in the illustrated embodiment, the inner layer blank 294 and the outer layer
blank 298 are
substantially the same length, it is contemplated that the inner layer blank
294 and the outer
layer blank 298 may have different lengths.
[0086] At a first end 300 of the three-layered arrangement 292, the inner
layer blank
294 and the middle layer blank 296 are stacked such that a first edge 302 of
the inner layer
blank 294 is generally aligned with a first edge 304 of the middle layer blank
296. A first
edge 306 of the outer layer blank 298 extends past the first edges 302, 304 of
the inner layer
blank 294 and the middle layer blank 296 at the first end 300. At an opposing
second end
308, a second edge 310 of the middle layer blank 296 is generally aligned with
a second edge
312 of the outer layer blank 298. A second edge 314 of the inner layer blank
294 extends
past the second edges 310, 312 of the middle layer blank 296 and the outer
layer blank 298 at
the second end 308. The blanks 294, 296, 298 of the three-layered arrangement
292 may be
attached using any suitable technique including those described above with
respect to FIGs.
2a-c.
[0087] The three-layered arrangement 292 of FIG. 8a may then be wrapped and
assembled into a cup 316 (FIG. 8b) including an inner layer 318 (formed from
the inner layer
blank 294), a middle layer 320 (formed from the middle layer blank 296), and
an outer layer
322 (formed from the outer layer blank 298). The wrapping is performed such
that the first
end 300 is on the outside of the cup 316 and an opposing second end 308 is on
the inside of
the cup 316. It is contemplated, however, that the wrapping may also be
performed such that
the first end 300 is on the inside of the cup 316 and the second end 308 is on
the outside of
the cup 316. It is contemplated that any suitable wrapping technique may be
used including
those described with respect to FIGs. 2a-c.
[0088] Referring to FIG. 8d, after the three-layered arrangement 292 is
wrapped, a
marginal portion of the outer layer 322 of the first end 300 overlaps a
marginal portion of the
inner layer 318 of the second end 308. Thus, the overlapping portion includes
two layers.
CA 02598153 2007-08-20
18
The two layers may then be attached to form a side seam 324, as shown in FIGs.
8d. More
specifically, a back side 325b of the outer layer 322 of the first end 300 may
be attached to a
front side 326a of the inner layer 318 of the second end 308 at an attachment
site 328. The
two layers may be attached using any suitable method, including the methods
described
above with respect to FIGs. 2a-e.
[00891 Referring now to an alternative embodiment of FIG. 8e, after the three-
layered
arrangement 308 is wrapped, a marginal portion of the outer layer 322 of the
first end 300
overlaps a marginal portion of the layers 318, 320, 322 of the second end 308.
Likewise, a
marginal portion of the inner layer 318 of the second end 308 overlaps a
marginal portion of
the layers 318, 320, 322 of the first end 300. Thus, the embodiment of FIG. 8e
includes two
overlapping portions each having four layers. A first overlapping portion
includes the outer
layer 322 of the first end 300 and the outer layer 322, the middle layer 320,
and the inner
layer 318 of the second end 308. The second overlapping portion includes the
outer layer
322, the middle layer 210, and the inner layer 318 of the first end 300 and
the inner layer 318
of the second end 308. The layers may then be attached to form a side seam
390, as shown in
FIG. 8e. More specifically, the back side 325b of the outer layer 322 of the
first end 300 may
be attached to a front side 325a of the outer layer 322 of the second end 308
at a first
attachment site 391a. A back side 326b of the inner layer 318 of the first end
300 is attached
to a front side 326a of the inner layer 318 of the second end 308 to form a
second attachment
site 391b. The layers may be attached using any suitable method, including the
methods
described above with respect to FIGs. 2a-e.
[00901 As described above, at least one of the surfaces at each of the
attachment sites
328, 391a,b includes an adhesive or a coating applied thereon such that a seal
may be formed.
Thus, at least one of the back side 325b of the outer layer 322 and the front
side 326a of the
inner layer 318 may be coated with, for example, polyethylene. Because it may
be desirable
for a back side 326b of the inner layer 318 to include a waterproof coating,
it is contemplated
that both the front side 326a and the back side 326b of the inner layer 318
may include a
polyethylene coating. It is contemplated that other surfaces or combinations
of surfaces of
the inner layer 318 and/or the outer layer 322 may be coated with
polyethylene.
[00911 According to another embodiment of the present invention, the thickness
of
the side seam may be reduced by using a skiving (thinning or shaving) unit to
slice or shave a
predetermined thickness off of a marginal portion of the inner layer and/or
the outer layer at
an attachment site(s) prior to wrapping. The thickness of the skived portion
is generally
CA 02598153 2007-08-20
19
between about 10% to about 90% and, more specifically, between about 25% to
about 75%
of the total thickness of the inner layer and/or outer layer. Although such a
skiving technique
may be applied to any of the embodiments of the present invention, the
technique is
illustrated in FIGs. 8f, 8g using the three-layered arrangement 292 of FIG.
8a. Thus,
referring to FIG. 8a, the thickness of a portion(s) of the inner layer blank
294 and/or a
portion(s) of the outer layer blank 298 that forms at least a part of the side
seam (e.g., side
seams 324, 390) is reduced. Reduced areas 392a,b are shown in FIGs. 8f and 8g.
The
reduced areas 392a,b are located at a first and second attachment site 402a,b.
[0092] As described above, at least one of the surfaces at each of the
attachment sites
402, 404 has an adhesive applied thereon such that a seal may be formed. Thus,
it may be
desirable that the surface(s) not including adhesive be skived such that a
sufficient amount of
adhesive remains at the attachment sites 402a,b to create a side seam 406
including a
generally leak-proof seal.
[0093] Referring back to FIG. 1, in order to finish the cup 10, an upper edge
49a of
the inner layer 24 is rolled radially outward to form a rim. The embodiment of
FIG. 1 (or a
similar embodiment), where the inner layer 24 extends past an upper edge 51a
of the outer
layer 26, may be desirable to facilitate the rolling process. The bottom 11 is
attached to the
inner layer 24, and a lower edge 49b of the inner layer 24 is folded inward
and heat sealed to
the bottom 11. It may be desirable for the inner layer 24 to extend past a
lower edge 51 b of
the outer layer 26 to facilitate sealing and attaching the bottom 11. It is
contemplated that
various suitable methods of forming and sealing the rim and the bottom of the
cup 10 may be
used.
[0094] The materials, relative sizes, arrangements, and the like of the parts
of the cups
of the embodiments of the present invention may be varied. For example, the
heights of the
inner layer, the middle layer, and the outer layer of the embodiments of the
present invention
may vary relative to one another. Furthermore, as shown in the illustrated
embodiments, the
middle layer and/or the outer layer may extend substantially around the entire
circumference
of the cup. Alternatively, the middle layer blank and/or the outer layer blank
may have a
shorter length, thereby extending around less than the entire circumference of
the cup. These
variations may be desirable to save paper and materials without significantly
affecting the
insulating performance of the cup. Additionally, it is contemplated that
mirror-image
embodiments of the three-layered arrangements of the illustrated embodiments
may also be
used in accordance with the present invention. It is also contemplated that
the blanks, layers,
CA 02598153 2007-08-20
and/or ends of the respective three-layered arrangements and/or cups of the
present invention
may be attached and/or sealed in any order.
[0095] The containers and cups of the present invention have many benefits
over
existing cups. For example, the cups of the present invention are generally
leak resistant and
have excellent thermal insulating properties. Additionally, the cups may be
formed on
existing cup machinery, resulting in high production speeds and low
manufacturing costs.
Moreover, the cups of the present invention have surfaces that are conducive
to printing with
sharp and crisp graphics.
[0096] As a consequence of using three separate layers to form the containers
and
cups of the present invention, a manufacturer may have the ability to alter
the various
thicknesses and materials of the layers to achieve the desired cup properties
including
insulating ability, weight, strength, percentage of recyclable materials, cost
of materials, and
the like. For example, the amount of recycled materials used in manufacturing
the cups of
the embodiments of the present invention may be optimized by varying the
amounts of
recycled material used to manufacture each of the inner layer, the middle
layer, and the outer
layer as necessary. Because the blanks of the present invention are not formed
from a single
sheet, the waste associated with the material removed from the portion of the
single sheet
surrounding the shortened middle layer and/or outer layer may be minimized or
eliminated.
This is particularly applicable in embodiments where the height of the middle
layer and/or the
outer layer is smaller than the height of the inner layer. Furthermore, in
embodiments where
it is desirable to print a "legend" in the inner ring of the bottom of the
cup, the present
invention only requires one-sided printing.
[0097] According to alternative embodiment A, a thermally insulated container
comprises an inner layer having a bottom portion with a bottom closure
attached to the
bottom portion, an outer layer wrapped around the inner layer, an insulating
middle layer
sandwiched between the inner layer and the outer layer, and a side seam
including five or less
layers, wherein at least one of the layers of the side seam is an end of the
middle layer.
[0098] According to alternative embodiment B, the container of alternative
embodiment A, wherein the container is a cup.
[0099] According to alternative embodiment C, the container of alternative
embodiment A, wherein the middle layer is attached to at least one of the
inner layer and the
outer layer.
CA 02598153 2007-08-20
21
[00100] According to alternative embodiment D, the container of alternative
embodiment A, wherein the middle layer includes spaced grooves formed in a
surface
thereof, said spaced grooves running substantially from a top edge to a bottom
edge of the
middle layer.
[00101] According to alternative embodiment E, the container of alternative
embodiment A, wherein each of the inner layer and the outer layer includes a
front side and a
back side, at least one of the front side and back side of at least one of the
inner layer and the
outer layer including a polyethylene coating.
[00102] According to alternative embodiment F, the container of alternative
embodiment A, further comprising a bottom blank attached to at least the inner
layer to form
a bottom of the container.
[00103] According to alternative embodiment G, the container of alternative
embodiment A, wherein the height of the middle layer is smaller than the
height of the inner
layer.
[00104] According to alternative embodiment H, the container of alternative
embodiment A, wherein the plurality of layers includes between three and five
layers.
[00105] According to alternative embodiment I, the container of alternative
embodiment A, wherein at least one of the layers of the side seam is skived.
[00106] According to alternative process J, a method of making a thermally
insulated container, comprises the acts of providing a bottom blank, an inner
layer, an outer
layer, and a middle layer, the middle layer comprising an insulating sheet
material, stacking
the inner layer, the outer layer, and the middle layer such that the middle
layer is sandwiched
between the inner layer and the outer layer to form a layered arrangement, the
layered
arrangement having a first end and an opposing second end, wrapping the
layered
arrangement such that the first end overlaps the second end to form an
overlapping portion,
and sealing at least part of the overlapping portion to form a side seam
having five or less
layers, wherein at least one of the layers of the side seam is an end of the
middle layer.
[00107] According to alternative process K, the method of alternative process
J,
further including attaching the middle layer to at least one of the inner
layer and the outer
layer.
[00108] According to alternative process L, the method of alternative process
J,
wherein the middle layer is attached to at least one of the inner layer and
the outer layer by
CA 02598153 2007-08-20
22
applying adhesive periodically along a length of at least one of the inner
layer, the middle
layer, and the outer layer.
[00109] According to alternative process M, the method of alternative process
J, wherein each of the inner layer and the outer layer includes a front side
and a back side, at
least one of the front side and the back side of at least one of the inner
layer and the outer
layer including a polyethylene coating.
[00110] According to alternative process N, the method of alternative process
J,
wherein the act of sealing includes applying pressure to the overlapping area
to form a heat
sea].
[00111] According to alternative process 0, the method of alternative process
J,
further comprising forming each of the inner layer, the outer layer, and the
middle layer from
three separate sheets of material.
[00112] According to alternative process P, the method of alternative process
J,
wherein the container is a cup, the method further comprising the act of
rolling a top portion
of at least the inner layer radially outward to form a rim.
[00113] According to alternative process Q, the method of alternative process
P
further comprising attaching at least the inner layer to the bottom blank to
form a bottom of
the cup.
[00114] According to alternative process R, the method of alternative process
J,
wherein the overlapping portion includes between three and five layers.
[00115] According to alternative process S, the method of alternative process
J
further comprising skiving at least a portion of at least one of the layers at
the overlapping
portion.
[00116] According to alternative embodiment T, a thermally insulated
container comprises an inner layer having a bottom portion with a bottom
closure attached to
said bottom portion, an outer layer wrapped around said inner layer, an
insulating middle
layer sandwiched between the inner layer and the outer layer, and a side seam
comprising
five or less layers, wherein at least one end of the outer layer is sealed
with at least one end of
the inner layer at the side seam.
[00117] According to alternative embodiment U, the container of alternative
embodiment T, wherein the middle layer extends around the entire container.
[00118] According to alternative embodiment V, the container of alternative
embodiment T, wherein the middle layer extends around less than the entire
container.
CA 02598153 2007-08-20
23
[001191 According to alternative embodiment W, the container of alternative
embodiment T, wherein at least one of the inner layer and the outer layer is
skived at the side
seam.
[00120] According to alternative embodiment X, a thermally insulated
container comprises an inner layer having a bottom portion with a bottom
closure attached to
the bottom portion, an outer layer wrapped around the inner layer, an
insulating middle layer
sandwiched between the inner layer and the outer layer, and a side seam
including six layers,
the six layers comprising a first end and a second end of the inner layer, a
first end and a
second end of the middle layer, and a first end and a second end of the outer
layer.
[001211 While the invention is susceptible to various modifications and
alternative forms, specific embodiments and methods thereof have been shown by
way of
example in the drawings and are described in detail herein. It should be
understood,
however, that it is not intended to limit the invention to the particular
forms or methods
disclosed, but, to the contrary, the intention is to cover all modifications,
equivalents and
alternatives falling within the spirit and scope of the invention.
