Note: Descriptions are shown in the official language in which they were submitted.
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SPECIFICATION
TITLE
REINFORCED PLASTIC FOAM CUP, METHOD OF AND APPARATUS OF
MANUFACTURING SAME
BACKGROUND
1100011 Drinking cups are commonly used in the consumption of
beverages and other products. Every day, millions of such cups are
distributed by fast food restaurants, coffee shops and convenience stores for
single use purposes. These cups are usually disposed of after a single use.
[00021 One type of known disposable cup is a conventional plastic foam
cup, such as a beaded polystyrene foam cup. A conventional plastic foam
cup, generally illustrated in Figs. 1 and 2, is generally indicated by numeral
10.
The conventional plastic foam cup 10 includes a resilient, frustoconical body
12. The body is open at a first or top end 14 and closed at a second or bottom
end 16. The top end has a greater diameter than the bottom end. The
frustoconical body is designed to facilitate stacking a plurality of cups
together
for transportation and dispensing purposes. The body includes a tapered side
wall 18 having an inner face or surface 20 and an outer face or surface 22
that
extends from the top end to the bottom end. The inner face or surface of the
tapered side wall may include at least one interior shelf which facilitates
stacking of a plurality of the cups. When the cup is positioned in an upright
position, the tapered side wall 18 is typically angled offset from a vertical
plane
at a suitable angle in the range of two degrees to fifteen degrees. The
tapered
side wall 18 includes an outwardly formed or extending lip 24. The outwardly
formed lip is suitably shaped such that an annular mounting portion of a
drinking cup lid (not shown) can be attached to the formed lip to secure the
drinking cup lid to the top of the cup. The outwardly formed lip is sometimes
utilized to hold the cup in place prior to the cup being dispensed from a
conventional cup dispenser.
[0003] One method of forming these conventional plastic foam cups
includes adding expanded polystyrene beads (which were previously modified
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with a suitable foaming agent) into a mold or cavity. Steam is injected into
the
mold or cavity which causes the polystyrene beads to expand to form the cup.
The formed cup is subsequently removed from the mold or cavity. However, it
should be appreciated that other suitable methods of forming a conventional
plastic foam cup, including any suitable injection molding technique, are
known.
[0004] Conventional plastic foam cups have outstanding heat-insulating
properties which make them particularly useful for serving hot beverages, such
as coffee, hot tea, soups and hot chocolate. These cups enable a person to
hold the cup without burning themselves and also tend to keep the beverage
hot. Conventional plastic foam cups also have outstanding cold-insulating
properties which make them particularly useful for serving cold food or
beverages, such as milk shakes, ice cream and chilled beverages. These
cups tend to keep the food or beverage cold for extended periods of time.
Such conventional plastic foam cups cost relatively less to manufacture than
paper or plastic based cups and are more leak resistant than cups which are
formed from more than one member as described below. However, the outer
surfaces of conventional plastic foam cups do not provide the tactile feel of
paper-based cups nor do such cups facilitate high-quality graphics to be
printed on the outer surfaces of such plastic foam cups
[0005] Other known insulated disposable cups for hot or cold beverages
are formed from paper. Paper cups are fabricated from a paper body member
which is bonded to a bottom paper panel member having an upper surface and
a bottom surface, wherein the joined portions of the bottom panel member and
body member form a seal. Paper-based cups include an inner lining which
covers the inner surface of the body and the upper surface of the bottom end,
wherein the inner lining is effective to prevent penetration of liquid into
the
paper during use. However, because these cups are formed from two
members (i.e., the body member and the bottom panel member), these cups
are more prone to leaking along the seam where the two members are joined.
Conventional paper cups have an outer surface which provides a comfortable
tactile feel but have very poor heat-insulating qualities. For example, paper
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cups are often too hot to handle for a period of time after being filled with
a hot
beverage. Beverage servers and consumers commonly nest two or more
paper-based cups together or add an insulating sleeve to provide insulation
for
hot drinks such as hot coffee, hot tea and hot chocolate. This is undesirable
because it increases the number of cups or sleeves used and costs additional
money. Double cupping can also make a filled cup more unstable or tipsy.
[0006] To solve these problems, it has been proposed to attach paper to
a plastic foam cup. One known method of applying paper to a plastic foam
cup is to spot glue portions of the inner face of a stationary piece of paper
with
a suitable adhesive and bringing a cup in contact with the stationary paper to
attach the paper to the plastic foam cup. This results in substantial portions
of
the paper not including adhesive. Due to the inconsistent and incomplete
placement of the adhesive on the paper, wrinkles are formed when the paper
is applied to or otherwise wrapped around the cup. Such wrinkles are
undesirable for a manufacturer and aesthetically displeasing to consumers.
[0007] Another known method includes applying a film to a plastic foam
cup and heat shrinking the film on the cup when the cup is formed. Such "in-
mold" method includes integrating the film with the material of the cup during
the cup manufacturing process. Such integration includes stretching the film
around the material which will form the cup and subsequently heating the
material and film to shrink the film to adhere to the material. While this cup
includes the desired insulation properties of a plastic foam cup, this method
is
relatively expensive.
[0008] Accordingly, a need exists to provide a disposable drinking cup
with the insulation properties of a plastic foam cup and the tactile feel and
high
quality graphic printing properties of a paper-based cup to provide an
enhanced drinking experience for a person. Furthermore, a need exists to
provide an apparatus, system and method for manufacturing such a
disposable drinking cup.
[0009] The various known machines, systems and methods for affixing
one or more labels to beverage containers do not solve these needs. For
instance, U.S. Patent Nos. 4,709,800; 4,729,81; 4,731,147; 4,743,469;
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4,911,285; 4,944,825; 4,944,830; 4,950,350; 4,973,374; 4,981,547; 4,994,135;
5,004,518; 5,017,261; 5,021,116; 5,037,499; 5,062,917; 5,062,918; 5,078,826;
5,082,520; 5,087,317; 5,110,402; 5,120,392; 5,121,827; 5,129,984; 5,160,570;
5,167,755; 5,174,851; 5,185,053; 5,188,696; 5,201,984; 5,217,538; 5,227,005;
5,271,783; 5,569,353; 5,713,403; 5,882,474; and 6,050,319 describe known
machines, systems and components for applying one or more labels to beverage
containers. These patents do not provide solutions to the above mentioned
problems. The reinforced cup and the cup reinforcing machines, apparatus,
systems and methods disclosed herein represent, at least in part, improvements
of
one or more of the machines, systems and methods disclosed in such patents.
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SUMMARY
[0010] The present disclosure relates in general to a reinforced plastic foam
cup,
and more particularly to a disposable plastic foam cup with an attached
reinforcing
member and to apparatus, methods and supplies for manufacturing the same.
[0011] In one embodiment, there is provided a reinforced plastic foam cup
comprising: a plastic foam conical body which has: an open top end including
an
outwardly rolled lip, a closed bottom end having a diameter less than the top
end,
and a tapered wall extending from the bottom end to the top end, said tapered
wall
having an outer surface and an inner surface; and a flat reinforcing member
affixed
around the outer surface of the tapered wall in an overlapping manner, said
reinforcing member including a body having: (i) a rigid material layer having
an inner
surface and an outer surface, and (ii) a pressure sensitive adhesive layer
which
covers substantially the entire inner surface of the material layer, wherein
prior to
being affixed around the outer surface of the tapered wall, the reinforcing
member
has: (a) a concave edge, (b) a convex edge, wherein a trough of the concave
edge
is aligned with an apex of the convex edge, (c) a leading edge extending along
a
first line, (d) a sensing edge configured to be sensed prior to the
reinforcing member
being affixed around the outer surface of the tapered wall, said leading edge
and
sensing edge extending between the concave and convex edges of one end of the
material layer, (e) a trailing edge extending along a second line which
intersects
said first line, and (f) an adhesive relief edge preventing the pressure
sensitive
adhesive layer from leaking from the inner surface of the material layer, said
trailing
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edge and said adhesive relief edge extending between the concave and convex
edges of an opposite end of the material layer, and said sensing edge and said
adhesive relief edge extending substantially parallel to each other; and
wherein
after being affixed around the outer surface of the tapered wall, the
reinforcing
member has: (i) the concave edge adjacent to the closed bottom end of the
plastic
foam conical body, (ii) the convex edge adjacent to the open top end of the
plastic
foam conical body, (iii) the leading edge and the trailing edge extending
substantially parallel to each other, and the sensing edge extending along a
third
line, and the adhesive relief edge extending along a fourth line which
intersects the
third line.
[0012] In anther embodiment, there is provided a reinforced plastic foam cup,
said
reinforced cup comprising; a plastic foam cup having: a bottom wall, a conical
shaped side wall integrally formed at one end with the bottom wall and
extending
from the bottom wall to a top end, said side wall having an inner surface and
an
outer surface, said bottom wall and said side wall defining a cavity, and said
top end
defining an opening for the cavity, the top end having a greater diameter than
the
bottom end, an outwardly extending lip integrally formed with the top end of
the side
wall, and a downwardly extending lip integrally formed with the side wall and
extending below the bottom wall; and a reinforcing member affixed around the
outer surface of the side wall in an overlapping manner, said reinforcing
member
including a body having: (i) a paper material layer having an inner surface
and an
outer surface, and (ii) a pressure sensitive adhesive layer which covers
substantially
the entire inner surface of the paper material layer, wherein prior to being
affixed
around the outer surface of the side wall, the reinforcing member has: (a) a
concave
edge, (b) a convex edge, wherein a trough of the concave edge is aligned with
an
apex of the convex edge, (c) a leading edge extending along a first line, (d)
a
sensing edge configured to be sensed prior to the reinforcing member being
affixed
around the outer surface of the side wall, said leading edge and said sensing
edge
extending between the concave and convex edges of one end of the material
layer,
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(e) a trailing edge extending along a second line which intersects said first
line, and
(f) an adhesive relief edge preventing said pressure sensitive adhesive layer
from
leaking from the inner surface of the paper material layer, said trailing edge
and
said adhesive relief edge extending between the concave and convex edges of an
opposite end of the material layer, and said sensing edge and said adhesive
relief
edge extending substantially parallel to each other; and wherein after being
affixed
around the outer surface of the side wall, the reinforcing member has: (i) the
concave edge adjacent to a bottom edge of the downwardly extending lip, (ii)
the
convex edge adjacent to the outwardly extending lip, (iii) the leading edge
and the
trailing edge extending substantially parallel to each other, and (iv) the
sensing
edge extending along a third line and the adhesive relief edge extending along
a
fourth line which intersect the third line.
[0013] In another embodiment, there is provided a plastic foam cup reinforcing
member supply roll comprising: an elongated backing release liner wrapped in a
roll; and a plurality of flat reinforcing members sequentially aligned along
the
elongated backing release liner, each reinforcing member including a paper
material
layer having an inner surface and an outer surface, prior to being affixed to
the
backing release liner, each reinforcing member having: (a) a concave edge, (b)
a
convex edge, wherein a trough of the concave edge is aligned with an apex of
the
convex edge, (c) a leading edge extending along a first line, (d) a sensing
edge,
said leading edge and said sensing edge extending between the concave and
convex edges of one end of the material layer, (e) a trailing edge extending
along a
second line which intersects said first line, and (f) an adhesive relief edge,
said
trailing edge and said adhesive relief edge extending between the concave edge
and the convex edge of an opposite end of the material layer, and said sensing
edge and said adhesive relief edge extending substantially parallel to each
other,
each of said reinforcing members configured such that when the reinforcing
member is affixed around an outer surface of a side wall of a conical cup
having a
bottom end and a top end, wherein the top end has a diameter greater than a
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diameter of the bottom end, (i) the concave edge is adjacent to the bottom end
of
the conical cup, (ii) the convex edge is adjacent to the top end of the
conical cup,
(iii) the leading edge and the trailing edge extend substantially parallel to
each
other, and (iv) the sensing edge extends along a third line, and the adhesive
relief
edge extends along a fourth line which intersects the third line, each of said
reinforcing members affixed to the backing release liner by a pressure
sensitive
adhesive layer which covers substantially the entire inner surface of the
paper
material layer, wherein for each of said reinforcing members, said adhesive
relief
edge of said reinforcing member prevents said pressure sensitive adhesive
layer
from leaking from the inner surface of the paper material layer.
[0014] In a still further aspect, there is provided a reinforced cup
comprising: a conical body which has: an open top end including an outwardly
rolled
lip, a closed bottom end having a diameter less than the top end, and a
tapered wall
extending from the bottom end to the top end, said tapered wall having: an
outer
surface and an inner surface; and a flat reinforcing member affixed around the
outer
surface of the tapered wall in an overlapping manner, said reinforcing member
including a body having: (i) a rigid material layer having an inner surface
and an
outer surface, and (ii) an adhesive layer which covers substantially the
entire inner
surface of the material layer, wherein when the rigid material layer resides
flat in a
first plane prior to being affixed around the outer surface of the tapered
wall, the
rigid material layer has: (a) a concave edge, (b) a convex edge, wherein a
trough of
the concave edge is aligned with an apex of the convex edge, (c) a leading
edge
extending along a first line, (d) a sensing edge configured to be sensed prior
to the
reinforcing member being affixed around the outer surface of the tapered wall,
said
leading edge and sensing edge extending between the concave and convex edges
of one end of the rigid material layer, (e) a trailing edge extending along a
second
line which intersects said first line, and (f) an adhesive relief edge
preventing the
adhesive layer from leaking from the inner surface of the rigid material
layer, said
trailing edge and said adhesive relief edge extending between the concave and
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convex edges of an opposite end of the rigid material layer, and said sensing
edge
and said adhesive relief edge extending substantially parallel to each other;
and
wherein after being affixed around the outer surface of the tapered wall, the
rigid
material layer has: (i) the concave edge adjacent to the closed bottom end of
the
conical body, (ii) the convex edge adjacent to the open top end of the conical
body,
(iii) the leading edge and the trailing edge extending substantially parallel
to each
other, and (iv) the sensing edge extending along a third line, and the
adhesive relief
edge extending along a fourth line which intersects the third line.
[0015] In a further aspect, there is provided a reinforced cup comprising; a
cup having: a bottom wall, a conical shaped side wall integrally formed at one
end
with the bottom wall and extending from the bottom wall to a top end, said
side wall
having an inner surface and an outer surface, said bottom wall and said side
wall
defining a cavity, said top end defining an opening for the cavity, and said
top end
having a greater diameter than the bottom end, an outwardly extending lip
integrally
formed with the top end of the side wall, and a downwardly extending lip
integrally
formed with the side wall and extending below the bottom wall; and a
reinforcing
member affixed around the outer surface of the side wall in an overlapping
manner,
said reinforcing member including a body having: (i) a paper material layer
having
an inner surface and an outer surface, and (ii) an adhesive layer which covers
substantially the entire inner surface of the paper material layer, wherein
when the
paper material layer resides flat in a first plane prior to being affixed
around the
outer surface of the side wall, the paper material layer has: (a) a concave
edge, (b)
a convex edge, wherein a trough of the concave edge is aligned with an apex of
the
convex edge, (c) a leading edge extending along a first line, (d) a sensing
edge
configured to be sensed prior to the reinforcing member being affixed around
the
outer surface of the side wall, said leading edge and said sensing edge
extending
between the concave and convex edges of one end of the paper material layer,
(e)
a trailing edge extending along a second line which intersects said first
line, and (f)
an adhesive relief edge preventing said adhesive layer from leaking from the
inner
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surface of the paper material layer, said trailing edge and said adhesive
relief edge
extending between the concave and convex edges of an opposite end of the
material layer, and said sensing edge and said adhesive relief edge extending
substantially parallel to each other; and wherein after being affixed around
the outer
surface of the side wall, the paper material layer has: (i) the
concave edge
adjacent to a bottom edge of the downwardly extending lip, (ii) the convex
edge
adjacent to the outwardly extending lip, (iii) the leading edge and the
trailing edge
extending substantially parallel to each other, and (iv) the sensing edge
extending
along a third line and the adhesive relief edge extending along a fourth line
which
intersect the third line.
[0021] In another aspect, there is provided a method of reinforcing a plastic
foam cup, said method comprising: (a) providing a plastic foam conical body
which
has: (i) an open top end having a first diameter, said open top end including
an
outwardly rolled lip, (ii) a closed bottom end having a second diameter less
than the
first diameter of the open top end, and (iii) a tapered wall extending from
the closed
bottom end to the open top end, said tapered wall having an outer surface and
an
inner surface; (b) providing a flat reinforcing member having: (i) a material
layer
having an inner surface and an outer surface, (ii) a pressure sensitive
adhesive
layer which covers substantially the entire inner surface of the material
layer, (iii) a
concave edge having a trough, (iv) a convex edge having an apex, (v) a leading
edge extending along a first line, (vi) a sensing edge, said leading edge and
said
sensing edge extending between the concave and convex edges at a first end of
the material layer, (vii) a trailing edge extending along a second line, and
(viii) an
adhesive relief edge, said trailing edge and said adhesive relief edge
extending
between the concave and convex edges at a second, end of the material layer
which is opposite the first end of the material layer, said first line
intersecting said
second line, and said sensing edge and said adhesive relief edge extending
substantially parallel to each other; (c) prior to affixing the pressure
sensitive
adhesive layer of the reinforcing member around the outer surface of the
tapered
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wall, sensing the sensing edge to determine a location of the trough of the
concave
edge and the apex of the convex edge; and (d) affixing the pressure sensitive
adhesive layer of the reinforcing member to the outer surface of the tapered
wall by
initially affixing a first portion of the pressure sensitive adhesive layer
between the
trough of the concave edge and the apex of the convex edge and thereafter
affixing
a plurality of remaining portions of the pressure sensitive adhesive layer
including
said leading edge, said sensing edge, said trailing edge and said adhesive
relief
edge, wherein said plurality of remaining portions of the pressure sensitive
adhesive
layer are affixed around the outer surface of the tapered wall such that: (i)
the
concave edge is adjacent to the closed bottom end of the plastic foam conical
body,
(ii) the convex edge is adjacent to the open top end of the plastic foam
conical body,
(iii) the leading edge and said trailing edge extend substantially parallel to
each
other, and (iv) the sensing edge extends along a third line, and the adhesive
relief
edge extends along a fourth line which intersects the third line.
[0022] In another embodiment, there is provided a method of reinforcing a
plastic foam cup, said method comprising: (a) providing a plastic foam cup
having:
(i) a bottom wall, (ii) a conical shaped side wall integrally formed at one
end with the
bottom wall and extending from the bottom wall to a top end, said side wall
having
an inner surface and an outer surface, said bottom wall and side wall defining
a
cavity, said top end defining an opening for the cavity, the top end having a
greater
diameter than the bottom end, (iii) an outwardly extending lip integrally
formed with
the top end of the side wall, and (iv) a downwardly extending lip integrally
formed
with the side wall and extending below the bottom wall; (b) providing a
reinforcing
member including: (i) a paper material layer having an inner surface and an
outer
surface, (ii) a pressure sensitive adhesive layer which covers substantially
the entire
inner surface of the paper material layer, (iii) a concave edge having a
trough, (iv) a
convex edge having an apex, (v) a leading edge extending along a first line,
(vi) a
sensing edge, said leading edge and sensing edge extending between the concave
and the convex edges at a first end of the material layer, (vii) a trailing
edge
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extending along a second line, and (viii) an adhesive relief edge, said
trailing edge
and said adhesive relief edge extending between the concave and the convex
edges at a second, end of the material layer which is opposite the first end
of the
material layer, said first line intersecting said second line, and said
sensing edge
and said adhesive relief edge extending substantially parallel to each other;
(c) prior
to affixing the pressure sensitive adhesive layer of the reinforcing member
around
the outer surface of the side wall sensing the sensing edge to determine a
location
of the trough of the concave edge and the apex of the convex edge; and (d)
affixing
said pressure sensitive adhesive layer of the reinforcing member to the outer
surface of the side wall by initially affixing a first portion of the pressure
sensitive
adhesive layer between the trough of the concave edge and the apex of the
convex
edge and thereafter affixing a plurality of remaining portions of the pressure
sensitive adhesive layer including said leading edge, said sensing edge, said
trailing
edge and said adhesive relief edge, wherein said plurality of remaining
portions of
the pressure sensitive adhesive layer are affixed around the outer surface of
the
side wall such that: (i) the concave edge is adjacent to a bottom edge of the
downwardly extending lip, (ii) the convex edge is adjacent to the outwardly
extending lip, (iii) the leading edge and said trailing edge extend
substantially
parallel to each other, and (iv) the sensing edge extends along a third line,
and the
adhesive relief edge extends along a fourth line which interests the third
line.
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[0029] It is therefore an advantage of the present apparatus and method to
provide a disposable plastic foam drinking cup with a substantially improved
tactile
feel, substantially increased rigidity, and substantially increased durability
due to a
completely affixed reinforcing member.
[0030] A further advantage of the present apparatus and method is to provide
a disposable plastic foam drinking cup with high quality graphics printed on
the
outside wall of the cup to enhance the drinking experience for a person.
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[0031] A further advantage of the present apparatus and method is to
provide a disposable plastic foam drinking cup with a wrinkle-free reinforcing
member that is relatively inexpensive to manufacture.
[0032] Additional features and advantages are described in, and will be
apparent from, the following Detailed Description and the figures.
BRIEF DESCRIPTION OF THE FIGURES
[0033] Fig. us a front perspective view of a conventional plastic foam
cup.
[0034] Fig. 2 is a cross-sectional side view of the conventional plastic
foam cup of Fig. 1.
[0035] Fig. 3 is a front perspective view of one embodiment of a
reinforced plastic foam cup disclosed herein.
[0036] Fig. 4 is a cross-sectional side view of the reinforced plastic foam
cup of Fig. 3.
[0037] Fig. 5 is a top plan view of the outside face of one embodiment of
a reinforcing member disclosed herein.
[0038] Fig. 6 is a bottom plan view of the inside face of the reinforcing
member of Fig. 5.
[0039] Fig. 7 is a top plan view of a plurality of reinforcing members
sequentially positioned on an elongated release liner.
[0040] Fig. 5A is a top plan view of the outside face of an alternative
embodiment of a reinforcing member disclosed herein.
[0041] Fig. 6A is a bottom plan view of the inside face of the reinforcing
member of Fig. 5A.
[0042] Fig. 7A is a top plan view of a plurality of reinforcing members of
Fig. 5A sequentially positioned on an elongated release liner.
[0043] Fig. 5B is a top plan view of the outside face of another
alternative embodiment of a reinforcing member disclosed herein.
[0044] Fig. 8 is a schematic block diagram illustrating one embodiment
of a method of manufacturing the reinforced plastic foam cup of Fig. 3
disclosed herein.
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[0045] Fig. 9 is a diagrammatic top plan view of one embodiment of a
cup reinforcing system disclosed herein, illustrating a pre-reinforced plastic
foam cup separate from a reinforcing member.
[0046] Fig. 10 is a diagrammatic top plan view of the cup reinforcing
system of Fig. 9, illustrating the pre-reinforced plastic foam cup and the
reinforcing member moving into an engagement position.
[0047] Fig. 11 is a cross-sectional side view of the separated pre-
reinforced plastic foam cup and reinforcing member of Fig. 10.
[0048] Fig. 12 is a diagrammatic top plan view of the cup reinforcing
system of Fig. 9, illustrating a centered vertical axis of the reinforcing
member
aligned with the tapered side wall of the pre-reinforced plastic foam cup.
[0049] Fig. 13 is a side view of the pre-reinforced plastic foam cup
aligned with the centered vertical axis of the reinforcing member.
[0050] Fig. 14 is a cross-sectional side view of the reinforcing member
engaging the tapered side wall of the plastic foam cup.
[0051] Fig. 15 is a diagrammatic top plan view of the cup reinforcing
system of Fig. 9, illustrating a first portion of the reinforcing member
attached
to the cup and a second portion of the reinforcing member not attached to the
plastic foam cup.
[0052] Fig. 16 is a side view of the partially attached reinforcing member
of Fig. 15.
[0053] Fig. 17 is a diagrammatic top plan view of the cup reinforcing
system of Fig. 9, illustrating the reinforcing member full attached to the
plastic
foam cup to form the reinforced plastic foam cup of Fig. 3.
[0054] Fig. 18A is a diagrammatic top plan view of one embodiment of
the cup reinforcing system disclosed herein.
[0055] Fig. 18B is a diagrammatic side view of the cup reinforcing
system of Fig. 18A.
[0056] Fig. 19 is a side view of the dual cup dispenser, the cup conveyor
and the vacuum chamber of one embodiment of the cup reinforcing system
disclosed herein.
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[0057] Fig. 20 is a front perspective view of one set of cup dispensing
screws of the dual cup dispenser of Fig. 19.
[0058] Fig. 21 is a top plan view of a set of cup dispensing screws of the
dual cup dispenser engaging a cup.
[0059] Fig. 22 is a front perspective view of the dual cup dispenser, the
cup conveyor, the vacuum chamber and the spacing screw of one embodiment
of the cup reinforcing system disclosed herein.
[0060] Fig. 23 is a partially cross-sectional perspective view of the
vacuum chamber of Fig. 22, illustrating the plurality of adjacent conveyor
belts
and the plurality of air inlets.
[0061] Fig. 24A is a schematic side view of the vacuum box of Fig. 22,
illustrating the flow of air from an area above the plurality of conveyor
belts,
entering the vacuum chamber via the plurality of air inlets and exiting the
vacuum chamber via the air outlet.
[0062] Fig. 24B is a schematic side view of an alternative embodiment
of a vacuum box, illustrating the flow of air from an area above the plurality
of
conveyor belts, entering the vacuum chamber via the plurality of air inlets
and
exiting the vacuum chamber via a plurality of air outlets.
[0063] Fig. 24C is a schematic side view of an alternative embodiment
of a vacuum box, illustrating the flow of air from an area above the plurality
of
conveyor belts, entering a plurality of air flow members via the plurality of
air
inlets and exiting the air flow members via a plurality of air outlets.
[0064] Fig. 25 is a side view of the spacing screw, the in-feed star
wheels and a portion of the cup mover of one embodiment of the cup
reinforcing system disclosed herein.
[0065] Fig. 26 is a front perspective view of one embodiment of a
portion of the cup feeder, the spacing screw and a portion of an in-feed star
wheel of one embodiment of the cup reinforcing system disclosed herein.
[0066] Fig. 27A is a top plan view of one embodiment of a portion of the
cup feeder, the cup spacer illustrating the spacing screw and a plurality in-
feed
star-wheels and a portion of the cup mover.
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[0067] Fig. 27B is a top plan view of an alternative embodiment of a
portion of the cup feeder, the cup spacer illustrating the spacing screw and
one
in-feed star-wheel and a portion of the cup mover.
[0068] Fig. 28 is a front perspective view of the portion of the cup
feeder, the cup spacer illustrating the spacing screw and the plurality in-
feed
star-wheels and the portion of the cup mover of Fig. 27A.
[0069] Fig. 29 is a cross-sectional side view of one of the cup pockets of
one of the star-wheels of the cup reinforcing system disclosed herein.
[0070] Fig. 30 is a front perspective view of one of the in-feed star
wheels and the cup mover of one embodiment of the cup reinforcing system
disclosed herein illustrating a plurality of cup holders associated with a
plurality
of centering bells.
[0071] Fig. 31A is a side view of the in-feed star wheel and the cup
mover of Fig. 30, illustrating the cup mover positioned adjacent to and
slightly
below the in-feed star wheel.
[0072] Fig. 31B is a side view of the in-feed star wheel, the cup mover of
Fig. 30 and a superstructure which supports the plurality of centering bells.
[0073] Fig. 32 is a front perspective view of the bottom member of one
of the cup holding stations of the cup mover of one embodiment of the cup
reinforcing system.
[0074] Fig. 33 is a side view of one embodiment of a centering bell of
the cup holding station engaging a cup which is positioned on the bottom
member of the cup holding station of the cup mover.
[0075] Fig. 34 is a front perspective view of one embodiment of a
centering bell of a cup holding station of the cup mover.
[0076] Fig. 35 is a cross-sectional side view of one embodiment of a
centering bell of the cup holding station engaging a cup which is positioned
on
the bottom member of the cup holding station of the cup mover.
[0077] Fig. 36 is a schematic block diagram of an electronic
configuration of one embodiment of the cup reinforcing system disclosed
herein.
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[0078] Fig. 37 is a front perspective view of one embodiment of the cup
remover of the cup reinforcing system disclosed herein.
[0079] Fig. 38A is a top plan view of one embodiment of the reinforcing
member dispenser of the cup reinforcing system disclosed herein.
[0080] Fig. 38B is a top plan view of an alternative embodiment of a
reinforcing member dispenser of the cup reinforcing system disclosed herein,
illustrating an alternative design of a release liner slack accumulator.
[0081] Fig. 39 a front perspective view of the reinforcing member
dispenser of Fig. 38A, illustrating the reinforcing member dispenser at an
appropriate angle relative to the cup mover.
[0082] Fig. 40 an enlarged front perspective view of the reinforcing
member dispenser of Fig. 38A, illustrating a portion of the reinforcing member
dispenser interacting with the cups transported via the cup mover.
[0083] Fig. 41A is a diagrammatic top plan view of an alternative
embodiment of the cup reinforcing system disclosed herein.
[0084] Fig. 41B is a diagrammatic top plan view of an alternative
embodiment of the cup reinforcing system disclosed herein.
[0085] Fig. 41C is a diagrammatic top plan view of an alternative
embodiment of the cup reinforcing system disclosed herein.
[0086] Fig. 41D is a diagrammatic top plan view of an alternative
embodiment of the cup reinforcing system disclosed herein.
[0087] Figs. 42A to 42E are perspective views of the interaction
between the cup mover and the reinforcing member dispenser of one
embodiment of the cup reinforcing system disclosed herein.
[0088] Figs. 43A to 43F are diagrammatic top plan views of the cup
reinforcing system disclosed herein, illustrating one embodiment of the
attachment of a reinforcing member to a plastic foam cup.
[0089] Figs. 44A to 44D are diagrammatic top plan views of an
alternative embodiment of the cup reinforcing system disclosed herein.
DETAILED DESCRIPTION
[0090] The present disclosure relates in general to a reinforced drinking
cup and more particularly to a disposable plastic foam reinforced drinking cup
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and a method of and apparatus for manufacturing the same. The reinforced
drinking cup is particularly suitable for carrying or transporting hot
beverages,
such as coffee, tea and hot chocolate or other products.
[0091] Referring now to Figs. 3 and 4, a reinforced plastic foam cup 30
of one embodiment disclosed herein is formed from the process of reinforcing
a base cup (such as a conventional plastic foam cup described above) with a
reinforcing member as described below. The reinforcing cup 30 includes a
body 32 which defines an open top end 34 and a closed bottom end 36,
wherein the top end has a greater diameter than the bottom end. The body
includes a tapered side wall 38 that extends from the bottom end to the top
end. The top end of the body includes an outwardly formed lip 40, however
the cup does not need to have a formed lip. It should be appreciated that the
plastic foam base cup may be formed from any suitable material, such as
beaded polystyrene. In another embodiment, the base cup includes a paper
based cup suitably coated or otherwise laminated with one or more layers of
polystyrene.
[0092] Unlike a conventional plastic foam base cup, a reinforcing
member 42 is attached to almost all of or a substantial portion of the outer
surface of the tapered side wall 38 to provide increased tactile feel, support
and rigidity to the tapered side wall. Accordingly, as best seen in Fig. 4,
the
tapered side wall 38 of the reinforced plastic foam cup 30 includes a plastic
foam layer 44, a pressure sensitive adhesive layer 46 and a rigid material
layer
48 which provides a better tactile feel. Compared to a non-reinforced plastic
foam cup which only includes a plastic foam layer, the reinforced plastic foam
cup with the multi-layered tapered side wall (i.e., the plastic foam layer 44,
the
adhesive layer 46 and the rigid material layer 48) provides a substantial
increase in the tactile feel and rigidity of the reinforced plastic foam cup.
Accordingly, the reinforced plastic foam cup provides a disposable cup with
the
insulation properties of a plastic foam cup and also the tactile feel of a
paper-
based cup. Such reinforced plastic foam cup costs less than a paper-based
cup with comparable insulation properties (i.e., such as a nested paper-based
cup). Moreover, as described in one embodiment below, when graphics are
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printed on the outer face of the rigid material of the reinforcing member, the
reinforced plastic foam cup further provides a disposable cup with the high-
quality graphic presentation properties of a paper-based cup.
[0093] Referring now to Figs. 5 to 7, in one embodiment, a reinforcing
member or reinforcer 42 includes a body 50 formed from a malleable, rigid
material, such as a suitable paper, a suitable plastic stock, a suitable
composite material or any other suitable material. The body 50 is
substantially
planar or flat with a thickness in the range 1.5 millimeters to 8.0
millimeters,
and in one preferred embodiment a thickness in the range of approximately 2.7
millimeters to 4.0 millimeters. As best illustrated in Fig. 6, in one
embodiment,
an inner face or surface 52 of the flat body 50 of the reinforcing member 42
is
completely or substantially completely coated with an adhesive and preferably
a pressure sensitive adhesive 54. It should be appreciated that any suitable
adhesive or bonding agent which completely or substantially completely coats
the inner face of the reinforcing member may be employed. As seen in Fig. 7,
in one embodiment, the adhesive coating of the reinforcing member 42 is
releasably attached to a suitable elongated release liner 56 which enables the
reinforcing member to be handled without the adhesive exposed. In this
embodiment, as described in more detail below, a plurality of reinforcing
members 42 are sequentially positioned linearly along a single release liner
56. The release liner 56 may be made of any suitable material, such as a
suitable plastic, paper or any combination thereof. For example, the release
liner is an approximately forty pound craft paper.
[0094] In one embodiment, as illustrated in Fig. 5, an outer face or
surface 58 of the flat body 50 includes one or more suitable branding areas 60
where high quality graphics, such as a company's logo or suitable marketing
graphics, text and/or images are printed thereon. In one embodiment, a
laminate material or a protective coating (not shown) is applied to the outer
face over the layer(s) of ink to protect and/or enhance the printed matter.
[0095] In one embodiment, the flat body 50 is defined by a curved or
annular edge 62, a curved or annular edge 64, an angled front or leading edge
66 and an angled rear or trailing edge 68. In one embodiment, the edge 62 of
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the reinforcing member is suitably concavely shaped and the edge 64 is
suitably convexly shaped, wherein a trough of the concavely shaped edge and
an apex of the convexly shaped edge reside in the same vertical plane. In one
embodiment, the length of the edge 62 is less than the length of the edge 64
such that the leading edge 66 is angled offset from a vertical plane at a
suitable angle (A degrees) and the trailing or rear edge 68 is also angled
offset
from a vertical plane at a suitable angle (B degrees). A sensing edge 70 which
includes a portion of the leading edge adjacent to edge 64 extends vertically
or
substantially vertically. As described in more detail below, the sensing edge
is
utilized in determining the exact location of the reinforcing member as well
as
preventing leakage of the adhesive when a plurality of reinforcing members
releasably attached to a release liner are wound into a supply roll.
[0096] In another embodiment, as seen in Figs. 5A, 6A and 7A, in
addition to a sensing edge 70 (i.e., a portion of the leading edge adjacent to
edge 64 extending vertically or substantially vertically), the reinforcing
member
includes an adhesive relief edge 72. The adhesive relief edge is a vertically
or
substantially vertically extending portion of the trailing edge adjacent to
edge
64 of the reinforcing member. In one embodiment, the sensing edge and the
adhesive relief edge are the same length or substantially the same lengths. In
another embodiment, the sensing edge and the adhesive relief edge are
different lengths or substantially different lengths. It should be appreciated
that
the reinforcing members are displayed in an upside down position to match the
upside down cups which they will engage with as described below.
Accordingly, as best seen in Fig. 5B, the graphics 60 printed on the
reinforcing
member may printed in any suitable configuration.
[0097] It should be appreciated that when a plurality of reinforcing
members are positioned linearly along the elongated release liner to form a
stock or supply roll of reinforcing members and the release liner is wound
about a central cylindrical tube into a roll, a relatively significant amount
of
pressure is placed on one or more of the wound reinforcing members,
especially on the inner reinforcing members which are wound at greater angles
(because of roll has a smaller diameter at such points). This pressure tends
to
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cause the adhesive coating on such wound reinforcing members to leak from
the point where the leading edge and the curved or annular bottom edge
intersect and/or the point where the trailing edge and the curved or annular
bottom edge intersect. Leaking of the adhesive coating from these points may
damage one or more of the wound reinforcing members and/or build-up on the
release liner separator or separation plate (as described below). This leaking
adhesion may also prevent the reinforcing member from properly adhering to
the cup in the desired manner. In one embodiment of the present disclosure,
the sensing edge and the adhesive relief edge each redistribute the formed
pressure from these respective points on the reinforcing member to an
extended portion of the reinforcing member. This redistribution relieves the
pressure which forms and thus reduces or prevents the leaking of the adhesive
coating from one or more of the wound reinforcing members.
[0098] It should be appreciated that the dimensions of the reinforcing
member will be specific to the specifications of the base cup. Therefore, the
respective angles of the leading and trailing edges of the reinforcing member,
the shape of the top and bottom edges, the length between the leading edge
and the trailing edge or any other suitable dimensions of the reinforcing
member will be based on the size of the base cup, the angle of the tapered
side wall of the base cup or any other specification of the base cup. It
should
be further appreciated that when the reinforcing member is initially attached
to
the cup, as described below, the sensing edge 70 is: (i) perpendicular or
substantially perpendicular to the bottom edge of the cup; and (ii) parallel
to
the centered vertical axis of the reinforcing member. Such a configuration
provides an absolute reference point for the cup reinforcing system to
determine the location of the reinforcing member.
[0099] For example, in one embodiment, if the base cup is a twelve
ounce cup, the reinforcing member is configured such that the angle between
the concave edge and leading edge is approximately ninety degrees, the angle
between the concave edge and trailing edge is approximately ninety degrees,
the angle between leading edge and the sensing edge is approximately one-
hundred-fifty degrees, the angle between the trailing edge and adhesive relief
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edge is approximately one-hundred-fifty degrees, the angle between the
convex edge and the sensing edge is approximately one-hundred-twenty
degrees, and the angle between the convex edge and the adhesive relief edge
is approximately one-hundred-twenty degrees.
[00100] In another example, if the base cup is a sixteen ounce cup, the
reinforcing member is configured such that the angle between the concave
edge and leading edge is approximately ninety degrees, the angle between the
concave edge and trailing edge is approximately ninety degrees, the angle
between leading edge and the sensing edge is approximately one-hundred-
fifty-five degrees, the angle between the trailing edge and adhesive relief
edge
is approximately one-hundred-fifty-five degrees, the angle between the convex
edge and the sensing edge is approximately one-hundred-fifteen degrees, and
the angle between the convex edge and the adhesive relief edge is
approximately one-hundred-fifteen degrees.
[00101] In another example, if the base cup is twenty ounce cup, the
reinforcing member is configured such that the angle between the concave
edge and leading edge is approximately ninety degrees, the angle between the
concave edge and trailing edge is approximately ninety degrees, the angle
between leading edge and the sensing edge is approximately one-hundred-
sixty degrees, the angle between the trailing edge and adhesive relief edge is
approximately one-hundred-sixty degrees, the angle between the convex edge
and the sensing edge is approximately one-hundred-ten degrees, and the
angle between the convex edge and the adhesive relief edge is approximately
one-hundred-ten degrees.
[00102] In general, as illustrated in Fig. 8, the method or process of
manufacturing the above-described reinforced plastic foam cup includes
determining a vertical axis which runs through a center point of the top and
bottom edge of the reinforcing member as indicated in block 80. The method
includes positioning the base or pre-reinforced plastic foam cup upside-down
and positioning the reinforcing member adjacent to the tapered side wall of
the
upside-down base cup at an angle which corresponds with the angle of the
tapered side wall of the base cup as indicated in blocks 82 and 84. At the
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point when both the base cup and the reinforcing member move into position,
as indicated in block 86, the inside face of the reinforcing member is
attached
to the outer face of the tapered side wall of the base cup along the
determined
centered vertical axis, wherein the reinforcing member is attached at an angle
which corresponds with the angle of the tapered side wall of the base cup.
After attaching the center of the reinforcing member to the tapered side wall
of
the base cup, the cup with the reinforcing member continues to move on the
cup conveyer and the remaining free or unattached portions are sequentially or
simultaneously attached to the tapered side wall as indicated in block 88. It
should be appreciated that such angling of the reinforcing member provides
that as the remaining unattached portions or sections of the reinforcing
member are attached to the tapered side wall of the base cup, the reinforcing
member will completely adhere to the tapered side wall of the base cup.
[00103] More specifically, as diagrammatically seen in Fig. 9, in one
embodiment, the method or process of manufacturing or sequentially
reinforcing at least one and preferably a plurality of individual plastic foam
cups
includes utilizing a processor controlled cup reinforcing system or apparatus
100. In one embodiment, the cup reinforcing system includes a cup conveyer
system which moves the cup into the attachment position and transports or
moves one or more base or pre-reinforced plastic foam cups 102 throughout
the cup reinforcing system 100 in a conventional manner. The cup reinforcing
system further includes at least one reinforcing member dispenser 104
operable to sequentially feed each reinforcing member toward the attachment
position for attachment to the individual base cup 102. The cup reinforcing
system also includes a suitable sensor 106 operable to determine the location
of each reinforcing member, wherein based on such determined location, the
cup reinforcing system 100 aligns a centered vertical axis 108 of the
reinforcing member 42 with the tapered side wall of an individual base cup
102. Accordingly, a system or apparatus for attaching a reinforcing member to
a cup includes a cup conveyor system, a reinforcing member dispenser (i.e., a
device for centering and affixing or attaching the reinforcing member to the
outer surface of the tapered side wall of the cup). It should be appreciated
that
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any suitable cup reinforcing system may be implemented in accordance with
the disclosed process of reinforcing a plastic foam cup
[00104] In one embodiment, as further described and illustrated below,
the cup conveyer includes one or more individual cup positions wherein each
individual cup position includes a rotationally mounted cup holding turntable
with a suitable cup positioning device to suitable position the cup at a set
position on the cup holding turntable. The cup holding turntable is also
operable to rotate the cup a full 360 degrees in clockwise and
counterclockwise directions. In one embodiment, the cup positioning device
includes a frictional engagement member or mandrel which frictionally
engages the inner face of the wall of the base cup to fix the cup in the
suitable
position on the turntable. In operation, a base cup 102 is placed face down
(i.e., resting on the open top end) on the cup conveyer system and the cup is
moved into a position that facilitates engagement with the reinforcing member.
[00105] In one embodiment, as illustrated in Figs. 9 and 10, the
reinforcing member dispenser 104 is operable (via one or more suitable rollers
110) to feed the reinforcing member in the direction of a face down base cup.
In one embodiment, the reinforcing member dispenser 104 is configured or
shaped to define or include a release liner separation section 112. In this
embodiment, based on the orientation of the reinforcing member 42 relative to
the release liner separation section 112, the reinforcing member 42 will
separate from the release liner 56 (which protects the pressure sensitive
adhesive) when the reinforcing member is fed through the release liner
separation section 112. In one embodiment, the cup reinforcing system also
includes one or more reinforcing member application pad(s) 114 which operate
to guide the reinforcing member and prevent the reinforcing member from
shifting positions after a portion of the reinforcing member 42 separates from
the release liner 56.
[00106] As best seen in Fig. 11, in one embodiment, the reinforcing
member dispenser is operable to feed the release liner 56 (which the
reinforcing member is releasably attached to) toward the base cup 102 at a
suitable angle offset from a vertical plane which corresponds with the angle
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(also offset from a vertical plane) of the tapered side wall of the base cup.
In
this embodiment, when the reinforcing member 42 separates from the release
liner 56, the reinforcing member will be positioned at a suitable angle which
corresponds with the angle of the tapered side wall of the base cup 102. In
one embodiment, the reinforcing member engages the tapered side wall of the
base cup at a suitable angle offset from a vertical plane while both the cup
and
the reinforcing member are moving. As described in more detail below, such
angling provides that the reinforcing member will completely adhere to the
tapered side wall of the base cup.
[00107] Referring back to Figs. 9 and 10, as described above, the cup
reinforcing system also includes at least one sensor 106 for determining or
verifying the location or position of the reinforcing member 42 relative to
the
position of the base cup 102. In one embodiment, the sensor detects the
location of the substantially vertical portion or sensing edge 70 of the front
or
leading edge of the reinforcing member 42 to determine the relative position
of
the reinforcing member. Based on this determined position of the reinforcing
member 42 and any other suitable information (such as the speed the cup is
moving, the speed the reinforcing member is being fed through the reinforcing
member dispenser, the length of the reinforcing member and the diameter of
the cup), the processor of the cup reinforcing system determines or calculates
when the reinforcing member 42 is moved into a position in which a centered
vertical axis 108 of the reinforcing member 42 is aligned with the tapered
side
wall of the base cup 102. In this embodiment, the centered vertical axis 108
is
the vertical axis that runs through both the trough of the concavely shaped
top
edge 62 of the reinforcing member and the apex of the convexly shaped
bottom edge 64 of the reinforcing member.
[00108] In one embodiment, at least one sensor is positioned or placed
such that the sensor detects the exact location of each reinforcing member
immediately prior to that reinforcing member being affixed to a base cup. In
this embodiment, positioning the sensor at such a position provides for
increased accuracy in the placement of the reinforcing member on the base
cup which, as described in more detail below, provides for a proper
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engagement between the reinforcing member and the cup. In alternative
embodiments, the alignment process is controlled by suitable timing
mechanisms wherein one or more sensors are utilized to verify that the timing
mechanisms are correct. In the illustrated embodiment, the sensor senses the
sensing edge. However, it should be appreciated that the sensor could sense
another suitable reinforcing member position indicator.
[00109] As seen in Figs. 12, 13 and 14, in one embodiment, the
processor of the cup reinforcing system causes the cup conveyer to move the
cup 102 into the attachment position and causes the reinforcing member
dispenser 104 to feed the reinforcing member 42 into the attachment position
where the centered vertical axis 108 of the reinforcing member 42 is aligned
with the tapered side wall of the base cup 102, and causes the inner face 52
of
the reinforcing member 42 (which is completely or substantially completely
coated with a pressure sensitive adhesive 54) to be initially attached to the
tapered side wall of the cup along the centered vertical axis (as best seen in
Fig. 13). In this embodiment, it should be appreciated that both the cup and
the reinforcing member are moving prior to and through the point of
attachment of the reinforcing member to the outer surface of the tapered side
wall of the cup. In one embodiment, the cup conveyer moves the base cup
into a position which engages the reinforcing member application pad 114,
such that the tapered side wall of the cup presses against or engages the
reinforcing member application pad to cause the reinforcing member 42 (which
is positioned between the tapered side wall and the reinforcing member
application pad 114) to engage the tapered side wall of the cup 102 as best
seen in Fig. 14.
[00110] As described above and best seen in Fig. 14, the reinforcing
member 42 is situated at an angle which corresponds with the angle of the
tapered side wall of the cup and thus the reinforcing member is attached to
the
base cup at an angle which corresponds with the angle of the wall of the base
cup. Moreover, as seen in Fig. 13, after the reinforcing member is initially
attached to the cup along the centered vertical axis of both the reinforcing
member and the cup, the leading edge 66 and trailing edge 68 of the
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reinforcing member remain unattached or are otherwise free. It should be
appreciated that because the cup is placed open end down, the top edge 62 of
the reinforcing member adheres to the tapered side wall at (or substantially
adjacent to) the bottom end of the cup and the bottom edge 64 of the
reinforcing member adheres to the tapered side wall at (or substantially
adjacent to) the top, open end of the cup. It should be further appreciated
that
based on manufacturing tolerances, the reinforcing member may be attached
to the cup slightly offset from the centered vertical axis of the reinforcing
member, and in one embodiment in a range of plus or minus three degrees.
[00111] As illustrated in Fig. 15, after the reinforcing member 42 is
attached to the tapered side wall of the cup 102 along the centered vertical
axis 108 of the reinforcing member, the cup reinforcing system 100 is operable
to cause the remaining unattached portions of the reinforcing member to
engage and attach to the tapered side wall of the cup. In one embodiment,
utilizing the turntable on which the cup resides, the cup rotates 180 degrees
in
a first direction. As the cup is rotating, the tapered side wall of the cup
102
presses against or engages the reinforcing member application pad 114 to
cause a first portion or section of the reinforcing member to engage and thus,
due to the pressure sensitive adhesive coating 54 on the reinforcing member
42, attach to the tapered side wall of the cup. In one embodiment, the first
portion or section includes the portion of the reinforcing member 42 which
extends from the centered vertical axis 108 to the trailing edge 68.
Accordingly, as seen in Fig. 16, after the first section of the reinforcing
member
is attached to the tapered side wall of the cup, a second section of the
reinforcing member remains unattached or is otherwise free.
[00112] As seen in Fig. 17, in one embodiment, following a rotation of
the cup in a first direction, the cup is then rotated 360 degrees in an
opposite,
second direction. As the cup is rotating, the tapered side wall of the cup
presses against or engages the reinforcing member application pad 114 to
cause the second portion or section of the reinforcing member to engage and
attach to the tapered side wall of the cup. In one embodiment, the second
portion or section includes the portion of the reinforcing member 42 which
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extends from the centered vertical axis to the leading edge. As described
above, the shape or configuration of the reinforcing member coupled with the
shape or configuration of the cup provides that as the remaining portions of
the
reinforcing member are attached to the cup, the reinforcing member will affix
to
the tapered side wall of the cup in the desired configuration (i.e., the cup
pulls
to the reinforcing member and the reinforcing member pulls to the cup). The
reinforced plastic foam cup provides a disposable drinking cup with the
insulation properties of a plastic foam cup and the tactile feel and high
quality
graphic printing properties of a paper-based cup to provide an enhanced
drinking experience for a person.
[00113] In one alternative embodiment, the cup reinforcing system may
be configured with a plurality of reinforcing member application pads which
are
positioned on opposite sides of the cup such that the cup is rotated 180
degrees in a first direction to attach the first portion of the reinforcing
member
to the cup, followed by rotating the cup 180 degrees in the second direction
to
attach the second portion of the reinforcing member to the cup. After the
rotation in the second direction, the reinforcing member is completely adhered
to the base cup and the reinforced plastic foam cup 30 described above (and
illustrated in Figs. 3 and 4) is formed. It should be appreciated that any
suitable apparatus for or method of attaching the reinforcing member to the
tapered side wall along the centered vertical axis may be implemented in
accordance with the present disclosure.
[00114] It should be appreciated that in one embodiment, as seen in
Fig. 17, the cup reinforcing system is operable to sequentially reinforce one
or
more individual cups. In this embodiment, one or more cups are each placed
face down and suitably spaced apart on the cup conveyer. Moreover, one or
more reinforcing members are positioned linearly along a single release liner
and wrapped in a supply roll. The supply roll is threaded about the
reinforcing
member dispenser to provide a continuous feed of reinforcing members.
[00115] In another embodiment (not shown), the cup is placed on the
cup conveyer resting on its closed bottom end. In another embodiment (not
shown), the reinforcing member dispenser is positioned such that the
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reinforcing member engages the tapered side wall of the cup situated in a
vertical plane. Accordingly, in this embodiment, the cup conveyer is
configured at a suitable angle to provide that the tapered side wall of the
cup
engages the reinforcing member in the vertical plane as well. In another
embodiment, the cup conveyer is suitably angled and the cup is transported
throughout the cup reinforcing system at such an angle. In these
embodiments, the reinforcing member dispenser and/or the reinforcing
member application pads are accordingly adjusted to any suitable angle to
account for the angle of the cup and/or reinforcing member to insure that the
reinforcing member is initially affixed to the tapered side wall of the cup at
an
angle which corresponds with the tapered side wall of the cup.
[00116] Referring now to Figs. 18A to 43F, various embodiments of the
cup reinforcing system or apparatus disclosed herein are illustrated and
generally indicated by numeral 200. As illustrated in Figs. 18A and 18B, the
cup reinforcing system 200 generally includes a cup conveyor system 202 and
one or more reinforcing member dispensers 204a and 204b (referred to
generally as 204). The cup conveyor system is configured to receive each
pre-reinforced cup, transport and space such received cups into an
appropriate position for attachment of a reinforcing member and remove each
cup from the cup reinforcing system after the attachment of a reinforcing
member to that cup. Each reinforcing member dispenser 204 is configured to
transport each reinforcing member into the appropriate position for attachment
with the transported cups and attach each reinforcing member, along a
centered vertical axis of the reinforcing member, to the wall of one of the
upside down positioned cups at an angle which corresponds with the angle of
the tapered side wall of the cup.
[00117] More specifically, the cup conveyor system includes a cup
dispenser 206, a cup feeder 208, a cup spacer 210, a cup mover 212, and a
cup remover 214. As generally illustrated in Fig. 36, the processor 402 of the
cup reinforcing system is in communication with and programmed to control
the cup dispenser 206, the cup feeder 208, the cup spacer 210, the cup
mover 212, the cup remover 214, and the reinforcing member dispenser 204.
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The processor is also in communication with and programmed to control at
least one input device or control panel 404, such as a touch screen or one or
more suitable switches or buttons, for enabling a user to operate the cup
reinforcing system and at least one display device 406 for displaying suitable
information to a user of the cup reinforcing system. The input device enables
a user to input appropriate commands and/or suitable information to the
processor of the cup reinforcing system. For example, a user utilizes at least
one input device to initiate and shut-off the cup reinforcing system, provide
information regarding the exact specifications of the cups and/or reinforcing
members, input the speed to move the cups throughout the cup reinforcing
system, and input the angle to set the reinforcing member dispenser relative
to
the cup mover. In another embodiment, one or more of the functions
described above may be manually adjusted utilizing one or more mechanical
or other suitable devices. For example, the angle to set the reinforcing
member dispenser relative to the cup mover may be manually adjusted
utilizing one or more individual hand cranks.
[00118] The processor is in communication with or operable to access
or to exchange signals with at least one data storage or memory device 408.
The memory device stores program code and instructions, executable by the
processor, to control the cup reinforcing system. In one embodiment, the
memory device includes random access memory (RAM), which can include
non-volatile RAM (NVRAM), magnetic RAM (MRAM), ferroelectric RAM
(FeRAM) and other forms as commonly understood in the art. In one
embodiment, the memory device includes read only memory (ROM). In one
embodiment, the memory device includes flash memory and/or EEPROM
(electrically erasable programmable read only memory). Any other suitable
magnetic, optical and/or semiconductor memory may operate in conjunction
with the cup reinforcing system disclosed herein. In one embodiment, part or
all of the program code and/or operating data described above can be stored
in a detachable or removable memory device, including, but not limited to, a
suitable cartridge, disk, CD ROM, DVD or USB memory device. The
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processor and memory device may sometimes be collectively, referred to
herein as a "computer" or "controller."
[00119] As described in more detail below, a pre-reinforced or base cup
enters the cup reinforcing system via the cup dispenser 206 from a supply of
nested cups. The cup travels via the cup feeder 208 to the cup spacer 210
and then to the cup mover 212. The cup mover 212 aligns the cup into the
appropriate alignment with the reinforcing member dispenser 204 and the
reinforcing member is attached or affixed to the cup by the reinforcing member
dispenser 204. The reinforced cup is removed from the cup reinforcing system
via the cup remover 214. It should be appreciated that any other suitable cup
conveyor system and any suitable reinforcing member dispenser which
attaches a reinforcing member to the tapered side wall of a base cup along the
centered vertical axis of the reinforcing member and subsequently attaches the
remaining portions of the reinforcing member to the tapered side wall of the
base cup may be implemented in accordance with the cup reinforcing system
disclosed herein.
[00120] As seen in Figs. 19 to 22, the cup dispenser 206 of the cup
reinforcing system includes a frame 230 which supports two independent,
offset guide members 232a and 232b (referred to generally as 232). Each
guide member is configured to hold a stack of nested pre-reinforced or base
cups 234a and 234b (referred to generally as 234) in upside down positions
above the cup feeder 206. Each guide member 232 is associated with at least
one and preferably a plurality of or set of vertically or substantially
vertically
disposed co-acting cup dispensing screws or cup de-nesters 236a, 236b, 236c
and 236d (referred to generally as 232 and as best seen in Figs. 20 and 21)
made of any suitable smooth surfaced, non-abrasive material with self-
lubrication properties, such as any suitable plastic, for example a DELRIN
plastic manufactured by E. I. DU PONT DE NEMOURS AND COMPANY.
[00121] Each cup dispensing screw 236 has internally extending
threading 238 on its outer surface. The threads are suitably sized and angled
to correlate to the top lips of the upside down positioned base cups 102 held
by the guide members 232. The cup dispensing screws 236 are each movably
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connected or coupled to at least one actuator 240, such as a motor or other
suitable movement generating device controlled by the cup reinforcing system
processor which causes each cup dispensing screw 236 to rotate in the
appropriate direction at a suitable speed.
[001221 In operation, as best seen in Figs. 19 and 21, the internal
threading located at or near the top 238a of each rotating cup dispensing
screw 236 engage a portion of the outwardly extending lip 24 of a first nested
upside down cup held by one of the guide members 232. Each cup dispensing
screw rotates to pull the first cup, via the top threading 238a of each cup
dispensing screw which engages the cup lip 24, from the nested set of cups
234. As each cup dispensing screw 236 continues to rotate, the cup lip 24 of
the first cup is passed to the threading located at or near the middle 238b of
each rotating cup dispensing screw and then to the threading located at or
near the bottom 238c of each rotating cup dispensing screw to slowly and
consistently pull the first cup further away from the nested set of cups 234.
As
the first cup is passed from the top threading 238a of each cup dispensing
screw to the middle threading 238b, the top threading 238a engages the lip 24
of a second nested upside down cup to pull the second cup, via the top
threading 238a engaging the lip of the second cup, from the nested set of cups
234. This process continues to separate each nested cup from the set of
nested, upside-down cups loaded into the cup dispenser 206. In other words,
the rotating threads of the cup dispensing screws co-act to separate each
engaged cup, one at a time, from the nested stack of pre-reinforced upside
down cups. After being de-nested, each separated cup 102 proceeds to drop
down to the cup feeder 208 located directly below the cup dispenser 206.
[00123] In one alternative embodiment, the cup dispenser includes
more than two independent, offset guide members. In this embodiment, each
guide member holds a stack of nested pre-reinforced cups and is further
associated with at least one and preferably a plurality of vertically disposed
cup dispensing screws as described above. In
another alternative
embodiment, one guide member is configured to hold a plurality of stacks of
nested pre-reinforced cups above a plurality of different locations of the cup
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feeder. In this embodiment, the guide member is associated with at least one
and preferably a plurality of vertically disposed cup dispensing screws for
each
held stack of pre-reinforced cups. In another alternative embodiment, one
guide member is configured to hold one stack of nested pre-reinforced cups
above a single location of the cup feeder. In this embodiment, the guide
member is associated with at least one and preferably a plurality of
vertically
disposed cup dispensing screws for the held stack of pre-reinforced cups. It
should be appreciated that any suitable apparatus or method for loading one
or more pre-reinforced cups onto the cup feeder may be implemented in
accordance with the cup reinforcing system disclosed herein. It should be
further appreciated that the cup dispenser disclosed herein may be located at
any suitable position upstream from the reinforcing member dispenser
described below.
[00124] As seen in Figs. 19 and 22 to 24, the cup feeder 208 of the cup
conveyor system includes a frame 250 which supports a plurality of rows of
adjacently positioned conveyor belts 252a to 252e (referred to generally as
252). The conveyor belts are suitably movably connected or coupled to at
least one actuator, such as a motor or other suitable movement generating
device 254 which causes the conveyor belts to move at any suitable speed in
a conventional manner.
[00125] It should be appreciated that static electricity can build up by
rapid movement of plastic foam cups. The use of multiple guide members 232
and multiple cup dispensing screws 236 reduces the likelihood of static
electricity buildup in the cup reinforcing system disclosed herein. That is,
the
use of multiple guide members and multiple cup dispensing screws reduces
the number of cups each individual guide member/cup dispensing screw must
dispense per minute. This reduced number of cups directly correlates to a
reduction in the speed which cups must be transported throughout the cup
reinforcing system and such a reduction in speed reduces the amount of static
electricity buildup.
[00126] In one embodiment, one, more or each of the conveyor belts
252 define one or more apertures or holes 256 through which air flows as
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described below. As best illustrated in Figs. 22, 24A and 24B, the conveyor
belts which are positioned or aligned beneath or under the offset guide
members 232a and 232b, in this case conveyor belts 252a and 252e, define
larger diameter apertures or holes 256a than the apertures or holes 256b of
the conveyor belts which are not positioned under the offset guide members, in
this case conveyor belts 252b, 252c and 252d. It should be appreciated that
any suitable number of holes, of any suitable diameter and of any suitable
shape (such as elongated oval shaped holes) which allows an adequate
amount of air flow as described below, may be implemented in accordance
with the cup reinforcing system disclosed herein.
[00127] As illustrated in Figs. 23, 24A and 24B, the frame 250 of the
cup feeder 208 supports a vacuum chamber, box or housing 258. The
vacuum box 258 includes a top wall or surface 260 and a spaced apart bottom
wall or surface 262. The top wall defines a plurality of apertures or air
inlets
264. The vacuum box includes spaced apart side walls 268, wherein the top
of each side wall is connected to the top wall and the bottom of each side
wall
is connected to the bottom wall. The vacuum box also includes spaced apart
end walls 270a and 270b, wherein the top of each end wall is connected to the
top wall, the bottom of each end wall is connected to the bottom wall, one
side
of each end wall is connected to one side wall and the other side of each end
wall is connected to the other side wall. At least one side wall of the vacuum
box (side wall 270a of Fig. 24A and side walls 270a and 270b of Fig. 24B)
each defines one or more apertures or air outlets 272 which are connected, via
suitable air communication lines, to one or more vacuum or negative pressure
sources (not shown). That is, the vacuum chamber is in fluid communication
with a suitable vacuum or negative pressure source.
[001281 In one alternative embodiment, as seen in Fig. 24C, the frame
250 of the cup feeder includes two air flow members 274a and 274b spaced
below the offset guide members of the cup dispenser. In this embodiment,
each air flow member is connected to a vacuum or negative pressure source
which pulls each base cup from the cup dispenser. It should be appreciated
that in this embodiment, air only flows through the larger diameter holes in
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conveyor belt (located directly above the air flow member) and not through the
smaller diameter holes, if any, in the conveyer belt not located directly
above
the air flow member.
[00129] As specifically illustrated in Fig. 24, the vacuum source
provides negative air flow from the area above the conveyer belts 252, through
the holes 264 of the conveyer belts, the air inlets 256 of the top surface 260
of
the vacuum box and the defined air outlet 272 of the vacuum box to the
vacuum source. In operation, each separated base cup is pulled downwardly
by the vacuum pressure, in a face down position, from the cup dispenser 206
onto the cup feeder 208. It should be appreciated that positioning the larger
apertures 256a of certain of the conveyer belts under the offset guide
members 232 of the cup dispenser 206 provides for an increased amount of
air to flow from above the conveyor belts 252, through the larger apertures
256a and to the vacuum source (not shown) near the location where the cup
dispenser 206 drops the cups 102. It should be further appreciated that
vacuum pressure applied to the cups provides that the relatively light-weight
base cups (as opposed to a heavier bottle) do not tip over when they are
dropped from the cup dispenser 206 to the cup feeder 208.
[00130] The cup reinforcing system is configured to move the cups
along the conveyor belts at a relatively slow speed when compared to the
speeds which bottles are moved though a bottle labeling system. That is,
while bottles of a bottle labeling system are typically labeled at
approximately
one-thousand bottles per minute, the disclosed cup reinforcing system applies
reinforcing members to base cups at less than half the rate of such bottle
labeling systems. As mentioned above, such a reduction in the speed which
the cups are moving through the cup reinforcing system eliminates static
electricity buildup often caused by rapid movement of plastic foam cups.
[00131] As seen in Fig. 22 and 24, the cup feeder 208 includes at least
two opposing spaced-apart elongated guide rails or guide tracks 266a and
266b (referred to generally as 266) supported by the frame 250 of the cup
feeder. The guide rails 266 are angled offset from a vertical plane at a
suitable
angle to match the angle of the tapered side walls of the cups transported by
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the conveyor belts 252. Guide rail 266a and 266b extend in intersecting
planes such that the space between the two guide rails 266 is reduced as the
guide rails extend out from an area substantially below the cup dispenser 206.
In operation, as each cup 102 moves along the conveyor belts 252 of the cup
feeder 208 in the direction of the cup spacer 210, each cup engages one of the
guide rails 266. As the cups move closer to the cup spacer, the engagement
with the guide rails 266 causes the cups to move into a single-file order. It
should be appreciated that the cup feeder may include any suitable apparatus
or method for transporting the cups from the cup dispenser to the cup spacer.
[00132] As illustrated in Figs. 25 to 27B, the cup spacer 210 of the cup
conveyor system includes a frame 280 positioned adjacent to and at
substantially the same height as the cup feeder 208. As seen in Fig. 27A, the
frame of the cup feeder supports an in-feed screw or spacing screw 282 and
two co-acting inlet stars or in-feed star-wheel conveyors 284a and 284b
(referred to generally as 284). As seen in Fig. 27B, in one embodiment, the
frame of the cup feeder supports an in-feed screw or spacing screw 282 and
one inlet star or in-feed star-wheel conveyor 284a. In these embodiments, the
cup spacer 210 is utilized to transport the each cup 102 from the cup feeder
208 to the cup mover 212.
[00133] The in-feed screw or spacing screw 282 of the cup spacer 210
is a horizontally or substantially horizontally disposed member made of any
suitable smooth surfaced, non-abrasive material with self-lubrication
properties, such as any suitable plastic, for example a DELRIN plastic
manufactured by E. I. DU PONT DE NEMOURS AND COMPANY. The spacer
screw has internally extending threading 286 on its outer surface. The
threading 286 is suitably sized and angled to correlate to the tapered side
wall
of the cups. As seen in Figs. 25 and 26, the space between the threads of the
spacer screw gradually and consistently increase from a first end 294 of the
spacer screw adjacent to the cup feeder 208 to a second end 296 of the
spacer screw adjacent to the cup mover 212. The increased spacing between
the spacer screw threads provides that as each cup 102 is transported from
the first end 294 of the spacer screw to the second end 296 of the spacer
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screw, each cup (which is engaged by a portion of the threading of the spacer
screw) is suitably spaced apart. Such spacing of the cups corresponds to the
spacing between each pocket 290 of the first in-feed star wheel 284a. In other
words, the in-feed screw or spacing screw 282 sequentially separates, regaps
or spaces the single-file cups transported by the conveyor belt 252 to
establish
a separation distance that corresponds to the spacing between the pockets
290 of the first in-feed star-wheel 284a. That is, the spacer screw 282
delivers, at the correct intervals, each cup into one of the pockets 290 of
the
first in-feed star-wheel 284a. It should be appreciated that due to the
direction
of rotation of the spacer screw 282, a cup may be slightly lifted off the
conveyor belt as that cup is transported form the first end 294 of the spacer
screw to the second end 296 of the spacer screw. Accordingly, a hold down
member 298, such as a bar made of any suitable smooth surfaced, non-
abrasive material with self-lubrication properties, such as any suitable
plastic,
for example a DELRIN plastic manufactured by E. I. DU PONT DE
NEMOURS AND COMPANY, is supported by the frame 280 of the cup spacer
210. In this embodiment, if the spacer screw lifts the cup off the conveyor
belt,
the hold down member 298 engages the bottom of the upside down cup to
keep the cup in contact with the threads of the spacer screw. In one
embodiment, the spacer screw is movably connected or coupled to at least
one actuator 288, such as a motor or other suitable movement generating
device controlled by the cup reinforcing system processor which causes the
spacer screw to rotate in any suitable direction at any suitable speed in a
conventional manner.
[00134] Each inlet star 284 of the cup spacer 210 is a horizontally or
substantially horizontally disposed circular or substantially circular member
made of any suitable smooth surfaced, non-abrasive material with self-
lubrication properties, such as any suitable plastic, for example a DELRIN
plastic manufactured by E. I. DU PONT DE NEMOURS AND COMPANY.
Each inlet star 284 defines a plurality of pockets 290 suitable spaced around
the circumference of that inlet star. The number of pockets is determined
based on the size of the cups and the size of the reinforcing members. Each
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pocket 290 is configured to hold or otherwise engage a cup 102 as the cup is
transferred from the cup feeder 208 to the cup mover or turntable 212. Each
inlet star is movably connected or coupled to at least one actuator (not
shown),
such as a motor or other suitable movement generating device controlled by
the cup reinforcing system processor which causes that inlet star to move in
any suitable direction at any suitable speed in a conventional manner.
[00135] As illustrated in Figs. 27A and 28, the frame 280 of the cup
spacer supports two inlet star guide members or guide rails 292a and 292b
(referred to generally as 284). Guide rail 292a is located adjacent to inlet
star
284a and guide rail 292b is located adjacent to inlet star 284b. Each guide
rail
292 prevents the cups transported by the inlet stars 284 from becoming
displaced, such as by tipping over. The cup guide members are suitable sized
and suitable angled offset from a vertical plane to correlate to the cups.
[00136] In operation, as best seen in Figs. 27A and 28, each cup 102 is
transported from at or near the second end 296 of the spacer screw 282 to a
first pocket 290 of the first inlet star 284a. The first inlet star 284a
transports
the cup to a second pocket of the second inlet star 284b. The second inlet
star
284b transports the cup, along a horizontally-disposed cup support member
297, to a cup holding station 302 of the cup mover 212 as described below.
That is, the pockets of the second inlet star 284b and guide rail 292b co-act
to
hold a cup in the proper position and place the cup onto one of the cup
holding
stations 302 of the cup mover. It should be appreciated that any suitable
means or manner for transporting one or more cups from the cup dispenser to
the cup mover or turntable may be employed in accordance with the cup
reinforcing system disclosed herein.
[00137] As seen in Fig. 29, the sidewall of each pocket 290 is angled
offset from a vertical plane at a suitable 'angle to match the angle of the
tapered side walls of the cup 102. That is, because even relatively small
amounts of forces may cause indentions to the outer surfaces of the cup 102,
each star-wheel pocket 290 is configured to prevent damaging the relatively
fragile surface of the base cups. In other words, unlike the star-wheel
pockets
of known bottle labeling machines which are designed to transport relatively
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durable glass bottles, the star-wheel pockets 290 of the cup spacer 210 of the
cup reinforcing system disclosed herein is designed to handle the relatively
fragile plastic foam cups.
[00138] As seen in Figs. 27A to 31B, the cup mover or turntable 212 of
the cup conveyor system is rotatably supported by a suitable frame 300
positioned adjacent to the cup spacer 210 and at a height slightly below the
cup spacer 210. The turntable is a horizontally or substantially horizontally
disposed cylindrical or substantially cylindrical member made of any suitable
smooth surfaced, non-abrasive material with self-lubrication properties, such
as any suitable plastic, for example a DELRIN plastic manufactured by E. I.
DU PONT DE NEMOURS AND COMPANY. The turntable 212 is movably
connected or coupled to at least one actuator, such as a motor or other
suitable movement generating device which causes the turntable to move in
any suitable direction at any suitable speed in a conventional manner. In
operation, as described above, the cup mover 212 transports each base cup
toward the attachment position adjacent to a reinforcing member dispenser
204.
[00139] The cup mover 212 includes a plurality of individual rotary cup
plates or cup holding stations 302a, 302b, 302c and 302d (referred to
generally as 302) positioned uniformly around the periphery of the cup spacer.
Each cup plate or holding station 302 is configured to receive a cup 102 from
a
pocket 290 of the second inlet star 284b. As described above, each cup
holding station includes a rotational base 303 operable to rotate a full 360
degrees in clockwise and counterclockwise directions. In
another
embodiment, each cup holding station is spring loaded and operable to rise to
engage the cup transported from the cup spacer and lower to disengage the
cup from the cup mover after a reinforcing member has been applied to the
cup.
[00140] Each cup holding station includes a plurality of suitably shaped
and sized walls which frictionally engage the walls of the cup to fix the cup
in
the suitable position on the cup holding station. In operation, as each cup
102
is placed on a cup plate or holding station, the cup is held in place by a
spring
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biased centering bell 312. Each centering bell is operable to rotate a full
360
degrees in clockwise and counterclockwise directions. It
should be
appreciated that any suitable manner of holding the cup which provides that
the tapered side wall of the cup is free for application of the reinforcing
member may be implemented in accordance with the cup reinforcing system
disclosed herein.
[00141] As best seen in Fig. 31B, each centering bell 312 is supported
from a rotatable superstructure 324. The rotatable superstructure includes a
cam 326 and a plurality of spring loaded members 328 suitably connected to
the plurality of centering bells 312. The spring loaded members are each
movably connected or coupled to at least one actuator, such as a motor or
other suitable movement generating device which causes each of the spring
loaded members to move in any suitable direction at any suitable speed in a
conventional manner. In operation, as the plurality of spring loaded members
328 rotate about the cam 326, the shape of the cam causes each spring
located member to coil or retract which causes each centering bell to extend
to
engage a plurality of the walls of the cup or retract to disengage the
plurality of
walls of the cup. The spring mounted pressure of the centering bells engages
the cups with at least enough force to hold the cup as the cup is rotated and
with less force than would damage the relatively fragile foam cup. It should
be
appreciated that any suitable mechanism or mechanisms which cause the
centering bells to engage and disengage a plurality of walls of the cup may be
implemented in accordance with the cup reinforcing system disclosed herein.
[00142] As illustrated in Figs. 32, 33, 34 and 35, the outer wall of each
cup holding station 302 is suitably beveled and tapered to match and engage
the taper of the inner side wall of the top portion of the base cup 102. As
best
illustrated in Fig. 32, each cup holding station 302 includes a vertically
disposed sidewall or cup support 304, a horizontally disposed first wall 306
connected to the sidewall, a vertically disposed second wall 308 connected to
the first wall and a beveled third wall 310 connected to the second wall. The
first wall 306 of the cup holding station engages the top 330 of the formed
lip
of the upside down cup and the second wall 308 of the cup holding station
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engages a top portion 332 of the inner surface of the upside down cup. It
should be appreciated that any suitable engagement surface which creates a
male-female connection between the cup holding station and the cup may be
implemented with the cup reinforcing system disclosed herein.
[00143] In one embodiment, to transport the base cup from the cup
spacer to the cup holding stations of the turntable, to account for the height
of
the frictional engagement members of the holding stations, the turntable is
positioned slightly below the cup spacer. Such positioning of the cup mover
below the cup spacer allows each transported cup to be placed directly on top
of one of the cup holding stations 302 of the cup mover 212. That is, to
account for the height of the vertically disposed second wall 308 of the
holding
stations 302 when transporting each cup 102 from the cup spacer 210 to the
cup holding stations 302 of the turntable 212, the turntable is positioned
slightly below the cup spacer.
[00144] Moreover, the walls of the centering bell are suitably configured
to match and engage a plurality of the walls of the cup. As best illustrated
in
Figs. 34 and 35, a first wall of the centering bell 314 engages the bottom rim
334 of the cup and a beveled or tapered second wall of the centering bell 316
engages the beveled or tapered inner side wall 336 of the cup. In this
embodiment, a third wall of the centering bell 318 engages the outer bottom
wall 16 of the cup, a fourth wall of the centering bell 320 engages the top
surface of a centered raised portion 337 of the outer bottom wall of the cup
and a fifth wall of the centering bell 322 engages the side wall 338 of the
centered raised portion of the outer bottom wall of the cup. It should be
appreciated that any suitable engagement surface which creates a male-
female connection between the centering bell and the cup may be
implemented with the cup reinforcing system disclosed herein.
[00145] It should be appreciated that when compared to a turntable of
known bottle labeling devices, the turntable of the cup reinforcing system
includes a reduced number of holding stations to accommodate the length of
the reinforcing member. That is, since the reinforcing members applied to the
base cups are of greater length than the labels applied to the bottles of a
bottle
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labeling machine and such greater length may cause interferences when the
reinforcing member is partially attached to the cups as described below, a
greater distance must be between each holding station/centering bell of the
turntable. Accordingly, providing a greater distance between each holding
station/centering bell of the turntable without increasing the size of the
turntable requires a reduction in the number of holding stations/centering
bells
of the turntable.
[00146] As described above and best illustrated in Figs. 42A to 43F, the
frame of the cup mover 212 supports a plurality of reinforcing member
application pads 390a and 390b (referred to generally as 390). Each
reinforcing member application pad 390 includes a base 392a and 392b
(referred to generally as 392) and a reinforcing member engaging surface
394a and 394b (referred to generally as 394), wherein the reinforcing member
engaging surface includes any suitable material with anti-adhesion properties,
such as a polytetrafluoroethylene or Teflon coated tape, which resists
adherence by the adhesive coated on the reinforcing member. Each
reinforcing member application pad 390 is positioned relative to the
reinforcing
member point of attachment to provide a suitable surface which is engaged by
the tapered side wall of the cup to secure the reinforcing member (which is
positioned between the tapered side wall of the cup 102 and the engaging
surface 394 of the reinforcing member application pad 390) to the tapered side
wall of the cup. Each reinforcing member application pad 390 is suitably
shaped and sized to accommodate the size and shape of the cups which are
reinforced as well as to accommodate the size of the cup mover 212 which is
moving the cups. For example, each reinforcing member application pad 390
is suitably beveled and tapered to match and engage the tapered side wall of
the cup. It should be appreciated that the height or angle of one or more
reinforcing member application pads may be suitable adjusted to
accommodate the shape and size of the cups.
[00147] As described above, the cup mover 212 is configured to
transport each base cup into a reinforcing member point of attachment or
engagement or attachment position. At this point of attachment, a reinforcing
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member, dispensed from the reinforcing member dispenser 204 described
below, is suitable partially attached to the tapered side wall of the cup 102.
[00148] After a reinforcing member is attached to a cup 102, the cup
mover 212 transports each reinforced cup to a cup remover 214. As illustrated
in Fig. 37, the cup remover 214 of the cup conveyor system includes a frame
340 positioned adjacent to and at substantially the same height as the cup
mover 212. The frame 280 of the cup feeder supports two co-acting inlet stars
or in-feed star-wheel conveyors 342a and 342b (referred to generally as 342),
an out-feed conveyor device 344 and a reinforced cup exhaust device 346. In
one embodiment, the cup reinforcing system includes one outlet star or out-
feed star-wheel which transports the cups from the cup mover to the out-feed
reinforced cup conveyor device. In one embodiment (not shown), the cup
reinforcing system utilized one or more brushes to engage the sidewall of
each cup to enhance the movement of each cup from the turntable of the cup
mover to the out-feed reinforced cup conveyor device. Each outlet star 342 is
movably connected or coupled to at least one actuator, such as motor or other
suitable movement generating device controlled by the cup reinforcing system
processor which causes the outlet star to rotate or move in any suitable
direction at any suitable speed in a conventional manner. Similar to the inlet
stars described above, each outlet star 342 includes a plurality of pockets
346
on its circumference. Each pocket 346 is configured to hold a cup 102 as the
cup is transferred from the cup mover 212. The sidewall of each pocket 246 is
angled offset from a vertical plane at a suitable angle to match the angle of
the
tapered side walls of the base cups.
[00149] The frame 340 of the cup remover 212 supports two outlet star
guide members or guide rails 348a and 348b (referred to generally as 348).
Guide member 348a is located adjacent to outlet star 342a and guide member
348b is located adjacent to outlet star 342b. Each guide member 348 prevents
the cups transported by their respective outlet star 342 from becoming
displaced, such as by tipping over. The cup guide members 348 are sized and
angled offset from a vertical plane to correlate to the specifications of the
reinforced cups. In another embodiment, the cup reinforcing system includes
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a plurality of inlet stars or in-feed star-wheels which co-act to transport
the cup
from the cup mover 212 to the out-feed cup conveyor device 344.
[00150] The out-feed cup conveyor device 344 is suitably movably
connected or coupled to at least one actuator, such as a motor or other
suitable movement generating device which causes the conveyor belts to
move at any suitable speed in a conventional manner. The cup remover
includes at least two opposing spaced-apart elongated guide rails or guide
tracks 350 supported by the frame 340 of the cup remover. The guide rails
350 are angled offset from a vertical plane at a suitable angle to match the
angle of the tapered side walls of the cups transported by the out-feed cup
conveyor device 344.
[00151] As seen in Fig. 37, each cup 102 is transported, via the out-
feed reinforced cup conveyor device 344, to a cup positioner 352, such as a
cup tipper or other suitable member, which positions or tips the reinforced
cup
onto its side (downside leading). The guide rails 350 insure that the tipped
cup
is positioned on its side. The tipped cup is then vacuum pulled via the cup
exhaust system 346 (not shown) to a stack of nested reinforced cups. It
should be appreciated that any suitable means or manner for transporting one
or more cups from the cup dispenser to the cup mover or turntable may be
employed in accordance with the cup reinforcing system disclosed herein.
[00152] In one embodiment, as illustrated in Figs. 38A, 38B, 39 and 40,
each reinforcing member dispenser 204 of the cup reinforcing system includes
a frame 360 which supports an adjustable base or support 386. As described
above, the reinforcing member dispenser 204 is operable to feed each
reinforcing member 42 toward a cup 102 at a suitable angle offset form a
vertical plane which corresponds with the angle (also offset from a vertical
plane) of the tapered side wall of the cup. Accordingly, the adjustable base
386 of the reinforcing member dispenser 204 is suitably angled offset from a
vertical plane. The angle which the adjustable base 386 of the reinforcing
member dispenser 204 is at may be adjusted (via a suitable angle adjustment
mechanism 382) to accommodate for different base cups with different angled
tapered side walls.
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[00153] In addition to adjusting the angle of the reinforcing member
dispenser offset from a vertical plane, the height of the adjustable base 386
of
the reinforcing member dispenser 204 may be adjusted (via .a suitable height
adjustment mechanism 384) to accommodate for different sized cups and
variances in different reinforcing members positioning on the liner. Moreover,
the angle which the adjustable base 386 of the reinforcing member dispenser
204 is at may be adjusted offset from a horizontal plane if necessary.
Accordingly, it should be appreciated that the reinforcing member dispenser
may be individually adjusted in three separate planes to facilitate a proper
attachment of a reinforcing member to the tapered sidewall of a cup. In
alternative embodiments, the reinforcing member dispenser may be adjusted
to any suitable angle in any suitable plane or number of planes to facilitate
a
proper attachment of a reinforcing member to the tapered sidewall of a cup.
[00154] The reinforcing member dispenser includes two reinforcing
member supply holders 362a and 362b (referred to generally as 362)
supported by the adjustable base 386. Each reinforcing member supply holder
362 is configured to hold a supply 364a and 364b (referred to generally as
364) of reinforcing members, wherein each supply of reinforcing members
includes a plurality of reinforcing members sequentially releasably attached
to
an elongated release liner (as best seen in Figs. 7 and 7A) wound about a
central cylindrical tube 388a and 388b (referred to generally as 388) into a
roll.
Each reinforcing member dispenser includes at least one and preferably a
plurality of drive rollers, such as drive rollers 366a and 366b (referred to
generally as 366) supported by the adjustable base 386 and configured to
drive or pull the release liner 56 (which the reinforcing members are
releasably
attached to). In operation, drive roller 366a pulls or drives the release
liner 56
from the supply roll toward drive roller 366a and into a designated area 374
of
a release liner slack accumulator 372 (as described below). Drive roller 366b
then pulls or drives the release liner from the designated area 374 of the
release liner slack accumulator 372 and towards the cup-reinforcing member
point of attachment or engagement. Each drive roller 366 is suitably movably
connected or coupled to at least one actuator (not shown), such as a motor or
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other suitable movement generating device which causes the drive rollers to
move at any suitable speed. In one embodiment, one, more or each of the
drive rollers 366 includes a knurled surface to better engage the release
liner
as it is fed through the reinforcing member dispenser. In another embodiment,
one, more or each of the drive rollers 366 includes a rubber surface to better
engage the release liner as it is fed through the reinforcing member
dispenser.
[00155] Each reinforcing member dispenser includes a powered take-
up roller 367, supported by the adjustable base 386 and configured to pull or
drive the used release liner 56 to a liner accumulation holder 376. The
powered take-up roller 367 is suitably movably connected or coupled to at
least one actuator (not shown), such as a motor or other suitable movement
generating device which causes the take-up roller to move at any suitable
speed.
[00156] Each reinforcing member dispenser also includes a plurality of
guides and tensioners, such as guide rollers 368, supported by the adjustable
base 386 and configured to guide the release liner (which the reinforcing
members are releasably attached to) toward the point of engagement with the
cups as well as maintain suitable amounts of tension on the release liner.
[00157] The reinforcing member dispenser 204 includes a vertically
disposed release liner splicer 370 supported by the adjustable base 386 and
configured to allow a plurality of supplies of reinforcing members to be
spliced
together. The release liner splicer 370 includes a first area (not shown)
configured for holding the trailing end of a first release liner supply and a
second area (not shown) for holding the leading end of a second release liner
supply. The release liner splicer provides a mechanism for a user of the cup
reinforcing system to splice the trailing end of the first release liner
supply to
the leading end of the second release liner supply to insure that the
reinforcing
member dispenser is provided a continuous supply of release liner.
[00158] For example, in one embodiment, when the last reinforcing
member of the first release liner supply is detected, a user centers the first
release liner supply over a cutting groove and utilizes one or more suitable
mechanisms to hold the first release liner supply in place. The user then
slides
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the second release liner supply over the first release liner supply, places
the
leading edge of the first reinforcing member of the second release liner
supply
exactly over the last reinforcing member of the first release liner supply and
utilizes one or more suitable mechanisms to hold the second release liner
supply in place. The user utilizes a suitable cutting head and cutting guide
to
cut the first and second release liner supplies, removes the scrap pieces from
the first and second release liner supplies and tapes the first and second
release liner supplies together.
[00159] As seen in Fig. 38A, the reinforcing member dispenser 204
also includes a release liner slack accumulator 372a supported by the
adjustable base 386 and configured to provide a designated area 374a where
slack in the release liner may accumulate. As seen in Fig. 38B, in an
alternative embodiment, the reinforcing member dispenser 204 includes an
alternatively designed release liner slack accumulator 372b supported by the
adjustable base 386 and configured to provide an alternatively designed
designated area 374b where slack in the release liner may accumulate. In one
embodiment (not shown), the release liner slack accumulator includes one or
more debris removes supported by the adjustable base and configured to
remove any debris, such as dust or powder, from the back side of the release
liner as the release liner is fed into and/or out from the designated area
where
slack in the release liner may accumulate. The reinforcing member dispenser
204 also include a liner accumulation holder 376 supported by the adjustable
base 386 and configured to hold the release liner after separation from the
reinforcing members.
[00160] As seen in Figs. 42B and 43A to 43F, the reinforcing member
dispenser 204 also includes at least one sensor 378 supported by the
adjustable base 386 and configured for determining the location of a
reinforcing member 42. It should be appreciated that the height and position
of
the sensor 378 may be adjusted depending on the configuration of the cups
which are being reinforced. In one embodiment, the reinforcing member
dispenser also includes one or more sensors (not shown) supported by the
adjustable base and configured for determining the position and amount of
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release liner which has accumulated in the designated area of the release
liner slack accumulator. The reinforcing member dispenser 204 includes a
release liner separator 380, such as a separation plate, supported by the
adjustable base 386 and configured for separating the reinforcing members
from the release liner.
[00161] Each reinforcing member supply holder 362 is configured to
hold a wound supply roll of liner 56 (which the plurality of reinforcing
members
are releaseably attached to). In one embodiment, each roll of wound
reinforcing members are held in a horizontal configuration. In this
embodiment, as the reinforcing members are held in the same configuration
which they will be applied to the base cups, it is not necessary to
reconfigure
or otherwise twist the reinforcing members prior to application to the cups.
In
another embodiment, each roll of wound reinforcing members are held in a
vertical configuration. In this embodiment, the reinforcing members must be
reconfigured or twisted prior to application to the base cups.
[00162] In one embodiment, the plurality of guide rollers 368 of the
reinforcing member dispenser 204 are designed to feed the liner 56 from the
liner supply roll 364, past the liner splicer 370, through the release liner
slack
accumulator 372, past the sensor 378 and the release liner separator 380 and
to the roll of used liner 376. In one embodiment, one, more or each of the
guide rollers 368 includes a knurled surface to better engage the release
liner
as it is fed through the reinforcing member dispenser. In another embodiment,
one, more or each of the guide rollers 368 includes a rubber surface to better
engage the release liner as it is fed through the reinforcing member
dispenser.
It should be appreciated that the rollers are of suitable height to
accommodate
the size of the release liner (and the attached reinforcing members) which are
engaged by the plurality of rollers.
[00163] As best illustrated in Figs. 39 and 40, the release liner slack
accumulator 372 is an elongated substantially u-shaped member which
provides a designated area 374 wherein slack in the liner 56 may accumulate.
That is, due to the need to accurately apply the reinforcing members to the
tapered side wall of the cup along the centered vertical axis of the
reinforcing
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member, the processor of the cup reinforcing system often must adjust the
speed which the reinforcing members are moving to insure that the cups
moving on the turntable and the reinforcing members dispensed by the
reinforcing dispenser come into contact at the appropriate time and location
such that the centered vertical axis of the reinforcing member is applied to
the
cup on a consistent basis with a range of error of less than plus or minus 0.1
inches. In other words, providing an area where slack can accumulate
enables the processor of the cup reinforcing system to adjust the speed at
which the liner is fed through the reinforcing member dispenser without
otherwise affecting the feed of the release liner from the supply of release
liner. For example, the designated area of the release liner slack accumulator
is operable to accommodate the length of release liner which five to six
reinforcing members are releasably attached to. It should be appreciated that
the release liner slack accumulator associated with the cup reinforcing system
disclosed herein is longer and more narrow than the release liner slack
accumulators of known bottle labeling systems to accommodate for the
increased length of the reinforcing members applied to the base cups.
[00164] As described above, the sensor 378 of each reinforcing
member dispenser 204 is utilized for determining or verifying the location or
position of the reinforcing member 42 relative to the position of the cup 102.
The sensor may be any suitable sensor, including but not limited to optical
sensors or ultrasonic sensors. In operation, the sensor 378 detects the
location of the substantially vertical portion of the front or leading edge 70
of
the reinforcing member 42 to determine the relative position of the
reinforcing
member. Based on this determined position of the reinforcing member and
any other suitable information (such as the speed the cup is moving, the speed
the reinforcing member is being fed through the reinforcing member dispenser,
the length of the reinforcing member and the diameter of the cup), the
processor 402 of the cup reinforcing system determines or calculates when the
reinforcing member is moved into a position in which the centered vertical
axis
of the reinforcing member is aligned with the tapered side wall of the base
cup.
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[00165] As best illustrated in Fig. 42B, the sensor 378 is positioned or
placed such that the sensor detects the relative location of each reinforcing
member immediately prior to that reinforcing member being affixed to a base
cup. In this embodiment, positioning the sensor at such a location provides
for
increased accuracy in the placement of the reinforcing member on the base
cup which provides for a proper engagement between the reinforcing member
and the cup. It should be appreciated that in a bottle labeling machine, since
the labels first engage the bottles at the labels leading edge, accuracy in
attaching the labels at a specific position of the label is sacrificed to
increase
the speed which the labels are attached. Accordingly, the sensor in known
bottle labeling machines is placed at a position substantially upstream from
where the labels are attached to the bottles. On the other hand, in the cup
reinforcing system disclosed herein, since the reinforcing members must be
attached to the tapered side wall of the base cup not by the leading edge but
at a specific position along the centered vertical axis, the sensor is placed
adjacent to where the reinforcing member will engage the base cup to increase
the accuracy in attaching the reinforcing member at a specific position. In
this
embodiment, the cup reinforcing system disclosed herein sacrifices the speed
which the cups may be reinforced in exchange for increased accuracy in the
proper reinforcement of such cups and specifically the proper positioning of
the
attachment of the reinforcing members to the tapered side walls of the cups.
[00166] The release liner separator 380, such as a separation plate, of
each reinforcing member dispenser 204 is configured to separate the
reinforcing members 42 from the release liner 56. That is, based on the
orientation of the reinforcing member 42 relative to the release liner
separator,
the reinforcing members will separate from the release liner (which protects
the pressure sensitive adhesive) when the reinforcing members are fed, via
the release liner, through the release liner separator 380. It should be
appreciated that since the reinforcing members are toward the base cups at a
suitable angle offset form a vertical plane which corresponds with the angle
(also offset from a vertical plane) of the tapered side wall of the base cup,
the
release liner separator 380 is also suitably angled offset from a vertical
plane.
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[00167] The liner accumulation holder 376 is configured to accumulate
and suitably wind the release liner after the reinforcing members are
separated
from the release liner. In one embodiment, after the release liner passes the
reinforcing member point of attachment or point of engagement, the release
liner is fed, via one or more suitable rollers, to the release liner
accumulation
holder. In one embodiment, the liner accumulation holder is movably
connected or coupled to one or more actuators (or other suitable movement
generating devices controlled by the cup reinforcing system processor) which
causes the liner accumulation holder 376 to rotate or move in any suitable
direction at any suitable speed. In different embodiments, each wound roll of
used release liner is held in a horizontal configuration or in a vertical
configuration.
[00168] As seen in Fig. 18A, the cup reinforcing system disclosed
herein may sequentially utilize a plurality of cup reinforcing dispensers 204a
and 204b. In operation, while a first cup reinforcing dispenser 204a is
applying
or attaching a plurality of reinforcing members 42 to a plurality of cups 102,
a
second cup reinforcing dispenser 204b is being suitably prepared (i.e., part
of
the wound roll of liner is fed, via the rollers, through the entire cup
reinforcing
dispense) to also apply or attach reinforcing members. Accordingly, when the
supply of reinforcing members of the first cup reinforcing dispenser 204a is
exhausted, the second cup reinforcing dispenser 204b begins applying or
attaching a plurality of reinforcing members to a plurality of base cups with
minimal delay.
[00169] As seen in Fig. 41A to 41D, in various alternative
embodiments, a plurality of reinforcing member dispensers 204a, 204b and
204c are operable to sequentially reinforce each cup 102. In this embodiment,
a first reinforcing member is applied to a base cup by a first reinforcing
member dispenser followed by the application of a second reinforcing member
by a second reinforcing member dispenser. For example, the first reinforcing
member dispenser 204a applies a first reinforcing member to a base cup at a
first point of engagement on the cup mover and at a second, downstream
point of engagement, a second reinforcing member is applied by a second
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reinforcing member dispenser 204b or 204c. It should be appreciated that in
this embodiment, any suitable number of reinforcing member dispensers 204
may be implemented in accordance with the cup reinforcing system disclosed
herein.
[00170] It should be appreciated that any suitable configuration of the
cup reinforcing system and specifically any suitable design of the cup
conveyor
system relative to one or more reinforcing member dispensers may be utilized
to attach a reinforcing member to a base cup as described above. For
example, Fig. 41A illustrates the configuration of the cup conveyor
illustrated in
Figs. 18A and 18B with three reinforcing member dispensers. Fig. 41B
illustrates another embodiment wherein the cup spacer and cup remover each
utilize one star-wheel and the cups enter and exit the cup reinforcing system
through opposite ends. Figs. 41C illustrates another embodiment wherein the
cup spacer utilizes two star-wheels, the cup remover utilizes one star-wheel
and the cups enter and exit the cup reinforcing system through the same end.
Figs. 41D illustrates another embodiment wherein the cup spacer utilizes a
plurality of star-wheels, the cup remover utilizes one star-wheel and the cups
enter and exit the cup reinforcing system through different ends.
[00171] In an alternative embodiment, as illustrated in Figs. 42A and
43A, a first base or pre-reinforced cup 102a is moved into an attachment
position and the reinforcing member dispenser 204 dispenses a first
reinforcing member 42a. As seen in Figs. 42B and 43B, the reinforcing
member engages the tapered side wall of the base cup. As described above,
the first reinforcing member 42a engages the tapered side wall of the first
base
cup 102a at an angle offset from a vertical plane which corresponds to the
angle of the tapered side wall of the base cup.
[00172] As illustrated in Figs. 43C, after the first reinforcing member
42a engages the first base cup 102a, in one embodiment, the first cup 102a is
moved, via the cup mover 212, downstream from the point of engagement or
attachment of the reinforcing member. In this embodiment, since the first
reinforcing member 42a is attached, along a centered vertical plane, to the
tapered side wall of the first base cup 102a, as the cup is moved away from
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the point of engagement, any remaining portion of the first reinforcing member
42a which is attached to the release liner is separated from the release liner
56.
[00173] As illustrated in Figs. 42C and 43D, after the first cup 102a and
first reinforcing member 42a are moved downstream from the point of
engagement to completely separate the first reinforcing member 42a from the
release liner 56, in one embodiment, the first base cup 102a is rotated 10
degrees to 20 degrees in a first, clockwise direction to attach a first,
centered
portion of the first reinforcing member 42a to the cup. In this embodiment,
the
rotation of the base cup causes a portion of the reinforcing member and the
base cup to engage a reinforcing member application pad 390a, such that the
tapered side wall of the cup presses against or engages the reinforcing
member engaging surface 394a of the application pad 390a to cause the first,
centered portion of the first reinforcing member 42a (which is positioned
between the tapered side wall and the reinforcing member application pad
390a) to engage with and adhere to the tapered side wall of the first cup
102a.
[00174] It should be appreciated that this first rotation of 10 degrees to
20 degrees reduces the length of the unattached reinforcing member and
reduces the possibility that at least one of the edges of the reinforcing
member
from the first cup will interfere with the attachment of a reinforcing member
to a
second, subsequently reinforced cup. Moreover, such a first rotation further
secures the reinforcing member to the base cup by providing that an area of
the reinforcing member greater than the centered vertical axis of the
reinforcing member is attached to the base cup. In another embodiment, the
reinforcing member is attached to the cup without such a first rotation of 10
degrees to 20 degrees. It should be further appreciated that when the
reinforcing member is initially attached to the cup, the sensing edge 70 is:
(i)
perpendicular or substantially perpendicular to the bottom edge of the cup;
and
(ii) parallel to the centered vertical axis of the reinforcing member. Such a
configuration provides an absolute reference point for the cup reinforcing
system to determine the location of the reinforcing member.
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[00175] As illustrated in Figs. 42D and 43E, in one embodiment, the
first rotation of the cup is followed by a second, counter-clockwise rotation
greater than 180 degrees to attach a second, trailing edge portion of the
first
reinforcing member 42a to the first cup 102a. In this embodiment, the rotation
of the base cup causes a portion of the reinforcing member 42a and the cup
102a to engage a reinforcing member application pad 390a, such that the
tapered side wall of the cup presses against or engages the reinforcing
member engaging surface 394a of the application pad 390a to cause the
second, trailing edge portion of the first reinforcing member 42a (which is
positioned between the tapered side wall and the reinforcing member
application pad 390a) to engage with and adhere to the tapered side wall of
the first cup 102a.
[00176] As seen in Figs. 42E and 43F, in one embodiment, the second
rotation is followed by rotating the cup a third, clockwise rotation greater
than
360 degrees to attach a third, leading edge portion of the first reinforcing
member 42a to the first cup 102a. In this embodiment, the rotation of the base
cup causes a portion of the reinforcing member 42a and the cup 102a to
engage a reinforcing member application pad 390b, such that the tapered side
wall of the cup presses against or engages the reinforcing member engaging
surface 394b of the application pad 390b to cause the third, leading edge
portion of the first reinforcing member 42a (which is positioned between the
tapered side wall and the reinforcing member application pad 390a) to engage
with and adhere to the tapered side wall of the first cup 102a.
[00177] It should be appreciated that as described above, the cup
reinforcing system disclosed herein is operable to sequentially reinforce a
plurality of cups. As best seen in Figs. 42D, 42E, 43E and 43F, after the
first
cup 102a and first reinforcing member 42a moved downstream from the point
of engagement, a second cup 102b and a second reinforcing member 42b are
moved into an appropriate attachment position.
[00178] In another embodiment, one or more reinforcing member
application pads are movable and suitably operable to attach, either
sequentially or simultaneously, the remaining free portions of the reinforcing
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member to the tapered side wall of the cup. In this embodiment, the cup is
kept substantially stationary or stationary and the reinforcing member
attachment pads rotate or move to attach the reinforcing member to the
tapered sidewall of the cup.
[00179] In another embodiment (not shown), the reinforcing member is
initially attached to the tapered sidewall of the cup not along the centered
vertical axis of the reinforcing member. In this embodiment, the reinforcing
member is applied along an off-centered vertical axis of the reinforcing
member and the methods described above are suitably modified to
compensate for the off-centered point of attachment. In another embodiment
(not shown), the reinforcing member is initially attached to the tapered
sidewall
of the cup along the leading edge of the reinforcing member. Accordingly, it
should be appreciated that any suitable method and apparatus operable to
target or attach a specific spot or location on the reinforcing member to a
specific spot or location on the cup may be utilized in the cup reinforcing
system disclosed herein.
[00180] In one alternative embodiment, as illustrated in Figs. 44A to
44D, one side of the reinforcing members are not completely or substantially
completely coated with an adhesive. In this embodiment, as described above,
the cups are placed on cup holding stations of the cup mover 212 and
transported to different areas of the cup reinforcing system. As best seen in
Figs. 44A, the cup reinforcing system includes an adhesive application device
420. In operation, when a suitable sensor 378a detects the appropriate
position of a cup 102, the adhesive application device 420 applies a suitable
adhesive directly to the surface of the tapered side walls of the base cup. In
one embodiment, the adhesive is applied or sprayed onto the surface of the
tapered side wall of the base cup as a mist or atomized spray. It should be
appreciated that the adhesive may be applied using other suitable processes
such as dipping the base cup into a container of the adhesive.
[00181] In one such embodiment, as best seen in Fig. 44B, after the
tapered side walls of the base cup are completely or substantially completely
coated with an adhesive and a suitable sensor 378b detects the appropriate
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position of the cup, a reinforcing member 42 is attached to the base cup. In
this embodiment, since one side of the reinforcing members are not coated
with an adhesive, the reinforcing members do not need to be stored along a
release liner and may be stored as a stack of reinforcing members 422.
Accordingly, in this embodiment, a suitable reinforcing member holding device
or mechanism 424 dispenses the non-adhesive backed reinforcing members,
one at a time, to engage the tapered side wall of the base cups. The
reinforcing member holding device 424 includes suitably spaced apart
sidewalls 426a and 426b which support the stack of reinforcing members. The
reinforcing member holding device may be connected or coupled to at least
one actuator, such as a motor, a spring-loaded mechanism or other suitable
movement generating device controlled by the cup reinforcing system
processor which causes the reinforcing member holding device to move into a
suitable position such that a held reinforcing member engages an adhesive
coated cup. In an alternative embodiment, the adhesive is suitably sprayed
onto an applicator which applies the adhesive to the sidewall of the cup. In
another embodiment, the adhesive is suitably sprayed onto an applicator
which applies the adhesive to one of the surfaces of the reinforcing member.
As described above, in these alternative embodiments, the reinforcing member
is situated at an angle which corresponds with the angle of the tapered side
wall of the cup and thus the reinforcing member is attached to the base cup at
an angle which corresponds with the angle of the wall of the base cup.
Moreover, as described above, in these alternative embodiments, the
reinforcing member must initially engage the base cup along the centered
vertical axis of the base cup.
1P01821 As best illustrated in Fig. 44C, after the reinforcing member 42
is attached to the tapered side wall of the cup 102 along the centered
vertical
axis 108 of the reinforcing member, this embodiment of the cup reinforcing
system is operable to cause the remaining unattached portions of the
reinforcing member to engage and attach to the tapered side wall of the cup.
In one embodiment, utilizing the cup holding station on which the cup resides,
the cup rotates 180 degrees in a first direction. As the cup is rotating, the
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tapered side wall of the cup presses against or engages a reinforcing member
engaging surface 394 of a reinforcing member application pad 390 to cause a
first portion or section of the reinforcing member to engage and attach, due
to
the adhesive coating applied to the sidewall of the cup, to the tapered side
wall
of the cup. In one embodiment, the first portion or section includes the
portion
of the reinforcing member which extends from the centered vertical axis to the
trailing edge.
[00183] As best seen in Fig. 44D, in one embodiment, following a
rotation of the cup in a first direction, the cup is then rotated 360 degrees
in an
opposite, second direction. As the cup is rotating, the tapered side wall of
the
cup presses against or engages the reinforcing member engaging surface 394
of the reinforcing member application pad 390 to cause the second portion or
section of the reinforcing member to engage and attach to the tapered side
wall of the cup. In one embodiment, the second portion or section includes the
portion of the reinforcing member which extends from the centered vertical
axis to the leading edge. It should be appreciated that this embodiment of the
cup reinforcing system is operable to sequentially reinforce a plurality of
cups.
For example, a first reinforcing member from the stack of reinforcing members
engages a first adhesive coated cup followed by a second reinforcing member
from the stack of reinforcing members engaging a second adhesive coated
cup.
[00184] In another alternative embodiment, the structure of the cup
reinforcing system illustrated in Figs. 18A and 18B is suitably reversed. That
is, rather than the cup mover 212 rotating in a counter-clockwise direction,
the
cup mover rotates in a clockwise direction. It should be appreciated that in
this
embodiment, the individual rotations of each cup holding station would be
modified to accommodate for the change in direction of the cup mover. In
other words, each cup holding station would rotate each individual cup 15
degrees to 20 degrees in a first, counter-clockwise direction, followed by a
second, clockwise rotation greater than 180 degrees and followed by a third,
counter-clockwise rotation greater than 360 degrees.
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[00185] It should be appreciated that the methods and apparatus
described above may also be utilized to apply a reinforcing member or
otherwise suitably wrap any other container or receptacle, such as a bowl, a
bottle, a carton, a dish, a jar, a mug, or a pitcher. It should be further
appreciated that the methods and apparatus described above may also be
utilized to apply a reinforcing member or otherwise suitably wrap a non-
plastic
foam container, such as a paper container or another type of plastic
container.
[00186] Accordingly, in one embodiment, the cup reinforcing system
disclosed herein produces a reinforced plastic foam cup including a plastic
foam conical body, and a flat reinforcing member affixed around the outer
surface of the tapered side wall in an overlapping manner. The plastic foam
conical body defines an open top end, a closed bottom end, and a tapered
side wall extending from the bottom end to the top end, wherein the top end
includes an outwardly rolled lip, the top end has a greater diameter than the
bottom end and the tapered side wall having an outer surface and an inner
surface. The flat reinforcing member includes a rigid material layer having an
inner surface and an outer surface, and a pressure sensitive adhesive layer
which covers substantially the entire inner surface of the material layer.
Prior
to being affixed around the outer surface of the tapered side wall, the
reinforcing member has a concave or first edge and a convex or second edge,
wherein a trough of the concave edge is aligned in a same plane as an apex of
the convex edge. The pre-affixed reinforcing member includes a leading or
third edge and a sensing or fourth edge, the leading edge and sensing edge
extending between the concave and convex edges at one end of the material
layer. The pre-affixed reinforcing member also includes a trailing or fifth
edge
and an adhesive relief or sixth edge, the trailing edge and adhesive relief
edge
extending between the concave and convex edges at an opposite end of the
material layer, the leading edge and trailing edge extending in intersecting
planes, the sensing edge and adhesive relief edge extending in substantially
parallel planes. After being affixed around the outer surface of the tapered
side wall, the concave edge is adjacent to the closed bottom end of the
plastic
foam conical body, the convex edge is adjacent to the open top end of the
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plastic foam conical body, the leading edge and trailing edge extend in
substantially parallel planes, and the sensing edge and adhesive relief edge
extend in intersecting planes.
[00187] In another embodiment, the cup reinforcing system produces a
reinforced plastic foam cup, the reinforced cup including a plastic foam cup
and a reinforcing member affixed around the outer surface of the tapered side
wall in an overlapping manner. The plastic foam cup includes a bottom wall,
and a conical shaped side wall integrally formed at one end with the bottom
wall and extending from the bottom wall to a top end, the side wall having an
inner surface and an outer surface, the bottom wall and side wall defining a
cavity, the top end defining an opening for the cavity, the top end having a
greater diameter than the bottom end. The plastic foam cup also includes an
outwardly extending lip integrally formed with the top end of the side, and a
downwardly extending lip integrally formed with the side wall and extending
below the bottom wall. The reinforcing member includes a paper material
layer having an inner surface and an outer surface, and a pressure sensitive
adhesive layer which covers substantially the entire inner surface of the
paper
material layer. Prior to being affixed around the outer surface of the side
wall,
the reinforcing member has a concave or first edge, and a convex or second
edge, wherein a trough of the concave edge is aligned in a same plane as an
apex of the convex edge. The pre-affixed reinforcing member includes a
leading or third edge, and a sensing or fourth edge, the leading edge and
sensing edge extending between the concave and convex edges at one end of
the material layer. The pre-affixed reinforcing member also includes a
trailing
or fifth edge, and an adhesive relief or sixth edge, the trailing edge and
adhesive relief edge extending between the concave and convex edges at an
opposite end of the material layer, the leading edge and trailing edge
extending in intersecting planes, the sensing edge and the adhesive relief
edge extending in substantially parallel planes. After being affixed around
the
outer surface of the side wall the concave edge is adjacent to a bottom edge
of
the downwardly extending lip, the convex edge is adjacent to the outwardly
extending lip, the leading edge and trailing edge extend in substantially
parallel
CA 02608826 2013-03-28
planes, and the sensing edge and adhesive relief edge extend in intersecting
planes.
[00188] In another embodiment, the cup reinforcing system disclosed herein
includes a plastic foam cup reinforcing member supply roll which includes an
elongated backing strip and a plurality of flat reinforcing members
sequentially
aligned along the elongated backing strip. Each reinforcing member including a
paper material layer having an inner surface and an outer surface. Each
reinforcing
member has a concave or first edge, and a convex or second edge, wherein a
trough of the concave edge is aligned in a same plane as an apex of the convex
edge. Each reinforcing member has a leading or third edge, and a sensing or
fourth
edge, the leading edge and sensing edge extending between the concave and
convex edges at one end of the material layer. Each reinforcing member also
has a
trailing or fifth edge, and an adhesive relief or sixth edge, the trailing
edge and
adhesive relief edge extending between the concave edge and convex edge at an
opposite end of the material layer, the leading edge and trailing edge
extending in
intersecting planes, the sensing edge and adhesive relief edge extending in
substantially parallel planes. Each reinforcing member configured such that
when
the reinforcing member is affixed around an outer surface of a tapered side
wall of a
conical cup having a bottom end and a top end, wherein the top end has a
diameter
greater than the diameter of the bottom end, the concave edge is adjacent to
the
bottom end of the conical cup, the convex edge is adjacent to the top end of
the
conical cup, the leading edge and trailing edge extend in substantially
parallel
planes, and the sensing edge and adhesive relief edge extend in intersecting
planes. Moreover, each the reinforcing member affixed to the backing strip by
a
pressure sensitive adhesive layer which covers substantially the entire inner
surface
of the paper material layer.
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[00189] It should be understood that various changes and modifications to
the presently preferred embodiments described herein will be apparent to those
skilled in the art. The scope of the claims should not be limited by the
preferred
embodiments set forth in the examples, but should be given the broadest
interpretation consistent with the description as a whole.
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