Note: Descriptions are shown in the official language in which they were submitted.
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TITLE: CONTAINER LID, CONTAINER-LID ASSEMBLY, AND METHOD OF
MANUFACTURE
PRIORITY
[0001] This application claims priority from US Provisional Patent
Application No. 61/167,319, filed April 7, 2009.
FIELD
[0002] The field of the invention relates generally to containers and
container lids.
INTRODUCTION
[0003] Lidded containers are often a convenient mode of transportation for
food and drinks. Some people use resilient washable (or reusable) containers,
while others use disposable, one-time-use containers. One of the most common
uses of a disposable container is for containing hot and cold beverages, but
containers may be used for food and other products as well.
[0004] Lids specifically adapted for fitting disposable beverage containers
are known in the art. Typically, such lids are manufactured using a plastic-
based
material.
SUMMARY
[0005] In view of the ongoing global push for sustainable development,
new and creative ways to reduce the use of materials with low rates of
decomposition are in continuous demand. Plastic is an example of such an
undesirable material and, as mentioned above, container lids-the use of which
is abundant-are often made from plastic-based materials. The applicant has
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accordingly recognized a need for new and improved container lids, which in
some embodiments comprise recyclable material.
[0006] The described embodiments relate to lids for containers, lid-
container assemblies, and methods of manufacture for container lids.
[0007] In one broad aspect, there is provided a container lid. The container
lid includes: a base; a wall extending substantially vertically from the base;
and a
wall support element positioned remote from the base. The lid is made with a
paper-based material.
[0008] In some instances, the paper-based material may be recyclable. As
well, the wall support element may comprise a helically rolled rim.
[0009] The base of the lid may include at least one aperture. The aperture
or apertures may serve one or many of a variety of functions. An aperture may,
for example, serve as a pouring aperture, a drinking aperture, or a venting
aperture.
[0010] In some instances, the lid may be in the form of a coffee cup lid. As
well, an outer wall surface of the lid may be configured to be water
resistant.
Additionally, the lid base may be circular in shape and may include an
attachment lip to facilitate the securing of the lid base to the lid wall. The
top of
the lid base may be provided with various indicia. Indicia may include
corporate
insignia such as company logos/trademarks, tradenames or slogans, quotes,
cartoon characters, photographs, written or pictorial instructions, and any
other
visual cue that may be desirable to have displayed or communicated to a user
of
the lid.
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[0011] In another broad aspect, there is provided an assembly for
containing a beverage. The assembly includes a container and a lid for
insertion
into the container. The lid includes a lid base and a lid wall extending from
the lid
base. When the lid is inserted into an opening of the container, a plurality
of
locations of an inner wall surface of the container exerts a friction fit
force on a
corresponding plurality of locations of an outer wall surface of the lid.
[0012] In some instances, the lid and the container may be made with a
paper-based material. The lid may further comprise a wall support element
positioned remote from the base.
[0013] The lid may further comprise a positioning element configured to
delimit the extent of insertion of the lid into the container. Additionally,
the
positioning element may comprise a helically rolled rim configured to rest
against
the top of a container wall when the lid is fully inserted into an opening of
the
container. The lid wall is substantially shorter in vertical height than the
container
wall.
[0014] In some instances, the container may be suitable for containing a
fluid. Also, the container may be in the form of a coffee cup. Further, the
container may take the form of a disposable container.
[0015] The lid wall and the container wall may be substantially frusto
conical proximate the plurality of corresponding inner wall and outer wall
locations. Also, the base of the lid may comprise at least one aperture. One
or
more apertures may serve, for example, as a pouring aperture, a drinking
aperture, and a venting aperture. A single aperture may provide one or a
combination of such aperture functions.
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[0016] The vertical height of the lid wall may be substantially shorter than
the vertical height of the container wall. In some instances, the vertical
height of a
lid wall may be less than fifteen percent of the vertical height of the
container
wall.
[0017] In some instances, the lid base may be circular in shape and may
include an attachment lip to facilitate the securing of the lid base to the
lid wall.
The top of the lid base may be provided with various indicia. Indicia may
include
corporate insignia such as company logos/trademarks, tradenames or slogans,
quotes, cartoon characters, photographs, written or pictorial instructions,
and any
other visual cue that may be desirable to have displayed or communicated to a
user of the lid.
[0018] In another broad aspect of the present invention, there is provided
a lid for sealing a container. The lid includes a lid base and a lid wall
extending
from the base. When the lid is inserted into an opening of the container, a
plurality of locations of an inner wall surface of the container exerts a
friction fit
force on a corresponding plurality of locations of an outer wall surface of
the lid.
The lid of this aspect comprises a paper-based material.
[0019] In some instances, the lid wall may further comprise an outwardly
biasing lid wall element positioned remote from the lid base. Additionally,
the
outwardly biasing wall element may comprise a helically rolled rim.
[0020] The lid wall may be substantially frusto conical proximate the
plurality of locations of the outer lid wall surface. As well, the lid may be
configured to seal a disposable container. The vertical height of the lid wall
is
configured to be substantially shorter than the vertical height of the
container
wall.
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[0021] In another broad aspect of the present invention, there is provided
a method of manufacturing a lid. The method may include providing a base for
the lid. A sheet of material from which a wall for the lid can be formed may
be
provided. The lateral ends of the sheet may be loosely rolled and joined to
form a
lid wall having a frusto conical shape with a bottom opening and a top
opening.
The lid base may be affixed to the lid wall near the bottom opening, thereby
closing the bottom opening and creating a lid.
[0022] In some instances, the lid base may be circular in shape and may
include an attachment lip to facilitate the securing of the lid base to the
lid wall.
The bottom surface of the lid base and the sheet of material may be treated
with
a water resistant coating or liner, and the top of the lid base may be
provided with
various indicia. Indicia may include corporate insignia such as company
logos/trademarks, tradenames or slogans, quotes, cartoon characters,
photographs, written or pictorial instructions, and any other visual cue that
may
be desirable to have displayed or communicated to a user of the lid.
[0023] The sheet of material may be in the form of an arcuate blank and
the lid base and the sheet of material may be made with a paper-based
material.
[0024] In another broad aspect of the present invention, there is provided
a second method of manufacturing a lid. The method may include providing a
base for the lid. One or more indicia may be printed on the top surface of the
lid.
Indicia may include corporate insignia such as company logos/trademarks,
tradenames or slogans, quotes, cartoon characters, photographs, written or
pictorial instructions, and any other visual cue that may be desirable to have
displayed or communicated to a user of the lid.
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[0025] In some instances, the bottom surface of the lid base may be
treated with a water resistant liner or coating. A lid wall extending
substantially
vertically from the lid base may be formed, and the outside surface of the lid
wall
may be treated with a water resistant liner or coating. Also, a lid wall
support
element may be formed remote from the lid base.
[0026] These and other aspects and features of various embodiments will
be described in greater detail below.
DRAWINGS
[0027] Embodiments are described in further detail below, by way of
example only, with reference to the accompanying drawings, in which:
[0028] Figure 1, in perspective view, illustrates an embodiment of a
container lid according to one aspect of the invention;
[0029] Figure 2, in a front view, illustrates the container lid of Figure 1;
[0030] Figure 3 illustrates a thin slice of the lid of Figure 1, taken
orthogonal to the lid base and intersecting a centre of the lid base;
[0031] Figure 4, in perspective view, illustrates an embodiment of a
container according to another aspect of the invention;
[0032] Figure 5, in a front view, illustrates the container lid of Figure 1,
configured for insertion with the container of Figure 4, showing the contact
surface of the lid;
[0033] Figure 6, in a front view, illustrates the lid of Figure 1 fully
inserted
into the container of Figure 4;
[0034] Figure 7, in perspective view, illustrates the lid of Figure 1 fully
inserted into the container of Figure 4;
[0035] Figure 8A illustrates the steps of a method of manufacture for a
container lid;
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[0036] Figure 8B illustrates the steps of an alternate method of
manufacture for a container lid; and,
[0037] Figure 9, in front view, illustrates a possible configuration for a
sheet of material used to manufacture the lid wall according to the methods
illustrated in Figures 8A and 8B.
DESCRIPTION OF VARIOUS EMBODIMENTS
[0038] With reference to Figures 1-3, a lid according to an embodiment of
the present invention is described. The structure of the lid 10 includes a
base 20
and a wall 30. In an exemplary lid depicted in the figures, the lid base 20
and the
lid wall 30 are separate components. It will be appreciated, however, that the
base 20 and the wall 30 need not be separate components; rather, the lid 10
can
be formed as a single piece. Single piece container lids may, for example, be
manufactured using commonly known molding and casting manufacturing
techniques. In some instances, a lid 10 may include one or more of a wall
support element 38, a positioning element 37, and an outwardly biasing wall
element 39, each of which will be further discussed below.
[0039] With continuing reference to Figures 1-3, the base 20 may be in the
form of a substantially circular sheet of material having an attachment lip 28
formed by folding the periphery of the base sheet in a generally downward
direction with respect to the unfolded portion 29 of the base 20. It will be
appreciated that the base 20 is not required to be substantially circular in
shape.
A circular base 20 may be appropriate for lids 10 meant for use with some
common disposable beverage containers having substantially circular cross-
sections; however, other containers of differing shapes will require lids 10
whose
base 20 generally corresponds to the cross-sectional shape of the container 50
(Figure 4) close to the container's opening 55 (Figure 4). For example, a
container with a rectangular base and four walls extending from the container
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base to form a substantially frusto rectangular container can be paired with a
lid
that has a rectangular base and that is also substantially frusto rectangular
in
shape.
[0040] The attachment lip 28 of the base 20 can facilitate the attachment
of the base 20 to the wall 30 in the case of a lid 10 with separate base 20
and
wall 30 components. An attachment lip angle 0 may be formed between the
attachment lip 28 and the unfolded portion 29 of the base 20. The attachment
lip
angle 0 may be slightly less than ninety degrees in order to produce a
substantially frusto conical lid. The attachment lip angle 0 is typically
selected to
be supplementary to the lid wall angle a (described in further detail below)
formed between the lid base 20 and the lid wall 30 (i.e. the attachment lip
angle 0
and the wall angle a add up to one hundred and eighty degrees).
[0041] The lid base 20 may be provided with one or more apertures 26 of
various shapes and sizes. An aperture 26 may be a drinking aperture to allow a
user to drink from a container 50 (Figure 4) without having to remove the lid
10.
The lid base 20 may also include a pouring aperture to allow a user to pour
out
various amounts of the contents of the container 50 (Figure 4) without being
required to remove the lid 10. A pouring aperture may be desirable when the
contents of the container are to be distributed to multiple other containers
(e.g.
bowls or cups). Yet another type of aperture 26 is a venting aperture. A
venting
aperture may be useful when a container 50 (Figure 4) is intended to carry a
hot
beverage and it is desirable to substantially seal the container 50 (Figure 4)
to
prevent spillage and allow for the hot beverage to cool down simultaneously.
It
will be appreciated that the base 20 may have multiple apertures 26 all
serving
different functions, or alternatively may have a single aperture 26 serving
several
functions simultaneously.
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r
[0042] In some instances in which a lid 10 is made with separate lid base
20 and lid wall 30 components, a lid wall 30 and a lid base 20 may be attached
by folding one end of the lid wall 30 around an attachment lip 28 of the lid
base
20 and bonding the two together. Once the wall 30 and the base 20 are
attached,
the wall 30 may extend upward and away from the base 20 forming a lid wall
angle a between the lid wall 30 and the lid base 20. The lid wall angle a may
be
slightly greater than ninety degrees in order to produce a frusto conical lid
10.
The lid wall angle a in Figures 2 and 3 is slightly exaggerated for
demonstrative
purposes in order to more clearly illustrate the frusto conical shape of some
lids
10. Nevertheless, the lid wall angle a may be greater or smaller than
illustrated
depending on the application. The lid wall angle a is typically selected to be
similar to the container wall angle (Figure 6) formed between the container
base 60 (Figure 4) and the container wall 70 of the container 50 within which
the
lid 10 is designed to fit.
[0043] The construction of the lid 10 may have some similarities to that of
the container 50. For example, a lid 10 designed to mate with a container 50
in
the form of a disposable coffee cup may look somewhat similar to the coffee
cup
itself, only shorter. For example, the vertical height LH of the lid wall 30
is
typically configured to be substantially shorter than the vertical height CH
of the
corresponding container wall 70 (see Figure 6). In some instances, the
vertical
height LH of a lid wall 30 may be less than fifteen percent of the vertical
height
CH of the container wall 70 it is designed to fit within. The vertical height
LH of
the lid 10 may be greater or lesser than fifteen percent of the vertical
height CH
of the container 50.
(0044] There are also spatial advantages to designing a lid 10 with a frusto
conical, frusto rectangular, or other shape with a wall angle a slightly
greater
than ninety degrees. Lids 10 of this construction, much like the containers 50
within which they are designed to fit, are able to fit inside one another to
permit
an efficient use of spatial resources when the lids 10 are required to be
stored or
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transported from one location to another. Also, maximizing spatial efficiency
may
help to minimize packaging costs and packaging waste.
[0045] With reference to Figures 2 and 3, a wall support element 38 can
be positioned near a remote (and typically upper) end 16 of the lid wall 30. A
wall
support element 38 can provide structural integrity and some rigidity to a lid
wall
30 proximate the remote end 16 of lid wall 30. In some instances, the wall
support element 38 may be in the form of a helically rolled rim 40 formed by
tightly rolling the remote end 16 of the lid wall 30 toward the lid base 20.
The
structure of a wall support element 38 in the form of a helically rolled rim
is best
illustrated in the cross-sectional slice of a lid 10 shown in Figure 3.
Tightly rolling
the lid wall 30 results in an increased concentration of material within the
annular
rim formed by the roll. The result is a lid wall 30 with increased resistance
to
deformation in and around the area of the rolled rim 40.
[0046] In Figure 3, the rim is formed by rolling the remote end 16 of the lid
wall 30 outwardly toward the lid base 20. It will be appreciated that a rim
could
also be produced by an inward roll of the remote end 16 of the lid wall 30. It
will
also be appreciated by those skilled in the art that some structural integrity
and
rigidity may be provided to a lid 10 at its remote end 16 by means other than
providing a helically rolled rim to the lid wall 30. For example, a wall
support
element 38 may be formed by using a two-plied lid wall 30 whereby the two
plies
are offset slightly at the remote end 16 of the wall 30 and folding one ply
over the
other. Another example includes folding the remote end 16 of the lid wall 30
outwardly or inwardly onto itself several times to produce an accordion-like
annular element surrounding the remote end 16 of the lid wall 30, and fixing
the
resulting accordion-like rim in a compressed position. Other ways to provide a
wall support element 38 to the lid 10 may be by increasing the thickness of
the lid
wall 30 or by coating an annular portion of, or all of the lid wall 30 with a
high
strength substance. Those skilled in the art will appreciate that there are
further
ways to provide a wall support element 38 to a lid 10.
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[0047] Reference is now made jointly to Figures 2, 4, and 6. A lid wall 30
may also include a positioning element 37. A positioning element 37 can
function
to delimit the extent of the insertion of a lid 10 into a container 50. A
positioning
element 37 may also take on the form of an outwardly helically rolled rim 40.
In
the case in which a positioning element 37 in the form of a helically rolled
rim 40
is used and the lid 10 is fully inserted into a container 50, the positioning
element
37 may rest atop a wall 70 of a container 50. Once the positioning element 37
is
in contact with the top of a container wall 70, the lid 10 is physically
inhibited from
further insertion into the container 50. As depicted in Figure 4, a container
50
may incorporate a helically rolled rim 78 at the upper end of the container
wall
70. Consequently, in such instances, when a lid 10 is fully inserted into the
container 50, the lower surface 41 (Figure 2) of the lid's 10 positioning
element
37 can rest on the upper surface 79 of the container's 50 helically rolled rim
78,
as illustrated in Figure 6. It will be appreciated by those skilled in the art
that an
outwardly helically rolled rim 40 can act as both a positioning element 37 and
a
wall support element 38 simultaneously. Therefore, the illustration of a wall
support element 38 of Figures 1-3 is equally applicable to illustrate a
positioning
element 37. Those skilled in the art will also appreciate that the positioning
element 37 can be a separate structural feature of a lid 10, distinct from the
wall
support element 38. For example, a frusto conical lid 10 may include an
inwardly
helically rolled rim as a wall support element 38 at the remote end 16 of the
lid
10, and may also include a positioning element formed by an increased
thickness
of the lid wall 30 at a distance partway up the lid wall 30.
[0048] A further structural feature that may be integrated into a lid wall 30
is an outwardly biasing element 39. An outwardly biasing element 39 can help
provide the outward force required from a lid 10, when inserted into a
container
50, to achieve a friction fit therewith. An outwardly biasing element 39 can
be
located remote from the lid base 20 and may be in the form of an outwardly
helically rolled rim 40. In such instances, the outwardly helically rolled rim
40 can
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also function as a wall support element 38 and a positioning element 37
simultaneously. It will be appreciated by those skilled in the art, however,
that an
outwardly biasing element 39, a positioning element 37, and a wall support
element 38 can coexist as separate structural features of the lid 10,
independent
of one another. For example, a container lid 10 could, all at once,
incorporate a
wall support element 38 in the form of an inwardly helically rolled rim, a
positioning element 37 functionally established as a result of a substantially
frusto conical lid construction, and an outwardly biasing element 39 formed by
coating an annular portion of the lid wall 30 with a high strength substance.
[0049] In the case in which a lid 10 is designed to mate with a container
typically used to carry a beverage, it may be desirable to configure a portion
of
the lid 10 to be water resistant; for example, by applying a water resistant
coating
or liner to the appropriate portion. The application of water resistant
coatings is
known in the art; one example being the polyethylene or wax coating applied to
the inner surface of the wall, and the upper surface of the base, of
disposable
paper cups. A water resistant coating or liner can function to prevent a
material
from absorbing liquids and losing its structural integrity, and can facilitate
the
storing of liquids in the case of paper cups.
[0050] A similar technique to that used to coat paper cups could be used
to apply a water resistant liner to a container lid 10. However, in the case
of a lid
10, it is the bottom surface 24 of the base 20 that may require waterproofing,
not
the top surface 22 of the base 20, as may be the case with some containers 50.
As will be discussed in further detail below, a lid 10 and its mating
container 50
may form a friction fit when the lid 10 is inserted into the container 50,
thereby
forming a seal between a plurality of locations 75 on the inner surface 73 of
the
container wall 70 (Figure 4) and a corresponding plurality of locations 36 on
the
outer surface 34 of the lid wall 30 (Figure 5). The corresponding plurality of
locations 36 on the outer surface 34 of the lid 30 (which will be positioned
directly
against a container wall's inner surface 73) may make up the entire outer
surface
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34 of the lid wall 30, thereby arguably diminishing the need for the lid
wall's 30
outer surface 34 to be treated with a water resistant coating in order to
prevent
absorption of liquids and maintain structural integrity of the lid 10.
Nevertheless,
a water resistant coating of the lid wall's 30 outer surface 34 may be used to
complement the friction fit between the lid 10 and a container 50 to further
secure
the lid 10 within the container 50 where the substance used for the liner is
slightly
adhesive in nature.
[0051] As was previously mentioned, the water resistant liner can take the
form of a coating of wax or polyethylene. Those skilled in the art will
appreciate,
however, that any hydrophobic substance that has a melting point higher than
the temperature of the contents expected to be carried in the container may be
used to provide the water resistant liner. Alternatively, the liner may be in
the
form of a separate substrate mated to the paper-based material.
[0052] In some instances, a lid 10 may be made from a paper-based
material. Paper-based materials are not limited to paper as it is commonly
known. Rather a paper-based material can be any material obtained by pressing
together moist cellulose-based fibers obtained from wood pulp, cotton, rags,
grasses, sugar cane, straw, waste paper, and other available sources of
cellulose. In addition to common paper, some examples of paper-based
materials include, but are not limited to paperboard, carton board, and
containerboard. Paper-based disposable container lids may offer advantages
over presently available plastic-based container lids commonly used with
disposable beverage containers. One such potential advantage is the reduced
environmental impact of paper-based materials as compared to plastic-based
materials. The use of paper-based container lids as contemplated herein may
help to address the growing concern regarding the use of plastic-based
materials
in view of the low rate of decomposition of plastic.
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[0053] The paper-based material that may be used to make a lid 10 may
be recyclable. Further, in some instances, the lid 10 may be made from the
same
paper-based material used to make the container 50 with which it is meant to
be
paired, thereby making the container and lid assembly recyclable as a unit.
Some
of the potential advantages associated with providing a disposable container
lid
made from a paper-based material, generally, and from a material in the same
recycling category as its mating container, more specifically, will now be
discussed in more detail.
[0054] In view of a growing environmental concern surrounding the use of
10 plastic-based materials due to the low decomposition rate of plastic, a
paper-
based disposable container lid offers the potential advantage of an
alternative to
the use of plastic. In addition, a lid and container combination capable of
being
recycled as a single unit may offer advantages that benefit not only the
environment, but also users of the lid and container combination as well as
recycled material processing staff.
[0055] Some advantages that may benefit the environment, the user, and
the recycled material processing staff are interrelated. For example, consider
less environmentally conscious consumers who do not feel compelled to expend
the extra energy to separate the container lid from their disposable container
merely for the sake of recycling. These users typically dispose of their lid
and
container combinations as a unit either into a waste receptacle or into a
single
recycling receptacle. Depending on their choice of receptacles, the effect of
their
actions is either to increase waste where this can be avoided, or to increase
the
amount of work for the recycling plant staff who are required to ensure non-
contamination (i.e. non-mixing) of recycling mediums. Providing a lid 10 and
container 50 combination that falls within one recycling category may decrease
the amount of effort required of users to properly recycle lid 10 and
container 50
combinations (potential advantage benefiting the user), and therefore may
facilitate recycling (potential advantage benefiting the environment). It will
also be
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appreciated that the probability of mixing recyclable materials is decreased
as a
result of using a container 50 and lid 10 of the same recycling family.
[0056] Another advantage of making a container lid 50 out of a paper-
based material is that such materials are typically suitable for printing
upon.
Consequently, common printing methods may be used to print various indicia 23
on the top surface 22 of the lid base 20 (Figure 1) for example, for
advertising
purposes. The endless printing possibilities may include corporate insignia
such
a company logos/trademarks, tradenames or slogans, quotes, cartoon
characters, photographs, written or pictorial instructions, and any other
visual cue
that may be desirable to have displayed or communicated to a user of the lid
10.
Additionally, and in the alternative, a lid 10 may be coloured according to
the
colours of a particular brand or the colours associated with a particular
holiday
season.
[0057] The contact resulting from the insertion of a lid 10 into a container
50 is now discussed in further detail with reference to Figures 4 and 5. The
container 50 depicted in Figure 4 is similar to some containers typically used
to
carry a hot beverage. The container 50 depicted is substantially frusto
conical
and has an outwardly helically rolled rim 78 as its upper most structural
feature.
[0058] A lid 10 may be inserted into an opening 55 of a container 50 in
order to substantially seal the container 50 making the lid and container
combination substantially leak and spill resistant. When the lid 10 is
inserted into
the container 50 via the container opening 55, a friction fit is effected
between the
lid 10 and the container 50. The friction fit is maintained as a result of
equal and
opposite friction fit forces exerted by a plurality of locations 75 of the
inner wall
surface 73 of the container 50 on a corresponding plurality of locations 36 of
an
outer wall surface 34 of the lid 10, and vice versa. The plurality of
locations 75 on
the inner wall surface 73 of the container 50 that experience the friction fit
force
make up the cross-hatched surface illustrated in Figure 4. Similarly, the
corresponding plurality of locations 36 on the outer wall surface 34 of the
lid 10
CA 02695042 2010-03-01
that experience the friction fit force make up the cross-hatched surface
illustrated
in Figure 5. For clarity, "plurality of locations" of the inner and outer wall
surface
of the container and lid, respectively, will be referenced when describing the
friction fit in terms of forces. Whereas lid and container "contact surfaces"
will be
referenced when describing the friction fit in terms of pressures.
[0059] When a lid 10 is inserted into a container 50 with a suitable amount
of force, the inward and outward pressures acting at the convergence of a
container contact surface 75 and a lid contact surface 36 create a friction
fit
thereby causing a snug fit between the lid 10 and the container 50. In other
words, when a lid 10 is inserted into a container 50, the lid 10 will not move
within
the container 50 absent a significant force applied to the lid 10 to either
push the
lid 10 farther into the container 50 or to pull the lid 10 out of the
container 50. A
seal is therefore effectively achieved between the lid 10 and the container
50.
[0060] Once the lid 10 is snugly inserted into the container 50 opening 55,
the lid 10 and container 50 define an internal storage area, shown generally
as
77 (Figure 6), in which food, beverage and other material may be stored.
[0061] In order to achieve the friction fit necessary for a lid 10 to
substantially seal a container 50, a radial cross section of the lid 10 should
substantially correspond to a radial cross section of the container 50 near
the
corresponding plurality of container inner wall locations 75 and lid outer
wall
locations 36. The size and shape of the lid 10 relative to the container 50
are
selected in most instances to provide a snug fit of the lid 10 within the
container
50. If this were not the case, a complete seal would not be established. In
some
instances, the lid wall 30 (Figure 1) and the container wall 70 can be
substantially
frusto conical around the container contact surface 75 and the lid contact
surface
36. It will be appreciated by those skilled in the art that a lid 10 and a
container
50 are not required to be frusto conical proximate the plurality of
corresponding
container inner wall locations 75 and lid outer wall locations 36. Desirable
results
may be achieved using appropriately selected shapes of lid 10 and container
50,
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provided the outer periphery of the lid contact surface 36 substantially
matches
(and is preferably slightly greater in size to ensure a snug fit) the inner
periphery
at the container contact surface 75.
[0062] One potential advantage of a lid 10 according to the various
embodiments described herein, generally, and for use with a disposable
beverage container, more specifically, is that the lids 10 may be more
ergonomic
than many of the lids that are currently used in the market. The lid 10
according
to the various embodiments described herein may be considered an "inverted"
lid
in that most of the lid 10, when removably secured to a container 50, is
internal to
the container 50, whereas current lids on the market are typically external to
the
container to which they are secured. The construction of an "inverted" lid 10
and
the nature of its fit within a container 50 can provide more comfort to the
user
when drinking by affording room to the upper lip and nose when the container
50
(and lid 10) is tipped toward a user's mouth for drinking.
[0063] With reference to the logical flow diagram of Figure 8A, a method of
manufacture (referred to generally as 100A) for a lid comprising separate base
and wall 30 components is now discussed. A lid base 20 may be provided at
Block 110A. The lid base 20 may be provided with one or more indicia 23
printed
on the top surface 22 thereof. Also, the bottom surface 24 of the lid base 20
may
20 be treated with a water resistant coating or liner. It will be appreciated
that the
optional steps of printing indicia 23 on a top surface 22 of the lid base 20
and
applying a water resistant coating or liner to a bottom surface 24 of the lid
base
20 can be performed before or after the assembly of the components of the lid
10. However, to streamline the manufacturing process, it may be desirable for
the printing and coating steps to be performed prior to the assembly of the
components of the lid 10.
17
CA 02695042 2010-03-01
[0064] At Block 120A of the method 100, a substantially arcuate sheet of
material to be used as a lid wall 30 is provided. Reference is made briefly to
Figure 9, which shows a sheet of material 80 in a flattened position. The
sheet of
material 80 may have two laterally opposed side edges 83 connected by an
arced top edge 85 and an arced bottom edge 87, giving sheet of material 80 an
arcuate periphery while in a flattened position. It will be appreciated that
multiple
sheets of material may be combined to form the sheet of material 80 that will
eventually be rolled or folded for use as the lid wall 30, and that arcuate
sheets of
material may not be appropriate for the formation of all lid walls 30. The use
of
multiple sheets of material to produce the sheet to eventually be folded for
use as
a container wall 70 is disclosed in U.S. Patent No. 2,252,360. It will further
be
appreciated that the method of manufacture for a lid according to the various
embodiments described in the foregoing discussion can be similar in some
respect to common methods of manufacture for disposable paper cups, thereby
potentially allowing for substantially the same machinery that is used to
manufacture some containers 50 to be used, with some modification, to
manufacture lids 10.
[0065] As with the bottom surface 24 of the lid base 20, a sheet of material
80 may be provided wherein one or both of its surfaces may be pre-treated with
a
water resistant coating or liner. Alternatively, a subsequent water resistant
treatment step may be performed.
[0066] At Block 130A, the substantially arcuate sheet of material 80 is
loosely rolled and the laterally opposed side edges 83 of the sheet 80 are
joined.
The side edges 83 may be joined using common bonding techniques such as
adhesive, chemical, mechanical and others known in the art. A lid wall 30 with
a
bottom opening and a top opening can be produced as a result of completion of
Block 130A. In some instances (particularly where the container opening 55
that
a lid 10 may be designed to fit snuggly within is substantially frusto conical
in
18
CA 02695042 2010-03-01
shape), the lid wall 30 produced at step 130A of the method 100A may have a
substantially frusto conical shape.
[0067] At Block 140A of the method 100A, a lid 10 may be formed by
affixing the lid base 20 to the lid wall 30 at a bottom portion (or end) of
the lid wall
30. The bottom end of the lid wall 30 may coincide with the bottom opening of
the
lid wall 30. The attachment may entail folding a bottom end of the lid wall 30
inward and around an attachment lip 28 formed around a contour of the lid base
20 (see Figure 3). A skilled person in the art will appreciate that the lid
wall 30
may be secured to the attachment lip 28 of the lid base 20 using other common
known attachment methods including but not limited to adhesives, mechanical
bonds, and chemical bonds. It will further be appreciated that the lid wall 30
may
be secured to the lid base 20 without the use of an attachment lip 28. For
example, a lid base 20 with a sufficient thickness base be directly adhered or
bonded to the inside surface 32 of the lid wall 30. Another way to attach the
lid
wall 30 to the lid base 20 may be to fold a contour of the lid wall 30 near
its
bottom opening radially inward and bond it to the bottom surface 24 of the lid
base 20.
[0068] With reference to the logical flow diagram of Figure 8B, an alternate
method of manufacture (referred to generally as 1008) for a lid 10 is now
discussed. In some instances a lid base 20 may be provided at Block 11OB. At
Block 150B, one or more indicia 23 may be printed on the top surface 22 of the
lid base 20. Indicia 23 may include corporate insignia such as company
logos/trademarks, tradenames or slogans, quotes, cartoon characters,
photographs, written or pictorial instructions, and any other visual cue that
may
be desirable to have displayed or communicated to a user of the lid.
19
CA 02695042 2010-03-01
[0069] At Block 160B, the bottom surface 24 of the lid base 20 may be
treated with a water resistant liner or coating. The water resistant liner or
coating
may be in the form of a wax or polyethylene, or may be an alternate
hydrophobic
substance that has a melting point higher than the temperature of the contents
expected to be carried in the container.
[0070] At Block 170B, a lid wall 30 may be formed to extend substantially
vertically from the lid base 20. Forming the lid wall 30 may require attaching
a
separate lid wall 30 component to the lid base 20, or in the alternative, the
lid
base 20 and the lid wall 30 may be a single piece, and forming the lid wall 30
may require a manipulation of a portion of the single piece in order to
appropriately orient the lid wall 30 portion of the single piece with respect
to the
lid base 20 portion of the single piece.
[0071] At Block 180B, the outside surface of the lid wall may be treated
with a water resistant liner or coating. Once again, the water resistant liner
or
coating may be in the form of a wax or polyethylene, or may be an alternate
hydrophobic substance that has a melting point higher than the temperature of
the contents expected to be carried in the container.
[0072] A wall support element 38 may be formed remote from the lid base
at Block 190B. The wall support element 38 may be formed by rolling the
20 remote end of the lid wall 30 outwardly or inwardly towards the lid base
20, or by
other means described herein (at paragraph 43).
[0073] The steps of a method in accordance with any of the embodiments
described herein may not be required to be performed in any particular order,
whether or not such steps are described in the claims or otherwise in numbered
or lettered paragraphs.
CA 02695042 2010-03-01
[0074] The invention has been described with regard to a number of
embodiments. However, it will be understood by persons skilled in the art that
other variants and modifications may be made without departing from the scope
of the invention as defined in the claims appended hereto.
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