Note: Descriptions are shown in the official language in which they were submitted.
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METHOD OF MANUFACTURING AN IMPROVED DISPOSABLE LID
FIELD
[01.1 The present invention relates to the art of lids manufactured from
aluminum such
that the lids are disposable, and more particularly, the present invention is
directed to a
method of manufacturing an improved disposable lid that helps alleviate
accidents by the
consumer and permits nesting of the lids.
BACKGROUND
[02] Disposable aluminum pans and lids are often referred to as foil pans/lids
widely
used by consumers to cook and keep food warm. The lids have been manufactured
by
well know methods. Typically a die is used to stamp a sheet of aluminum into a
lid. During
the stamping process upper and lower dies are pressed together with the sheet
of
aluminum feed between the dies. After pressing the lid is formed. The main
issues with
the existing lids (Prior Art Figures 1A ¨ 3) is that the dies are formed such
that only the
edges between the corners have a rolled lip. The corners are not rolled which
often leaves
a sharp edge from which consumers can and often cut themselves on the corner
edges.
In addition, the dies are formed such that the edge walls extend at a ninety
degree angle
from the top edge of the lid. As shown in Prior Art Figure 16, the prior art
lids cannot
stack and nest properly. This makes shipping a lot of lids together
problematic. A lot of
space in shipping cartons are wasted because stacked lids simply do not nest
properly and
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the nested lids take up a lot of space. These problems are addressed with the
manufacturing of improved lids.
SUMMARY
[03] In accordance with one embodiment of the present invention, there is
provided a
method of manufacturing an improved disposable aluminum lid.
[04] The improved disposable aluminum lid is formed from stamping aluminum.
The
improved disposable aluminum lid includes a top base that terminates about an
edge to
raised ridge around the periphery of the edge. The raised ridge extends into a
downwardly extending skirt. The skirt terminates into a rolled lip formed into
the sides
of the improved disposable aluminum lid. In addition, during the forming of
the improved
disposable aluminum lid the corners of the skirt are crimped and rolled into a
corner
rolled lip of aluminum. The corner rolled lip in the corners prevents the user
from cutting
themselves when handling. In addition, the improved disposable aluminum lid is
formed
with a slight tapering 13 between the raised ridge and the downwardly
extending skirt.
Preferably the tapering is defined at an angle between 3 and 10 degrees and
more
preferably at about 5 degrees. Therefore, when stacking or nesting the
improved
disposable aluminum lids, the lids nest easily and virtually perfectly on top
of each other.
As such, the improved disposable aluminum lid can be packaged and shipped
without
concern of damage to the lids.
[05] Accordingly, then, in one aspect, there is provided an improved
disposable
aluminum lid comprising: a lid stamped from aluminum, the lid being configured
to
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include: a top base terminating around a periphery at an edge; a raised ridge
extending
around the periphery of the edge; a skirt downwardly extending from the raised
ridge and
extending continuously around the top base to form a well there-between, the
skirt
having an internal surface facing the well and an external surface facing
directly opposite
of the internal surface and the well, and wherein the skirt has a lower edge
that directly
transitions into a rolled lip; an angle defined between the raised ridge and
the
downwardly extending skirt to be between 3 degrees and 10 degrees; and wherein
the
rolled lip is formed continuously into the skirt and uninterruptedly around
the well
covering all sides and all corners defined by the lid, and wherein the
external surface of
the skirt has a length defined along a longitudinal plane and has a lateral
width and
wherein the lower edge of the skirt terminates at an edge on the longitudinal
plane and
where a point of the rolled lip is coincident with the lower edge of the skirt
on the
longitudinal plane.
[06] In accordance with another aspect, there is provided a method of
manufacturing an
improved disposable aluminum lid comprising the steps of: placing a
sheet of
aluminum between a pair of die shoes; stamping the pair of die shoes together
to form,
from the sheet of an aluminum, an improved disposable aluminum lid; and
configuring
the pair of die shoes, such that the improved disposable aluminum lid is
configured to
include: a top base terminating around a periphery at an edge; a raised ridge
extending
around the periphery of the edge; a skirt downwardly extending from the raised
ridge and
extending continuously around the top base to form a well there-between, the
skirt
having an internal surface facing the well and an external surface facing
directly opposite
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of the internal surface and the well, and wherein the skirt has a lower edge
that directly
transitions into a rolled lip; an angle defined between the raised ridge and
the
downwardly extending skirt to be between 3 degrees and 10 degrees; and wherein
the
rolled lip is formed continuously into the skirt and uninterruptedly around
the well
covering all sides and all corners defined by the lid, and wherein the
external surface of
the skirt has a length defined along a longitudinal plane and has a lateral
width and
wherein the lower edge of the skirt terminates at an edge on the longitudinal
plane and
where a point of the rolled lip is coincident with the lower edge of the skirt
on the
longitudinal plane.
[07] In accordance with a further aspect, there is provided a method of
manufacturing
improved disposable aluminum lids to provide nesting of the lids, the method
comprising
the steps of: placing a sheet of aluminum between a pair of die shoes;
stamping the pair
of die shoes together to form, from the sheet of an aluminum, an improved
disposable
aluminum lid; and configuring the pair of die shoes, such that the improved
disposable
aluminum lid is configured to include: a top base terminating around a
periphery at an
edge; a raised ridge extending around the periphery of the edge; a skirt
downwardly
extending from the raised ridge and extending continuously around the top base
to form
a well there-between, the skirt having an internal surface facing the well and
an external
surface facing directly opposite of the internal surface and the well, and
wherein the skirt
has a lower edge that directly, transitions into a rolled lip; an angle
defined between the
raised ridge and the downwardly extending skirt to be between 3 degrees and 10
degrees;
and wherein the rolled lip is formed continuously into the skirt and
uninterruptedly
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around the well covering all sides and all corners defined by the lid, and
wherein the
external surface of the skirt has a length defined along a longitudinal plane
and has a
lateral width and wherein the lower edge of the skirt terminates at an edge on
the
longitudinal plane and where a point of the rolled lip is coincident with the
lower edge of
the skirt on the longitudinal plane; and nesting a plurality of the improved
disposable
aluminum lids on top of each other wherein the angle defined between the
raised ridge
and the downwardly extending skirt allows the plurality of nested improved
disposable
aluminum lids to rest over one another such that the entire rolled lip of one
of the
improved disposable aluminum lids rests adjacently over the entire rolled lip
of an
adjacent improved disposable aluminum lid positioned underneath the one of the
improved disposable aluminum lids.
[08] Numerous other advantages and features of the invention will become
readily
apparent from the following detailed description of the invention and the
embodiments
thereof, from the claims, and from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[09] A fuller understanding of the foregoing may be had by reference to the
accompanying drawings, wherein:
[10] FIG. 1A is a prior art top plan view of a disposable aluminum lid;
[1.1.1 FIG. 1B is a sectional view of a corner from the disposable aluminum
lid of FIG. 1A;
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[12] FIG. 1C is a side sectional view of the corner of the disposable aluminum
lid of
FIG. 1A;
[13] FIG. 2 is a prior art side view of the disposable aluminum lid from FIG.
1;
[14] FIG. 3 is an enlarged prior art cross sectional view of the disposable
aluminum lid
from FIG. 1;
[15] FIG. 4A is a top plan view of an improved disposable aluminum lid;
[16] FIG. 48 is a sectional view of a corner from the improved disposable
aluminum lid
of FIG. 4A;
[17] FIG. 4C is a side sectional view of the corner of the improved disposable
aluminum
lid of FIG. 4A;
[18] FIG. 5 is a side view of the improved disposable aluminum lid of FIG. 4A;
[19] FIG. 6 is an enlarged cross sectional view of the improved disposable
aluminum lid
of FIG. 4A;
[20] FIG. 7 is a representation of a stamp machine used in manufacturing the
improved
disposable aluminum lid of FIG. 4A;
[21] FIG. 8 is a representation of the press stamping showing the upper and
lower dies;
[22] FIG. 9 is a representation of an aluminum roll used in manufacturing
improved
disposable aluminum lids;
[23] FIG. 10 is a representation of the aluminum feed between the upper and
lower dies
of the stamping machine;
[24] FIG. 11 is a representation of the improved disposable aluminum lid being
stamped;
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[25] FIG. 12 is a representation of the improved disposable aluminum lid after
being
stamped in the stamp machine;
[26] FIG. 13 is a representation of the output of the stamp machine showing
the
improved disposable aluminum lid existing the stamp machine;
[27] FIG. 14 is a representation of the improved disposable aluminum lid being
aligned
for stacking;
[28] FIG. 15 is an illustration of improved disposable aluminum lids stacked
and nested
for packaging before shipping;
[29] FIG. 16 is an illustration of prior art lids stacked and nested for
packaging before
shipping; and
[30] FIG. 17 is a side by side comparison of prior art lids and improved
disposable
aluminum lids nested for packaging before sipping.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[31] While the invention is susceptible to embodiments in many different
forms, there
are shown in the drawings and will be described herein, in detail, the
preferred
embodiments of the present invention. It should be understood, however, that
the
present disclosure is to be considered an exemplification of the principles of
the invention
and is not intended to limit the spirit or scope of the invention and/or
claims of the
embodiments illustrated.
[32] With reference to Prior Art FIGS. 1A through 3, there is provided a
disposable lid
formed from stamping aluminum, generally referenced a lid 50. The prior art
lid 50
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includes a top base 52 that terminates about an edge 54 to raised ridge 56
around the
periphery of the edge 54. The raised ridge 56 extends into a downwardly
extending skirt
58. The skirt terminates into a rolled lip 60 formed only into the sides (62 /
64) of the lid.
The corners 66 of the skirt 58 are crimped when formed but always terminate
into a free
edge 68 of aluminum. The crimped free edge 68 in the corners 66 always remain
sharp.
The sharpness of the corners are capable of cutting a user's fingers when
handling. While
the cuts may not be particularly deep when they occur, it still is a nuisance
to the
consumer to be cut. Moreover, complaints are continuous submitted to
the
manufacturers of disposable aluminum lids when a consumer is cut. As such
there has
always been a desire and need to improve the lids to avoid this issue. In
addition to this
major concern, disposable aluminum lids have always been manufactured in a
very
simplistic manner in that the angle defined between the raised ridge 56 and
the
downwardly extending skirt 58 are formed at a virtual right angle (FIG. 3)
such that the
skirt 58 extends downwardly in a substantially zero degree taper. As further
explained
below, from a material standpoint, when forming the lids, keeping the skirt at
a zero
degree taper will use less material, which will reduce expenses especially
when the
manufacturer is producing thousands of lids an hour. The major problem with
this type
of disposable aluminum lids is that the lids cannot stack or nest on top of
each other
without damaging the shape of the lid. Prior Art FIG 16 illustrates disposable
aluminum
lids manufactured in accordance with the prior art stacked after forming and
prior to
shipment. The prior art disposable aluminum lids utilize a lot of space and
are after
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slightly bent and thus slightly damaged when packaged and shipped. As such
there is a
desire and need to improve the lids to avoid this issue.
[33] To solve the above concerns and problems an improved disposable aluminum
lid
was developed, referenced generally a numeral 100 (FIGS 4A through 6). The
improved
disposable aluminum lid 100 is formed from stamping aluminum. The improved
disposable aluminum lid 100 includes a top base 102 that terminates about an
edge 104
to raised ridge 106 around the periphery of the edge 104. The raised ridge 106
extends
into a downwardly extending skirt 108. The skirt terminates into a rolled lip
110 formed
into the sides (112 / 114) of the improved disposable aluminum lid 100. In
addition,
during the forming of the improved disposable aluminum lid 100 the corners 116
of the
skirt 108 are crimped and rolled into a corner rolled lip 111 of aluminum. The
corner
rolled lip 110 in the corners 116 prevents the user from cutting themselves
when
handling. In addition, the improved disposable aluminum lid 100 is formed with
a slight
tapering 13 (FIG. 6) between the raised ridge 106 and the downwardly extending
skirt 108.
Preferably the tapering 13 is defined at an angle between 3 and 10 degrees and
more
preferably at about 5 degrees. Therefore, when stacking or nesting the
improved
disposable aluminum lids, the lids nest easily and virtually perfectly on top
of each other
(FIG. 15). As such, the improved disposable aluminum lid 100 can be packaged
and
shipped without concern of damage to the lids.
[34] From a material standpoint, when forming the improved disposable aluminum
lid
100, a taper between the raised ridge 106 and the downwardly extending skirt
108 uses
more material then if the skirt extends at a zero degree taper if the overall
length
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extension of the skirt is the same. In comparing Prior Art FIG. 3 against FIG.
6 the overall
length of the skirt is maintained at .6250 inches. In the Prior Art disposable
aluminum lid
50 the length of material for the skirt length is the same at .6250 inches.
However, in the
improved disposable aluminum lid 100, the length of material would be
calculated as
X/sin(90 ) = 0.6250/sin(85 ), where X represents the length of the sidewall
with the 5
degree taper. Once solved the length of the sidewall is 0.627 inches. Over the
entire
perimeter of the lid and multiplied by thousands of lids, there is a definite
increase in
costs to manufacture the improved disposable aluminum lid. However, the
benefits
outlined herein outweigh the increased costs.
[35] Referring now also to FIGS 7 through 14 there is shown a method of
manufacturing
the improved disposable aluminum lids 100. In the method of manufacturing, a
die
machine press 200 includes an upper shoe 205 and a lower shoe 210. A sheet of
aluminum 220, fed from a roll 215, is positioned between the shoes, which are
then
hydrically pressed together forming the lid. The upper and lower shoes 205 /
210 are
configured to stamp the improved disposable aluminum lids 100 with a slight
tapering (3
between the raised ridge 106 and the downwardly extending skirt 108, and
further
configured to stamp the improved disposable aluminum lids 100 with a rolled
lip 110
formed around the entire periphery of the downwardly extending skirt 108,
which
includes both the sides (112 / 114) and the corners 116 of the improved
disposable
aluminum lid 100.
[36] Excess aluminum can then be recycled for future use. The improved
disposable
aluminum lids 100 when formed are then moved away from the stamping section
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packaging. As shown in FIGS 15 ¨ 17, the improved disposable aluminum lids 100
when
stacked show an improved nesting ability not shown in the prior art aluminum
lids.
[37] As provided by various embodiments of the present invention there is
provided an
improved disposable aluminum lid. The improved disposable aluminum lid is
defined to
include a lid stamped from aluminum and configured to have (a) a top base
terminating
around a periphery at an edge; (b) raised ridge extending around the periphery
of the
edge; (c) a skirt downwardly extending from the raised ridge; and (d) a rolled
lip formed
into the terminating edge of the skirt, wherein the rolled lip is formed into
the entire
terminating edge of the skirt including sides and corners defined by the lid.
In other
__ aspects, the improved disposable aluminum lid is further configured to
include an angle
defined between the raised ridge and the downwardly extending skirt to be
between 3
and 10 degrees, and is preferred to be at 5 degrees.
[38] In other embodiments, there is provided a method of manufacturing
improved
disposable aluminum lids to provide nesting of the lids. The method comprising
the steps
__ of (a) placing a sheet of aluminum between a pair of die shoes; (b)
stamping the pair of
die shoes together to form, from the sheet of an aluminum, an improved
disposable
aluminum lid; and (c) configuring the pair of die shoes, such that the
improved disposable
aluminum lid is configured to include: (i) a top base terminating around a
periphery at an
edge; (ii) a raised ridge extending around the periphery of the edge; (iii) a
skirt
__ downwardly extending from the raised ridge; (iv) a rolled lip formed into
the terminating
edge of the skirt, wherein the rolled lip is formed into the entire
terminating edge of the
skirt including sides and corners defined by the lid; and (v)an angle defined
between the
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raised ridge and the downwardly extending skirt to be between 3 and 10
degrees. The
method further comprising the step of nesting a plurality of the improved
disposable
aluminum lids on top of each other wherein the angle defined between the
raised ridge
and the downwardly extending skirt allows the plurality of nested improved
disposable
aluminum lids to rest over one another such that the entire rolled lip of one
of the
improved disposable aluminum lids rests adjacently over the entire rolled lip
of an
adjacent improved disposable aluminum lid positioned underneath thereto.
[39] From the foregoing and as mentioned above, it will be observed that
numerous
variations and modifications may be effected without departing from the spirit
and scope
of the novel concept of the invention. It is to be understood that no
limitation with respect
to the specific methods and apparatus illustrated herein is intended or should
be inferred.
It is, of course, intended to cover by the appended claims all such
modifications as fall
within the scope of the claims.
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