Note: Descriptions are shown in the official language in which they were submitted.
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CARRIER FOR SECURE CUP DELIVERY
Field of the Invention
[0001] The present application relates to a carrier for secure cup delivery.
More particularly, the carrier provides a barrier to unauthorized access and
it
is seated to prevent the carrier from being opened and the cups from being
accessed without visible signs of being opened.
Background of the Invention
[00021 It is not uncommon these days for consumers to order food and
beverage deliveries from restaurants, coffee shops and other shops that sell
beverages or other products in cups. Traditionally, deliveries were made by
employees of the business selling the goods. If it was a pizza restaurant the
restaurant had staff that delivered the pizzas, but in the past, the drinks
ordered to accompany pizza were in sealed containers like cans or bottles,
which made delivery easier. Now, customers using businesses such as Tiber
EatsTM and Skip the DishesTM can order food and drinks online and have it
delivered to them from restaurants like McDonalds TM, Tim HortonsTM,
SubwayTM, and Wendy'STM. When a customer orders drinks from this
broader range of options, many of these restaurants serve the drinks in
disposable cups and it can be hard to deliver drinks in the types of cups that
they normally use, without them tipping over and spilling some of the
contents. Even if the cups are kept separate from food items that are part of
the order it can be difficult for the delivery person to handle a plurality of
cups that might be associated with an order. Some restaurants provide trays
that have recesses for holding up to four cups, but tall cups can still tip
over
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even if held in such trays, US Design Patent No. D655,207, entitled
"Beverage Cup Carrier", offered an improved tray that adds a handle in the
middle. US Patent No. 3,661,417 entitled "Carrier and Foldable Blank for
Making Same" discloses a paperboard blank that is foldable into a cup
carrier that has hole cut-outs shaped to receive cups that are to be carried.
The cups have a circular bottom but at the upper rim of the cup, it has a
larger cross section that is still rounded but no longer circular. Near the
top,
the cups have a more three-sided cross section rather than a circular one.
The rim of the cup is rolled to have a bead that is an enlarged portion that
will not pass through the hole cut-out. In this way the cup carrier uses the
bead of the cup to support it. A disadvantage of this approach is that the
hole cut-out is sized for a specific size and style of cup. It would be
advantageous for a cup carrier to be adaptable to different cup styles so that
the same design can be used more universally by restaurants and delivery
services, for example, so that the same cup carrier could be used by
Wendy'sTM, Tim HortonsTM and SubwayTM. When folded, the tops of the
cups are covered, but the carrier is not sealed, and it would be easy for
anyone to release the tabs from the assembled carrier to fold back the top
panels without any obvious indication that this has been done. Accordingly,
the drinks are not well secured against tampering or access by the delivery
person, who might be thirsty. Security against access and tampering is not a
concern when the cup carrier is used by the customer to transport take-out
orders that are picked up by the customer, but now that home delivery is
gaining popularity, preventing unauthorized access to drinks being delivered
in a cup carrier is becoming a concern.
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unauthorized access to drinks being delivered in a cup carrier is becoming a
concern.
[0003] Food delivery services often hire casual workers who operate more
like independent contractors than employees. There have been instances
reported where it appears that a beverage might have been partly consumed,
but it can be hard for the consumer to prove it and even harder to prove who
did it. With carbonated beverages, after some of the gas dissipates the cup
may not be full even if filled to the top at the restaurant, so this makes it
hard
to prove that a drink has been tampered with. With a third-party delivery
service that uses contractors or casual employees, the person making the
delivery could be a different person each time, so there might not be the
same level of trust, as when the delivery person is employed by the
restaurant and the same person every time. If the delivery person is making
more than one delivery and the beverages are carried in a single thermally
insulated container, if not held securely the cups are more likely to tip and
spill, contaminating other items in the container. The delivery person might
also use the container to carry other things that could contaminate the
beverages. Perhaps the consumer is a bad tipper or someone that the
delivery person knows and holds a grudge with. If the delivery person is an
independent contractor associated with a third-party delivery service, the
delivery person could have a grudge with a restaurant and might purposely
tamper with food that is ordered from that restaurant. In other
circumstances, the delivery person could be upset with the third-party
delivery service. If the cups are not secure against unauthorized access,
some consumers might wonder if the delivery person drank from a cup that
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is not full or spat into the cup or otherwise contaminated it. Perhaps the
delivery person is just unreliable, irresponsible and/or dishonest. These are
just examples, and there could be many other reasons why a delivery person
might intentionally taint or otherwise tamper with the contents in a container
that is being delivered. There could be other circumstances, where a
delivery person is making a series of deliveries and leaves some food and
drink packages unattended while making a delivery, and unsealed food
packages could be vulnerable to tampering while out of the sight of the
delivery person Accordingly, a secure cup carrier would provide more
peace of mind to customers.
[0004] US Patent No. 7,243,785, entitled "Carrier and Method" discloses
a two-piece carrier that can carry both food and beverages. One piece has
hole cut-outs or compartments and is folded to form a cup carrier. A second
piece is folded into a food tray that slides down the handle of the cup
carrier
so that the one handle can be used to carry both beverages and food. While
one paperboard sheet blank could be used for both pieces, this method still
requires folding two pieces and if one piece is used more often than the other
pieces, then the restaurant could be left with too many food trays or too
many cup carriers. An ideal use for such a carrier might be bringing a
family-sized food and drink order from a concession stand to seats in a
stadium. However, like the other known prior art, this design does not
secure the food and drinks against tampering by a delivery person. With this
design, the food and drinks are all accessible to the delivery person and the
drinks are not secure against tampering, unauthorized access and
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contamination from contact with other food or unsanitary exposure while
being delivered.
[0005] Korean Patent No. 101366687 B1 discloses another cup carrier that
can be made from a paperboard blank sheet. Like with other carriers, when
the carrier is used by the customer for a take-out order, security is not an
issue of concern, and it is beneficial for carrier designs to be fast and easy
to
assemble. The disclosed carrier is foldable to form a handle that folds up
from two top sheets that cover the tops of the cups. Tabs on the side fold up
to hook onto the handle, to hold the two halves of the handle together.
However, like with other known cup carriers, this design has not been
designed with any features that provide security against unauthorized access,
tampering, and contamination, whether deliberate or accidental. While this
and other cup carriers might facilitate the transportation of a plurality of
cups, it would be easy for a delivery person to access the cups by simply
unhooking the side tabs, and the customer would not be able to see any
visible signs of unauthorized access.
[0006] Accordingly, now that food and beverage delivery is gaining
popularity and is being made available from more restaurants through home
delivery business models provided by companies like Skip the DishesTM
and Uber EatsTM there is a need to improve current designs for cup carriers
so that they provide more security against unauthorized access, and that
allow businesses to continue to use the types of cups that they currently use.
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Summary of the Invention
[0007] In relation to the disclosed carrier for secure cup delivery, an ideal
material for the blank sheet is a bending grade of paperboard or small flute
corrugated board. These materials can be cut and creased and delivered flat
to the customer where it is assembled as needed. Paperboard and corrugated
board are desirable material choices because relative to other materials, such
as plastic, with the same strength, stiffness, and resistance to tearing,
paperboard and corrugated board can be less expensive, bio-degradable, and
easily recycled. However, cup carriers that will be re-used can be made
from a more durable material such as a rigid plastic sheet that can be formed
with bendable lines for easy assembly. Even if the unit cost for each plastic
carrier is more, the overall life-cycle cost can be lower, if one considers
every cost from "cradle to grave" meaning everything from the making of
the materials, to the manufacture of the blank sheet, and on to the cost of
recycling (including estimates of how many cup carriers are recycled). If a
cup carrier made from a rigid plastic sheet is re-used many times and then
recycled, then the environmental impact can be lower compared to one-use
cup carriers made from paperboard or corrugated board. Accordingly,
while preferred embodiments are described as being made from paperboard
or corrugated board, different materials can be substituted so long as they
have the requisite physical properties for carrying cups without breaking or
dropping the cups, and without deflecting so much that the contents of the
cups spill.
[0008] For making an improved carrier for secure cup delivery, a single
blank sheet is provided that is foldable into an improved carrier that
provides
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an enclosed and sealed space for secure delivery of a cup. The single blank
sheet comprises a plurality of sections divided by pre-creased lines to
facilitate folding for assembly of the improved carrier. One of the plurality
of sections is a receiving section that has a hole cut-out sized smaller than
a
base of a cup for receiving the cup. The base of the cup has a smaller lateral
cross-sectional area than that of the top of the cup and the hole cut-out is
sized to have a lateral open cross-sectional area smaller than that of the top
of the cup, so that the cup will not slip through the opening. The other
sections are foldable around the top of the cup to form the enclosed space.
At least one seal is positioned on the single blank sheet where it can seal to
another section of the sheet blank to hold the carrier in its assembled shape
after being folded. The seal prevents the improved carrier from being
opened or attempted access into the enclosed space without causing visible
damage to the seal or to the improved carrier.
[00091 In exemplary embodiments the seal is an adhesive strip that is
bonded to the blank sheet and covered with a removeable non-stick cover.
After the blank sheet is folded with the top of the cup inside the enclosed
space, the removeable non-stick cover is removed from the adhesive strip
and the seal is stuck onto another section of the blank sheet to seal the
enclosed space. The seal can be one of a plurality of seals to ensure that the
enclosed space and the top of the cup inside the enclosed space is kept
secure from unauthorized access and tampering without there being visible
evidence of access.
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[0010] The hole cut-out provided in the single blank sheet can further
comprise tabs extending into the hole cut-out. The tabs can be defined by
pre-creased lines so that the tabs are bendable to adjust the size of the
opening through the hole cut-out to accommodate different cup sizes that
have different lateral cross-sectional areas. The tabs can also have
perforations to allow the tabs to be divided into smaller tabs to fit better
= against the curved side-surface of the cup.
[0011] In preferred embodiments of the single blank sheet, the hole cut-
out is one of a plurality of hole cut-outs, whereby the carrier facilitates
the
secure delivery of a plurality of cups. Previously known cup carriers such as
those discussed in the background of this disclosure, were not designed to
= provide an enclosed and sealed space for secure delivery of cups and also
accommodate a predetermined range of cup sizes and allow cups of different
sizes to be carried at the same time. When there is a plurality of hole cut-
outs, the subject carrier can carry cups of different sizes at the same time,
within a predetermined range of cup sizes, when the enclosed space has a
height above the hole cut-outs that accommodates the different cup sizes.
The height of the enclosed space is preferably less than the height of the
shortest cup in the predetermined range of cup sizes, so that all of the cups
in
the range can be carried by the carrier and held securely without being
pushed fully into the enclosed space. In some embodiments, for a broad
range of conventional cup sizes, the height of the enclosed space is at least
5
centimeters, and more preferably 10 centimeters. Different heights can be
made for businesses that use cup sizes smaller or larger than the normal
conventional cup sizes. In other embodiments, if a cup is shorter than the
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height of the enclosed space, before the enclosed space is sealed, a spacer
can be inserted between the top of the cup and the underside of the top
section of the carrier. When the carrier is used to carry cups of different
sizes at the same time, and the carrier with the held cups is set down, the
height of the enclosed space allows the bottoms of the cups to conform to
shape of the surface to a certain extend as permitted by the height of the
enclosed space. For example, if the surface is flat, the taller cups can to
rise
within the enclosed space so that some of the shorter cups can also rest on
the flat surface, making the carrier and cups more stable and less prone to
tip
over. Depending upon the cup sizes and the shape of the surface the cups
are being set down upon, not all of the cups may be able to rest on the
surface, but if at least two cups of different sizes can rest their bottoms on
the surface this is more stable than a situation where only cups of one size
can rest on the surface. That is, in preferred embodiments, if the carrier is
carrying large and medium sized cups, then the height of the enclosed space
allows the large cups to lift within the enclosed space so that the bottoms of
both the large and medium cups can rest on a flat surface if the carrier is
set
down. Likewise, in preferred embodiments, if the carrier is carrying small
and medium sized cups then the height of the enclosed space allows the
medium cups to rise within the enclosed space so that the bottoms of both
the small and medium cups can rest on the flat surface. Depending upon the
shape of the cups and the differences in height, in some cases the height of
the enclosed space can be made to allow cups of all sizes in the
predetermined range to rest with their cup bottoms on a flat surface if the
carrier is set down.
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[0012] In another embodiment, the pre-creased lines comprise more than
one set of creases so that the carrier can be assembled in different
configurations with different heights for the enclosed space as a function of
the set of creases that are selected when the carrier is assembled. Since
there
can be many combinations of orders, with some orders being for cups of the
same size, and other orders for cups of different sizes, it is desirable for
the
same single blank sheet to be adaptable for a better fit in each case. The
preferred height of the enclosed space for an order of all small cups can be
different from the preferred height of the enclosed space for an order of all
large cups. A sheet blank designed for carrying small cups might not fit for
carrying large cups. By providing a plurality of pre-crease lines, the sheet
blank is made more universal, meaning that the same sheet blank can be
assembled with different configurations to accommodate different cup sizes
within a predetermined range.
[0013] The enclosed space need not be any particular shape as long as
there is a physical barrier to prevent unauthorized access to the tops of the
cups. For example, in one embodiment when the carrier is assembled the
enclosed and sealed space defines a shape in the form of a rectangular prism
and the plurality of sections further comprise two opposing side walls, two
opposing end walls and a top surface parallel and spaced apart from the
receiving section by the height of the side walls and end walls. Additional
seals can be positioned on sections of the single blank sheet for sealing
along
the vertical corners of the rectangular prism. The enclosed space can be in
other shapes such as a trapezoidal prism or a triangular prism with a flat
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bottom for the receiving section with the plurality of sections comprising
two sloped side walls and two triangle-shaped opposing end walls.
[0014] The improved carrier for secure delivery of a cup comprises a
single blank sheet foldable to define an enclosed and sealed space
surrounding the top of the cup. The enclosed and sealed space has an
interior height that enables cups from a predetermined range of cup sizes to
be carried, with the interior height being less than the height of the
shortest
cup in the predetermined range of cup sizes. The enclosed and sealed space
has a bottom section with hole cut-outs shaped to receive the bottoms of the
cups in the predetermined range of cup-sizes, and with an open area that is
smaller than the lateral cross-sectional area of the top of the smallest cup
in
the predetermined range of cup sizes. The carrier further comprises a seal
that joins one section of the sheet blank to another section to prevent the
enclosed and sealed space from being opened or otherwise accessed without
visible damage to the seal or the carrier. In some embodiments, the seal is
put onto the blank sheet when the blank sheet is manufactured. In other
embodiments, the seal is a tamper proof label that is applied to the carrier
after it has been assembled. A tamper proof label that is applied to the
carrier after assembly can be used for carriers made from re-usable sheets,
for example, made from plastic or plastic-coated paperboard. There are
many types of tamper proof labels that could be used for this embodiment,
such as, for example, a label that will deform or tear if anyone tries to
remove it.
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[0015] Also disclosed is a method of assembling a carrier from a sheet
blank for secure delivery of a cup. The method comprises the following
steps: (a) filling a cup with product; (b) placing a cover on the cup; (c)
positioning the bottom of the cup inside a hole cut-out in the sheet blank;
(d)
lifting the sheet blank until the sides of the hole cut-out contact the cup
and
the cup is supported by thereby; (e) folding the sheet blank along pre-
creased lines to assemble the carrier to form an enclosed space around the
top of the cup, the assembled carrier providing a physical barrier to prevent
access to the top of the cup; (f) applying seals to prevent the carrier from
being opened to access the enclosed space without visibly damaging the seal
or the carrier.
[0016] In preferred embodiments of the method, the cup is one of a
plurality of cups and the carrier has a plurality of hole cut-outs for
carrying
the plurality of cups and the enclosed space is sized to enclose the tops of
each one of the plurality of cups. All of the cups to be carried by the
carrier
are filled with product and covered, before each being placed inside one of
the hole cut-outs in a receiving section of the sheet blank. When the method
is applied to a cup carrier for carrying a plurality of cups, then the step of
lifting the sheet blank is completed when the sides of all of the cups have
come into contact with the respective contact features of the hole cut-outs,
so
that each of the cups is supported by being in a position where the cup will
not slip further down into the hole-cut out. If the plurality of cups includes
cups of different sizes, this can result in some cups being lifted into the
air
before other cups reach a supported position in their respective hole cut-
outs.
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[0017] The covers for the cups can be the normal covers that a restaurant
or other business uses to cover its cups. For example, many restaurants use
plastic lids that are pressed onto a lip of the cup. Other businesses use a
plastic film that is heat sealed onto the lip of a plastic cup.
[0018] The method of assembly can further comprise adapting the height
of the enclosed space to better fit the size of the cups being delivered. This
can be facilitated by a sheet blank that has more than one set of pre-creased
lines with each set of pre-creased lines associated with a different height
for
the enclosed area.
[0019] The method can also allow adaptation of the carrier to carry more
cup sizes, beyond those within a predetermined range of cup sizes. For
example, the method can further comprise adapting the carrier to carry a cup
with a diameter smaller than the hole cut-out by installing an adapter ring
that has an opening smaller than the hole cut-out. To keep the adapter ring
centered in the hole cut-out the adapter ring can have pre-creased lines that
define sections that can be folded to extend into the hole cut-out, the method
further comprising folding along the pre-creased lines so that the folded
sections extend into the hole cut-out. In another embodiment, the method
can further comprise adapting the carrier to carry cups that are shorter than
the height of the cup carrier by installing a spacer between the top of the
cup
and the underside of the top surface of the enclosed space, the spacer
preventing the cup from being lifted out of the hole cut-out. The spacer can
be folded from a pre-creased spacer sheet blank.
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Brief Description of the Drawin2s
[0035] Figure 1 illustrates a first embodiment of a paperboard blank sheet
for an improved carrier for secure cup delivery.
[0036] Figures 1A, 1B, 1C and 1D illustrate four different designs for the
hole cut-out for receiving cups.
[0037] Figure 2 illustrates an end view of the first embodiment of the
improved carrier for secure cup delivery from Figure 1, after being
assembled.
[0038] Figure 3 illustrates a second embodiment of a paperboard blank
sheet for an improved carrier for secure cup delivery.
[0039] Figure 4 illustrate a side view of the second embodiment of the
improved carrier for secure cup delivery from Figure 3, after being
assembled.
[0040] Figure 5 illustrates a third embodiment of a paperboard blank
sheet for an improved carrier for secure cup delivery.
[0041] Figure 6 illustrates an end view of the third embodiment of the
improved carrier for secure cup delivery from Figure 5, after being
assembled.
[0042] Figure 7 shows a side view of a re-usable cup carrier for secure
cup delivery.
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[0043] Figure 8 is a side cross section view of an assembled cup carrier
that shows an adapter ring for holding smaller cups.
[0044] Figure 9 is a top view of the adapter ring of Figure 8.
[0045] Figure 10 is a side cross section view of an assembled cup carrier
with a spacer for holding different cup sizes.
[0046] Figure 11 is a perspective view of spacers of the type shown in
Figure 10.
[0047] Figure 12 illustrates a fourth embodiment of a paperboard blank
sheet for an improved carrier for secure cup delivery.
Detailed Description of Illustrative Embodiment(s)
[0048] The following detailed description represents embodiments that are
intended to provide an overview or framework for understanding the nature
and character of the claims. The accompanying drawings are included to
provide further understanding of the claims and constitute part of the
specification. Accordingly, the detailed descriptions and drawings are non-
limiting to the scope of what is claimed and are intended to illustrate and
explain the principles and operations of these embodiments, as claimed. For
example, the different configurations for the cup carrier that are illustrated
in
the Figures are non-limiting examples, and are intended to show by way of
example, that variations can be made to the cup carrier while retaining all
the key elements of the improvements. For example, variations can be made
to the carriers for carrying different numbers of cups, for accommodating
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cups of different sizes at the same time, and for folding into different
shapes,
and for being made more re-usable. The drawings are not to scale, and some
features are exaggerated or enlarged to better illustrate what it is and how
it
works.
[0049] With reference to the diagram in Figure 1, paperboard blank sheet
100 is cut and creased along the dotted lines where it will be folded to
assemble the carrier. Paperboard blank sheet 100 can be delivered to
restaurants, food trucks and coffee shops as flat unfolded sheets so that they
are easy to store without taking up too much space. When a cup carrier is
needed it is easy for restaurant workers to assemble it, for example, by
placing the cups already filled into hole cut-outs 110 and then folding first
along crease lines 120, 122, 124 and 126 to create the side walls. Then
handle 150 is folded back along crease lines 136 and 138 so that handle 150
will be oriented up from the top of the assembled cup carrier after sheet 100
is folded along crease lines 128 and 130. At this point in the assembly steps,
the non-stick cover to adhesive strip 140 can be removed. When paperboard
blank sheet 100 is lifted, the sides of the cups come into contact with tabs
106. Tabs 106 enable hole cut-out 110 to accommodate cups with different
profiles, since tabs 106 will bend to conform to the diameter of the cup.
Cups of different sizes can have different profiles. For example, a small
cup can be shorter than a large cup, but it can also have a smaller diameter.
Most cups have a tapered profile with the diameter of the cup being smaller
at the bottom. Tabs 106 can optionally have perforations 107 that can be
torn to allow a better fit with the cups. To continue the assembly, sheet 100
is folded along crease lines 128 and 130 to cover the tops of the cups, when
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sheet edge 102 meets edge 104, adhesive strip 140 holds sheet edges 102
and 104 together. With sheet 100 having already been folded along crease
lines 136 and 138, the two sides of handle 150 are then joined. In the
illustrated example the side of handle 150 on the left side of the drawing has
its center punched out to make a hand hold. On the right side of the
drawing, the other side of handle 150 has its center cut on three sides but
not
punched out, so that the center is used as a tab with adhesive strip 140 to
help to seal the top of the cups inside the assembled cup carrier. Assembly
of the cup carrier is completed by peeling off the non-stick covers to
adhesive strips 142 and 144, folding the sheet along crease lines 132 and 134
until adhesive strips 142 and 144 are stuck onto the top surface of the cup
carrier. Once the cup carrier is assembled, the cups are securely held with
the carrier providing a tamper proof barrier that physically prevents access
to
the tops of the cups, now sealed within an enclosed space. The adhesive is
chosen to be a type that forms a bond that cannot be broken without tearing
the carrier or otherwise damaging the carrier such that it would be visually
obvious to the customer that the carrier had been opened. Paperboard blank
sheet 100 has three-hole cut-outs 110 because this is a number that allows
the assembled carrier to be balanced when carrying one cup in just the
middle spot, two cups in the two outer spots, or three cups by occupying all
three spots. Another feature of the disclosed cup carrier is that paperboard
blank sheet 100 is simple and easy to manufacture from one sheet and
without any tabs or other paperboard pieces that need to be glued onto the
single sheet. To be manufactured, paperboard blank sheet 100 is cut,
creased, and the adhesive strips with non-stick covers are applied. Hole cut-
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outs 110 can all be pre-cut, or they can be partially cut or perforated but
still
attached. If only partially cut or perforated, if a three-cup carrier is used
to
deliver two cups, then two of the hole cut-outs can be easily punched out,
and the third hole cut-out left unpunched so that it remains closed to block
access to the enclosed space. In an alternative approach, if a carrier with a
plurality of hole cut-outs is assembled with a lesser number of cups than the
number of pre-cut hole cut-outs, the assembler can optionally install cover
panels to block access to the enclosed space through the hole cut-out. Such
cover panels can be provided with a strong adhesive strip or adhesive tape
can be applied by the assembler.
[0050] The simplicity of the design for the improved carrier reduces the
manufacturing costs compared to carriers that are made from more than one
sheet, or that have sections glued on, or sections of itself pre-glued to
itself.
In assembled form, the externally facing surfaces are on one side of the sheet
so that it is easy to print advertising or brands onto just one side of the
sheet.
The printed side can also be made with a surface treatment that will tear or
be otherwise visibly damaged if anyone attempts to open the cup carrier on
its way to being delivered to the customer.
[0051] In this embodiment, the length of the end wall sections has a length
Li between crease lines 132 and 134 and the respective outer edges that is
equal to, or less than length L2. If Ll is equal to L2, then when the cup
carrier is assembled, areas 113 and 115 will cover the gap between sheet
edges 102 and 104 up to handle 150, and adhesive 140 seals the gap under
the handle. Dimension H corresponds to the height of the enclosed space
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when the improved carrier is assembled. Dimension H is the same
dimension between crease line 120, 122, 124 and 126 and respective crease
lines 128, 132, 130 and 134.
[0052] In Figure 1, each hole cut-out 110 is shown with four tabs 106 that
have square corners and that extend into the opening so that different sized
cups can be gripped by the same hole cut-out. By way of example, Figures
1A, 1B, 1C and 1D show other hole cut out designs that have differently
shaped tabs or perforations, demonstrating that the shape of hole cut-outs
110 and tabs 106 is not limited to the illustrated shapes. In Figure 1A tabs
106A have a trapezoidal shape with the tabs getting wider as they extend
into the opening. In Figure 1B there is no spacing between tabs 106B.
Perforations 107B can be torn to bend tabs 106B to make the opening larger.
In other embodiments, cuts can be substituted for some or all of perforations
107B to make it easier to bend tabs 106B. Figure 1C shows another
embodiment with tabs 106C being trapezoidal-shaped with the tab tapering
to a smaller width as it extends towards the center of the opening. Figure 1D
shows yet another embodiment, similar to that of Figure 1C except that the
free edge of tab 106D that faces the center of the opening is curved so that
more of this edge will be in contact the side of a cup. Cups typically have a
circular horizontal cross section shape, so the hole cut-outs are generally
circular, but hole cut-outs with different shapes can be used to hold cups
that
are shaped differently.
[0053] Paperboard blank sheet 100 can be made from any material that
has the requisite strength to carry the filled cups and enough stiffness that
it
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will not be deflected and lose its shape when used to transport the filled
cups. By way of example, corrugated cardboard has been found to be a
suitable material and it is inexpensive enough to be used as a disposable
carrier that can be recycled, and that is bio-degradable if not recycled.
However, other materials with the requisite strength and stiffness can be
substituted. A carrier that is inexpensive and disposable is a convenience for
carriers that are used for deliveries because it can be inconvenient for the
customer to go back to the restaurant to return the carrier since this negates
some of the advantage of getting the drinks delivered. That said, people are
becoming more environmentally conscious and responsible. By way of
example, a money-based deposit system could be implemented to give
incentives to the customers to return carriers, and with such a system in
place, the carriers can be made from materials that would be durable enough
to be re-used. Some restaurants may see a re-usable cup carrier used by
customers upon payment of a deposit as an incentive for customers to come
to the restaurant or to re-order delivery.
[0054] Figure 2 depicts an end view of an improved carrier for secure cup
delivery that has been assembled from the paperboard blank sheet of Figure
1. Corners 220, 224, 228 and 230 correspond to respective crease lines 120,
124, 128 and 130 shown in Figure 1. Handle 150 is shown in it folded up
position where it can be used as a hand hold for carrying cup carrier 200
with one hand. Cup carrier 200 can carry between one and three cups in a
row, using the hole cut-outs shown in Figure 1. From the end view, only
one cup 280 can be seen. The outline of cup 280 is shown in dashed lines
where the top of the cup is held within enclosed space 290 inside cup carrier
CA 3023375 2018-11-07
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200. Hole cut-out 110 is sized so that cup 280 will not fall through. For a
smaller cup, tabs 106 can remain horizontal, but for larger cups tabs 106 can
bend down, as shown in Figure 2, to hold cup 280 securely. In preferred
embodiments, cup carrier 200 is dimensioned with height H that gives room
for it to accommodate cups of different sizes, but with height H being less
than the height of the smallest cup size used by the restaurant or other user;
this way the top of cup carrier 200 prevents the cup from being pushed out
from hole cut-out 110, for example, if cup carrier 200 and the carried cups
are set down on a table or counter. That is, cup carrier height I I prevents
even the smallest cups from leaving hole cut-put 110 after cup carrier 200 is
assembled, and so long as cup carrier 200 is kept upright, cup 280 will not
tip over. This is achieved by cup carrier height H being less than cup height
h for the shortest cup that cup carrier 200 is designed to carry. Figure 2
shows that once assembled, cup carrier 200 completely covers the tops of the
cups, which are held in enclosed space 290 so that access to whatever is
being delivered in the cups is physically blocked, preventing anyone from
accessing the tops of the cups and the contents of the cups without breaking
open cup carrier 200. The cup carriers described herein can be used for the
secure delivery of beverages, but the contents of the cups could be anything
that is packaged by a business and delivered to a customer in a cup or cup-
shaped container, and could include, for example, food or legal marijuana.
[0055] Figure 3 illustrates paperboard blank sheet 300 that has hole cut-
outs 310 for carrying six cups. In this embodiment the creases indicated by
the dashed lines are functionally the same as those in the embodiment of
Figure 1, and the assembly of the cup carrier made from blank sheet 300 will
CA 3023375 2018-11-07
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not be described except to describe features and functions that are different
in this embodiment. Blank sheet 300 shows that cup carriers can be made in
different sizes and configurations to hold a different number of cups. Hole
cut-outs 310 are still generally circular in shape and cut with tabs 106, but
in
this embodiment, there are six-hole cut-outs in a two-by-three configuration,
meaning that there are two rows of hole cut-outs with each row having three-
hole cut-outs. In this embodiment, side walls 301A and 301B have
respective extensions 303A and 303B, and crease lines 305A and 305B.
Before end walls 309A and 309B are folded along respective crease lines
322 and 326, extensions 303A and 303B are folded in along respective
crease lines 305A and 305B so that these extensions extend along the inside
of end walls 309 when the cup carrier is assembled. These extensions 303A
and 303B at each corner of the cup carrier serve as a further physical barrier
for blocking access to the interior space defined by the assembled cup
carrier. Optional adhesive strips 346 can be used in some embodiments to
hold extensions 303A and 303B in position against end walls 309A and
309B and thereby further strengthen the structure of the assembled cup
carrier by reinforcing the corners. By positioning adhesive strips 346 on
sections 309A and 309B, then all of the adhesive strips are positioned on one
side of blank sheet 300, facilitating manufacturing. In some embodiments,
the reinforced corners can enable the use of a lighter weight paperboard. In
other embodiments, it can be more desirable to keep assembly of the cup
carrier simpler and faster, and adhesive strips for the corner extensions are
not necessary because cups held in the corner positions will prevent
extensions 303A and 303B from being pushed away.
CA 3023375 2018-11-07
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[0056] Figure 3 also shows another optional feature with regard to the
handle design. In this embodiment area 311 is not punched out but is instead
cut on three sides as depicted by solid lines 312, and creased, but not cut,
along dashed crease line 308. Area 311 is lifted up and away from the plane
defined by paperboard sheet 300 so that when left handle 350 is brought next
to right handle 351, area 311 can pass through the opening of right handle
351 and be folded up flat against the outward facing surface of right handle
351, providing a smooth gripping surface for the person holding the handle,
instead of the two edges of the punched out handles 350 and 351. At the
same time, area 307, which has adhesive strip 340, is inserted through the
opening of left handle 350 and attached to the top of cup carrier to hold
sheet
edge 302 next to sheet edge 304. In this embodiment, left handle 350 and
right handle 351 are also made longer so that adhesive strip 340 seals most
of the gap between sheet edges 302 and 304, which allows length L3 to be
shorter compared to length L1 in the embodiment of Figure 1.
[0057] Figure 4 depicts a side view of an improved carrier 400 for secure
cup delivery that has been assembled from paperboard blank sheet 300 of
Figure 3. In the side view of Figure 4, the outline of three cups 480, 482 and
484 are shown. To demonstrate how cup carrier 400 facilitates carrying
cups of different sizes, each of the three cups is a different size. Cup 482
is
the largest, and cup 480 is the smallest. Cup carrier 400 has height H which
facilitates carrying a range of cup sizes by allowing space for the tops of
different cup sizes to be held in the sealed and enclosed space 490, while the
bottoms of all of the cups can be at the same level, which makes it easier to
set the carrier down on a level counter or table with all of the cups
supported
CA 3023375 2018-11-07
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and without any of the cups tipping over. Cup carrier height H is less than
cup height h1, which is the height of cup 480, which is the smallest and
shortest cup. Since cup 480 has the smallest diameter, in this example tabs
406 can remain almost horizontal (as shown) or could be bent slightly
upwards as they are for medium size cup 484, as an extra precaution to
prevent the cup from falling through hole cut-out 310. Instead of a circular
hole without any tabs, tabs 406 enable a snug fit with a range of cup sizes,
by changing how much tabs 406 are bent. The hole cut out is also sized to
accommodate cup 482 which is the largest cup size, by making the hole cut-
out large enough to receive cup 482 to a point where the top of this cup is
within enclosed space 490 by ensuring that the diameter of the hole cut-out
is at least as large as the horizontal cross-sectional diameter of cup 482 a
distance H from the top of cup 482. In the embodiment of Figure 4, when
cup 482 is inserted into the hole cut out, tabs 406 in the hole cut-out have
been bent completely out of the way so that this is the maximum cup
diameter that can be accommodated.
[0058] Figures 5 and 6 illustrate a third embodiment that demonstrates
that the improved cup carrier can be made in different shapes, that can give
the cup carrier a more distinctive look, which can become associated with
secure drink delivery and/or a certain restaurant, while still providing all
of
the functionality of the other embodiment to discourage unauthorized access
to the cup contents for improved security during delivery. As shown in
Figure 5, paperboard blank sheet 500 has three-hole cut-outs 510 for
carrying three cups, like the embodiment of Figure 1. Like in the other
figures, the creases indicated by the dashed lines function in the same
CA 3023375 2018-11-07
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manner to facilitate assembly. However, in this embodiment, when
assembled, as shown in the end view of Figure 6, the sides are sloped and
not vertical. End walls 509 can be vertical, but when sides 501 are folded
they meet in the middle to form sloped roof panels as shown in Figure 6.
This embodiment also shows that hole cut-outs 510 can be round and
without any tabs. Some restaurants use fewer cup sizes or use cups that have
a similar diameter so that tabs are not necessary. With the sloped roof
design, end walls 509 cannot fold over to cover the gap between edges 502
and 504 of side sections 501 like they do in the embodiment of Figure 1.
Figure 5 also shows that a cup carrier can be made with extra assembly tabs
and adhesive strips to better seal the gap between sheet edges 502 and 504 of
the assembled cup carrier. Tabs 507A, 507B and 507C, each having a
respective adhesive strip 540A, 540B and 540C. Alternatively, handle 550
can be made longer, similar to the handle shown in Figure 3 so that adhesive
strip 54013 for tab 507B underneath the handle seals most of the top edge
where the sloped sides meet. An advantage of the triangle shape is that end
walls 509 can comprise tabs with adhesive strips 546A, 546B, 547A and
547B that can be used to seal the edges where end walls 509 meet sloped
sides 501, so that extensions like those described in relation to the
embodiment of Figure 3 are not needed to seal and reinforce the corners.
[0059] With reference to Figure 7, a re-usable cup carrier is shown. Re-
usable cup carrier 700 can be assembled in essentially the same way as the
other embodiments, and parts that are the same are indicated with the same
reference numbers as in other embodiments. A difference is that a different
sealing mechanism is needed, and a re-usable cup carrier is preferably made
CA 3023375 2018-11-07
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from a more durable material such as plastic, which will not weaken after
repeated use, and that will not degrade if subjected to drink or food spills
or
wetness from rain or exposure to other substances encountered by normal
use. Releasable and re-usable closures 740 such as hook and loop fasteners
(also known by the tradename VelcroTm), or a re-adherable strip of glue, for
example, a low-tack pressure sensitive adhesive. However, such releasable
and re-usable closures only help with assembly and to hold cup carrier 700
in its assembled configuration. These releasable closures will not provide
the security feature that is provided by the adhesive strips shown in the
other
embodiments. To provide the security of a sealed cup carrier for a re-usable
cup carrier, after it is assembled, seals 795 are applied to prevent the re-
leasable closures from being opened while the cups are being delivered.
Seals 795 can use one or more mechanisms that will give a visible indication
if the cup carrier has been opened when being delivered. For example, seal
795 can be an adhesive label made from a material that will tear or that will
stretch and deform if anyone tries to remove it. Seal 795 can be made with
cuts or perforations that will tear the seal into pieces as a visual
indication if
anyone tries to remove it. Other tamper proof seal technologies can be used
to prevent a re-usable cup carrier from being opened in the course of
delivery, so that like the other embodiments, once the cup carrier is
assembled it defines a secure and enclosed space 790 for the tops of the cups
that establishes a physical barrier during delivery that gives visible
evidence
of tampering if access is attempted.
[0060] For reducing manufacturing costs, it is best for the manufacturer
of the paperboard sheet blanks to be able to sell the same sheet blanks to
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many different customers. However, there may be some customers that have
cup sizes that are smaller than the smallest cup size used by most customers.
It might be impractical to size the hole cut-outs for the smallest cup size
when this is not the ideal size for most customers. Figure 8 is a cross-
section end view of a cup carrier that shows an embodiment that solves this
problem by installing adapter ring 860. For a customer that has a cup size
that is smaller than most cups and small cup 880 is at risk of falling through
the hole cut-out, adapter ring 860 provides the support needed for securely
holding small cup 880 in the assembled cup carrier.
[0061] Figure 9A is a top view of one embodiment of an adapter ring that
can be inserted like adapter ring 860 in Figure 8. In this embodiment
adapter ring 960 is simply a ring that has a hole cut-out that is smaller than
the hole cut-out in the cup carrier and that has an outside diameter that is
much larger than the hole cut-out of the cup carrier. When deployed,
adapter ring 960 rests on top of the hole cut-out in the cup carrier and
prevents small cup 880 from falling through the hole cut-out in the cup
carrier. Adapter ring 960 can have its own tabs 906 so that it can hold a
range of small cup sizes by controlling how much tabs 906 are bent.
Different tab designs can be used, as shown, by way of example, in Figures
1A through 1D. Tabs 906, when bent down can also extend into hole cut-
out 110, preventing adapter ring 960 from sliding too far off center from
alignment with hole cut-out 110.
[0062] Figure 9B is a top view of another embodiment of an adapter ring
that can be inserted like adapter ring 860 in Figure 8. In this embodiment
CA 3023375 2018-11-07
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sections 963 define a diameter larger than the hole cut-out of the cup
carrier.
Sections 964 can be pre-cut as shown by cut lines 966 or can instead have
perforated sides. In either embodiment, section 964 can be bent downwards
along crease lines 965, which are collectively positioned at a diameter that
is
less than the diameter of hole cut-out 110 of the cup carrier. In this way,
section 964 extends into the cup carrier's hole cut-out and keeps adapter ring
960 centered in hole cut-out 110. Section 964 is shown extending through
the cup carrier's hole cut-out in Figure 8.
[0063] Another way to make a paperboard sheet blank more universal is
to provide spacers as shown in the side cross section view of Figure 10. In
Figure 10, it can be desirable to prevent small cup 1080 from being lifting
out of hole cut-out, for example, if the cup carrier is set down on a table.
While cup carriers are preferably designed so that for most customers the
cup height is greater than side height H of the cup carrier, there can be some
customers who use irregular-sized cups. Spacer 1070 allows universal cup
carrier 1000 to be adapted for shorter than normal cup sizes. As shown in
Figure 10, spacer 1070 can be combined with adapter ring 860. Figure 11 is
a perspective view of spacer 1070 that has been folded fo'r insertion into a
cup carrier. If just one of the cups is an extra small cup, then spacer 1070
can be torn along perforated line 1072 so that it is sized to be deployed as a
spacer for just one cup. Perforated line 1072 divide spacer 1070 into three
segments. Perforated lines 1072 are located to divide the spacer sheet into
segments, with a single segment being sized to provide spacing for one cup,
so that for a six-cup carrier that is being used to deliver six extra small
cups,
two spacers can be used for a cup carrier that has two rows of three cups to
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cover all six cups. For illustrative purposes, by way of example, spacer
1070 is configured with three segments to complement the three-cup and
six-cup carriers shown in the other embodiments, but other configurations
can be used, for example, single segments, two segment spacers and four
segment spacers. When a food source purchases cup carriers and spacers
from a supplier, both the blank sheets and the spacers are on hand when the
cup carrier is being assembled. Spacer 1070 is made to fit the interior
dimensions of the assembled cup carrier and this makes the spacer segments
adaptable for other uses, such as covering the hole cut-outs so that there are
no openings into the enclosed space when a cup carrier is used to deliver
fewer cups than the number of hole cut-outs in the carrier. That is, the
segments of spacer 1070 can be sized to fit the bottom of the cup carrier with
the side folds aligned with side walls so that it difficult to lift out of the
way,
and to facilitate being fixed in place with some adhesive tape. While the
design of spacer 1070 provides this multi-functionality, the concept of the
spacer is not limited to just this embodiment. Other spacers known in the
food packaging field can be adapted to function in the same way as spacer
1070 for preventing a small cup from being lifted from the hole cut-out. For
example, in the packaging for pizzas, some restaurants use a plastic spacer
that has three or four plastic legs and a small round "tabletop" that can be
inserted inside a pizza box near the middle of the pizza. This spacer
prevents the pizza box lid from deflecting and coming into contact with
pizza toppings. A similar spacer could be provided with the cup carrier.
This spacer could be inverted so that the legs are oriented upward, and the
flat round tabletop can be attached to the top of the cup with some adhesive
CA 3023375 2018-11-07
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so that it does not slide out of position. Other types of spacers could be
substituted for spacer 1070 and combined with the cup carrier to function in
substantially the same way to achieve substantially the same result.
[0064] Figure 12 illustrates a fourth embodiment of a blank sheet for a
cup carrier that has additional features for adapting to different cup sizes.
The features that are the same as those in other embodiments function in
substantially the same way and will not be described again in relation to this
embodiment. Only the features that are different from the other
embodiments are described in detail. As shown by the dashed lines that
indicate parallel crease lines in the end and side walls of cup carrier
paperboard blank sheet 1200, during assembly, the person who is
assembling the cup carrier can select the crease lines that define a height
for
the cup carrier that best fits the cups. This allows more adaptability of a
universal paperboard blank sheet that can accommodate more cup sizes, and
for restaurant, coffee shops and other establishments that offer a range of
cup sizes, the cup sizes for each customer order are often different. Sheet
blank 1200 can be folded to best suit the cup sizes of each particular order.
There are also parallel crease lines for other elements affected by the wall
height, such as the carrier top panels. If the lowest crease lines 1228 and
1230 are chosen, then the innermost crease lines 1236 and 1238 are folded
so that top sheet edges 1202 and 1204 are both oriented upwards. This will
make the handles 1250 and 1251 slightly taller. Cut lines 1255 and 1256
allow the top surfaces underneath the handle to overlap and remain flat so
that adhesive strip 340 still seals the two top pieces of cup carrier 1200
together. Area 311 can still be folded along crease line 308 to be wrapped
CA 3023375 2018-11-07
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under the grip area of handle pieces 1250 and 1251 to provide a more
comfortable hand hold, with cut lines 1255 allowing the more inward section
below handle piece 1250 to be folded in the opposite direction so that it can
form a seal against adhesive strip 340. To complete the assembly when the
lowest carrier side height is selected, to accommodate the longer dimension
of the end flaps that folds over on top of the top surface, and the side parts
of
the handles which are now oriented upwards, sheet blank 1200 is cut with
notches 1218 and 1219.
[0065] While the illustrated embodiments show particular examples,
various modifications and alterations can be made to the examples within the
scope of the claims and aspects of the different examples can be combined in
different ways to achieve further examples. Accordingly, the scope of the
claims is to be understood from the entirety of the present disclosure in view
of, but not limited to the embodiments illustrated and described herein. That
is, with the benefit of the teachings of this disclosure it will be apparent
that
various modifications and variations can be made without departing from the
spirit or scope of the claims.
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