Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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CUP CARRIER WITH THUMB HOLDS AND CURVED STABILIZING WALLS
BACKGROUND ART
Carrying trays for holding and carrying beverage cups are well-known and in
widespread
use throughout fast-food restaurants, stadiums, convenience stores, coffee
shops and the like.
Typically, the trays are comprised of a main body portion provided with a
number of
cup-holding sockets. The number of cup-holding sockets can vary, depending on
the style of the
carrying tray. Multiple designs exist, each having different shapes and sizes
of cup-holding
sockets with varying degrees of accommodation for beverage cups of different
shapes and sizes.
Over time the demands on these carrying trays have evolved. The fast-food
restaurant
industry has continued to increase maximum portion sizes, including the use of
very large
beverage cups for soft drinks. One type of beverage cup that has become very
popular has a
"step-walled" structure where the bottom portion of the cup is smaller in
diameter than the top
portion of the cup. These "step-walled" cups are designed to hold large
amounts of beverage
while maintaining a base small enough to fit into reasonably-sized cup
holders, such as those
present in automobiles or the arm rests of stadium seats. These cups often
have the capacity to
hold 32 or even 44 ounces of liquid. However, the design of these cups only
provides a carrying
tray with a smaller gripping area towards the bottom, while raising the height
of the liquid load,
thus making the cups top-heavy.
More recently, many restaurants have introduced and heavily marketed high-end
coffee
and tea beverages, which are typically served in smaller, narrower cups than
traditional soda
cups. These cups may only hold 10 or even less ounces of liquid.
These combined trends have created broader requirements on the range of cup
sizes that
must be accommodated by a cup carrier.
Manufacturers have attempted to accommodate the variety of large and small cup
sizes
in several ways. The most common method is to provide flexible members on the
sides of the
cup-holding sockets that deflect as the cup is inserted, in an attempt to
accommodate a range of
cup base sizes. Examples of this approach are shown in U.S. Pat. Nos.
4,208,006 to Bixler,
4,218,008 to Vellieux, and 6,398,056 to Letourneau. The problem with this
approach has been
that, due to the downward sloping walls, the contact point with the cup is
related to the cup base
size. Therefore, cups with smaller base sizes are gripped at very low points,
thereby decreasing
stability.
Another method to address this problem has been to increase the depth of the
cup-
holding sockets. A deeper socket can provide some tipping resistance to a
small cup, even if it
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is not gripped securely. Some examples of this approach are illustrated in
U.S. Pat. Nos.
D438,100 to Cekota, and 7,225,927 to Sweeney. A drawback of this approach is
that it
necessitates a taller structure, preventing the design from being run on
certain molding
machines. Another disadvantage of this approach is that it increases the
developed area of a
carrier. If the product is made to the same weight as a shorter carrier, the
weight per unit area
must be lower, thereby weakening the structure. If the weight is increased to
compensate, this
results in higher material, energy, and transportation costs and increases the
amount of natural
resources used. Another disadvantage of this approach results because bundles
of these carriers
create taller stacks, thereby requiring an increase in storage space and
shipping costs.
A third method has been to replace the angled sidewall members with short,
flexible
tabs. Some examples of this approach are illustrated in U.S. Pat. Nos.
6,679,380 to Brown and
6,651,836 to Hofheins. The longer the tabs, the wider a range of cup sizes can
be contacted by
them. However, the longer the tabs, the weaker their gripping force becomes.
Also, the rigidity
of the socket structure is weakened due to the lack of material near the base
of the socket. Cup
tipping tendency may be greater if the bottoms of the cups are not captured by
the socket.
A fourth method has been to provide sockets of different sizes on the same cup
carrier, as
shown for example in U.S. Pat. Nos. D319579 to Vigue, 5,096,065 to Vigue, and
6,679,380 to
Brown. The problem with this approach is that the practicality of the cup
carrier is significantly
decreased. Such a cup carrier is restricted to a limited number of
combinations of large and
small cups. The cup carriers disclosed in these references have four cup
carrying sockets - two
of which can only carry large cups and two of which can only carry small cups.
U.S. Pat. No. 7,762,396 to Yang et al. describes a modification on the above
approaches,
including a stabilizing wall divided into two distinct slopes, an upper
portion and a lower
portion. The upper portion has a downward slope that is shallower than the
downward slope of
the lower portion. This configuration is an improvement over the above
configurations, but it
still limits the range of cup sizes that this carrier can accommodate
securely. Cups having bases
that do not fit into one of the two specified slopes, either the upper portion
or the lower portion,
may not receive the full advantages of this stabilizing wall configuration.
In addition to problems with cup fit discussed above, cup carriers also have
been called
upon to support heavier weights, due to the use of larger sized cups. The
heavier weights often
make it more difficult for persons carrying two or more cups in the cup
carrier to achieve a grip
on the carrier such that they can comfortably and securely carry the
additional load, particularly
with one hand. Often, the user attempts to grip the carrier on one side of the
carrier between the
cups. The user places their thumb between the cups on the top of the carrier
and wraps their
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hand or other fingers around the rim underneath the carrier. The carriers of
the prior art include
flat or convex areas for the thumb to bear against. In these embodiments, the
user's thumb has a
propensity to slip, particularly when only using one hand and when the
cantilevered weight is
too much over time or the weight of the load shifts suddenly. Further, cup
carriers that have
been overloaded tend to buckle in a predictable manner, collapsing along a
line between
adjacent cup sockets, through or near the center of the tray. The area between
the cup sockets is
a weak point in a typical cup carrier.
Accordingly, a need exists for a cup carrier capable of carrying beverage cups
within a
wide range of sizes, including large cups, "step-walled" cups, and small cups,
in a secure and
stable manner. A need also exists for a cup carrier capable of being
comfortably and securely
held and carried by a user. A need also exists for a cup carrier capable of
carrying several filled
cups at a time without having the carrier collapse or buckle from the weight
of the filled cups. A
further need exists for a cup carrier that can be produced using pre-existing
molding machines
and is composed of less material.
DISCLOSURE OF INVENTION
The present invention involves the provision of a cup carrier formed of a
resilient
material having cup-holding sockets capable of holding and securing a variety
of cups having
different shapes and sizes. Each socket has stabilizing posts positioned in a
spaced apart
arrangement around the socket and a floor at the bottom of the socket on which
a cup can rest.
Extending inwardly and downwardly from each stabilizing shoulder are
stabilizing walls. The
stabilizing walls are composed of a curved portion. The curved portion has a
tangent slope that
is shallower proximate an upper end of the curved portion and gradually
increases along the
curve toward a lower end such that the slope may be substantially vertical at
one or more points
along the lower end of the curve.
This socket configuration extends the stabilizing wall further into an upper
region of the
socket, thereby enabling the stabilizing wall to contact smaller diameter cups
at a higher point.
The higher contact point increases cup stability. In one embodiment, the
socket configuration
allows the stabilizing wall to be substantially in contact with the cups from
the upper most
contact point down to the stabilizing wall's lower most edge, thereby
providing a larger area of
contact increasing the pull out friction area. In another embodiment, the
curvature of the
stabilizing wall of the socket allows the stabilizing wall to flex so that the
cup wall will run
tangent to the curve of the stabilizing wall for each of a wide range of cup
sizes, automatically
adjusting to the appropriate angle to be in optimal contact with the cups.
Both of these
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embodiments include elements that increase the gripping effect and the
ultimate stability of the
cup within the socket.
The socket configuration also allows the carrier to hold larger cups, such as
"step-
walled" cups. In one embodiment, the entire curved portion of each stabilizing
wall is in contact
with the larger cups. The fact that the upper part of the curved portion is in
contact with the
larger cups is beneficial. Because the upper portion initially has a
relatively shallow angle, it in
turn exerts more gripping force against the cup when it is deflected outwardly
by the cup's
sidewall. This is especially advantageous in the case of "step-walled" cups
because, as
mentioned above, these types of cups only provide a small gripping area, while
raising the
height of the liquid load, thus making the filled cups top-heavy and more
susceptible to tipping.
The cup carrier also includes a feature to increase the user's ability to
comfortably and
securely hold and carry the cup carrier. The cup carrier includes stabilizing
posts between or
surrounding a socket. This is the area where a user typically grips the
carrier to carry it. The
cup carrier includes recessed "thumb holds" in the top surface of at least one
stabilizing post to
provide a depressed surface to ergonomically mimic the natural shape of the
exterior of a thumb
and create an increased area of friction and/or a vertical surface to prevent
the thumb from
sliding off the top of the post when a loaded carrier is held in a single
hand. The cup carrier may
alternatively include projections protruding upwardly from the top surface of
the stabilizing
posts and/or the corners.
The carrier also includes structural features to increase strength and
rigidity. For
example, the carrier may have a stepped center cavity or well. The center
cavity may include a
stepped sidewall which resists buckling and provides increased rigidity.
Further, a portion of the
outer rim may be recessed and/or may be angled inward to create a stiffer rim
member. In
addition, a portion of the outer rim may have a wider horizontal top face to
further increase the
torsion and bending stiffness of the cup carrier. Another element that may
provide extra
strength and stiffness to the cup carrier is the smoothly contoured or curved
gutter members
between the outer rim and the stabilizing posts. This configuration provides
the same or greater
stiffness with less material, or a greater stiffness with the same amount of
material.
Other aspects and advantages of the present invention will be apparent from
the
following detailed description of the preferred embodiments and the
accompanying drawing
figures.
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BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings form a part of the specification and are to be read
in
conjunction therewith, in which like reference numerals are employed to
indicate like or similar,
parts in the various views, and wherein:
Fig. 1 is perspective view of one embodiment of a cup carrier in accordance
with the
teachings of the present invention;
Fig. 2 is a top side view of a cup carrier in accordance with one embodiment
of the
present invention;
Fig. 3 is a fragmentary cross-sectional view of a socket portion of the cup
carrier of Fig.
2 taken generally along line 3-3 in the direction of the arrows;
Fig. 4 is a fragmentary cross-sectional view of a socket receiving a smaller
beverage cup
in accordance with one embodiment of the present invention;
Fig. 5 is a fragmentary cross-sectional view of a socket receiving a larger
beverage cup
in accordance with one embodiment of the present invention;
Fig. 6 is a fragmentary cross-sectional view of a post of the cup carrier
shown in Fig. 2
taken generally along line 6-6 in the direction of the arrows;
Fig. 7 is a perspective view of one embodiment of a cup carrier in accordance
with the
teachings of the present invention; and
Fig. 8 is a top view of one embodiment of a cup carrier in accordance with the
teachings
of the present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
The following detailed description of the invention references the
accompanying drawing
figures that illustrate specific embodiments in which the invention can be
practiced. The
embodiments are intended to describe aspects of the invention in sufficient
detail to enable those
skilled in the art to practice the invention. Other embodiments can be
utilized and changes can
be made without departing from the scope of the present invention. The present
invention is
defined by the appended claims and the description is, therefore, not to be
taken in a limiting
sense and shall not limit the scope of equivalents to which such claims are
entitled.
As such, those skilled in the art will appreciate that the conception upon
which this
disclosure is based may readily be utilized as a basis for the designing of
other structures,
methods and systems for carrying out the several purposes of the present
invention.
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The entire disclosure, including the specification and drawings, of U.S.
Patent No.
7,762,396 issued July 27, 2010 to Keegan Y. Yang, et al., entitled Cup Carrier
(the `396
patent") and U.S. Patent App. No. 61/345,134 filed on May 16, 2010 to Keegan
Y. Yang, et al.,
entitled "Cup Carrier with Thumb Holds and Curved Stabilizing Walls" are
incorporated herein
by reference.
The invention will now be described with reference to the drawing figures, in
which like
reference numerals refer to like parts throughout. For purposes of clarity in
illustrating the
characteristics of the present invention, proportional relationships of the
elements have not
necessarily been maintained in the drawing figures.
Reference numeral 10 designates generally a cup carrier formed of a resilient
material,
such as molded fibrous pulp. Cup carrier 10 may be manufactured by molding
fibrous pulp
against molds or dies in a process and manner well-known in the art. In an
alternative
embodiment, cup carrier 10 may be made from other materials, such as plastics,
foams, or other
materials having desirable strength and resiliency.
Cup carrier 10 has at least one cup-holding socket 12 molded therein to
securely hold
beverage cups of a variety of shapes and sizes. Such cups may be of a
conventional style having
a frustoconical sidewall with a circular cross-section and a bottom wall
secured thereto. The
cups may also include "step-walled" cups wherein the bottom portion of the cup
is smaller in
diameter than the top portion of the cup. The cups may have a flat bottom
surface or a rimmed
bottom surface and can be made from materials such as plastic, paperboard,
foam, or the like.
The cups may have a variety of capacities, for example, ranging from compact
cups capable of
holding only four ounces (4 oz.) of liquid to very large "step-walled" cups
capable of holding
forty-four ounces (44 oz.) of liquid.
Fig. 1 shows a cup carrier 10 being substantially rectangular in shape that
includes four
cup-holding sockets 12 of substantially the same size, one being provided in
each corner 20 of
the carrier 10, with a center cavity 16 positioned therebetween. However, the
carrier 10 can take
on different configurations and numbers of sockets 12. Even though the
illustrated carrier 10
includes four sockets 12, it will be understood that the number of sockets 12
may be varied to be
less than or greater than four sockets 12. For example, in one embodiment, the
carrier 10
includes one or two sockets 12 with the remainder of the carrier 10 comprising
a substantially
flat food carrying surface. The carrier 10 can also include a downturned
continuous peripheral
rim or flange 18 having a top surface 22.
Each cup-holding socket 12 comprises at least two stabilizing posts 14
positioned in a
spaced apart arrangement around socket 12. Stabilizing posts 14 may be
positioned at a level
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substantially equal to the top surface 22 of the rim 18, as depicted in Fig.
1, or may be
positioned at a level above or below the top surface 22 of the rim 18. Each
post 14 includes two
generally opposing stabilizing walls 24. In addition, each corner 20 also
includes a stabilizing
wall 24 extending inwardly and downwardly therefrom as shown. The three
stabilizing walls 24
are spaced substantially equidistantly around each cup-holding socket 12. As
discussed in
further detail below, the upper edges 26 of the three stabilizing walls 24
(which are shown in the
Figures as curved structures) define the size of the socket 12 opening, and
thus the diameter of
the widest cup that may be received within socket 12. As shown in Fig. 1, the
outer edges 26 of
the stabilizing posts 14 and corners 20 are also the upper edges 26 of the
stabilizing walls 24.
As best seen in Figs. 2-3, each socket 12 is provided with a floor 28. The
socket floor 28
is integrally molded with sidewall portions 30 that are located around socket
12 between
stabilizing posts 14 and corners 20. The socket floor 28 optionally has
reinforcing ribs 32
associated therewith. The reinforcing ribs 32 are slightly raised above the
socket floor 28,.
normally to a distance between 1/16-1/4 of an inch. In the embodiment
illustrated in Fig. 2, there
are three reinforcing ribs 32 associated with each socket floor 28.
In one embodiment, the reinforcing ribs 32 comprise horizontal portions 34
associated
with the socket floor 28 and generally vertical portions 36 connected
therewith that extend at
least partially up the sidewalls 30, as best shown in Fig. 3. This
configuration provides socket
12 with additional rigidity and strength.
The bottom of a cup inserted into the cup-holding socket 12 normally, though
not
always, will rest on a cup-contacting surface as shown in Fig. 4. The cup-
contacting surface can
either be the top surface of the floor 28, or if reinforcing ribs 32 are
present, then the top surface
40 of the reinforcing ribs 32. If the cup-contacting surface is the top
surface of the socket floor
28, then the bottom of the cup will rest directly on the socket floor 28. When
the top surface 40
of the reinforcing ribs 32 is the cup-contacting surface, then the bottom of
the cup is slightly
elevated above the socket floor 28. In the embodiment shown in Figs. 4, the
cup-contacting
surfaces are the top surfaces 40 of the reinforcing ribs 32.
Now turning back to Figs. 1 and 3, extending downwardly and inwardly from each
stabilizing post 14 and each comer 20 is a stabilizing wall 24 that continues
to a distance above
the socket floor 28. Each stabilizing wall 24 has a curved profile as will be
discussed in further
detail below. As seen in Fig. 3, the curve may resemble a parabolic curve
starting with a very
flat tangent slope angle wherein the tangent slope angle gradually increases
to a substantially
vertical slope. Each stabilizing wall 24 may optionally include a slot 44
which vertically bisects
the wall 24. The slot 44 may extend upward from an opening 46, which is
defined between the
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lower edge 48 of the stabilizing wall 24 and the socket floor 28. The slot 44
may terminate at a
point at, below, or above the outer edge 26 of stabilizing post 14 or corner
20. The
configuration formed by the opening 46 and slot 44 is commercially known as a
T-Slot .
However, while a T-Slot configuration is illustrated in the figures, it will
be understood that in
other embodiments, different types of openings and slots may be defined
through the stabilizing
walls. For example, in other embodiments, the configuration defined through
the stabilizing
wall may take the form of a triangle, a rectangle, an inverted Y-shape, or any
other suitable
configuration now known or hereafter developed.
The stabilizing walls 24 are deflected outwardly when a cup is inserted into
the cup-
holding socket 12. The deflection, elasticity and stiffness of the stabilizing
walls 24 can be
controlled by adjusting the thickness, density, nature of material, and/or
degree of curvature of
the curved portion 42 of stabilizing walls 24. The material, such as molded
pulp, should have a
resiliency and texture such that the deflected walls 24 exert a gripping force
on the inserted cup,
regardless of the cup size. The curved shape of stabilizing walls 24 act like
a spring to resist
displacement by the extents of the cup and thereby exert a resistance force
against the walls of
the cup. The combination of the three curved walls 24 surrounding the cup and
the resulting
spring action of the walls 24 exert a substantially horizontal "clamping"
force against the cup
providing an increased frictional force resisting the removal of the cup
within the socket. This
configuration provides a more solid seating of the cup within socket 12 of cup
carrier 10.
As described above, an important aspect of the invention is the configuration
of socket
12. In order to securely hold the cups placed within sockets 12, the curved
portion 42 of
stabilizing walls 24 is designed to contact the cups (of varying sizes) at a
point desirably high up
on the side of the cups. Curved portion 42 provides stabilizing walls 24 with
increased strength
and allows them to better support and hold the cups. Curved portion 42 also
affords the cup
carrier the ability to more effectively hold a larger range of cup diameters.
This is also why a
parabolic-like shape works well. Additionally, as shown in Fig. 4 curved
portion 42 may also be
comprised of an upper curved transition portion 42a with a substantially
linear face 42b
extending downward and inward toward the center of socket 12. Another
embodiment includes
curved portion 42 being configured such that curved portion 42 extends
downward and outward
at the lower edge 48 (directed away from the center of socket 12) forming more
of a "C" shape
profile.
Curved portion 42 allows stabilizing wall 24 to protrude laterally into socket
12 higher
on socket 12 than a dual-sloped or single-sloped linear wall of existing cup
carriers. This
configuration of stabilizing walls 24 affords socket 12 the ability to contact
both small and large
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cups at a higher point on the slant or vertical height of the sides of the
cups. This is
demonstrated in Figs. 4-5. Fig. 4 shows a socket 12 holding a smaller cup 56,
similar to one
used to contain coffee. Fig. 5 shows a socket 12 holding a "step-walled" cup
60, as described
above. Fig. 4 illustrates that the stabilizing wall 24 is not totally
deflected and still contains a
curved section while contacting the smaller cup 56 at a desirable height. Fig.
5 illustrates cup
carrier 10 carrying the larger cup 60 wherein there is little curved portion
42 visible and the
substantial length of the stabilizing wall 24 is in contact with the cup's
side wall.
The stabilizing wall's 24 curved profile also enables the socket to
accommodate
relatively large cups, as the upper end of curved portion 42 of the
stabilizing wall 24 is
configured to facilitate a relatively large amount of inward deflection. In
fact, as seen in Figs. 4-
5, the fact that stabilizing wall 24 includes curved portion 42 necessarily
results in stabilizing
wall 24 having an upper transition zone (i.e., the area where the tangent of
the curved portion 42
begins to change in slope) that is further from the center of the socket as
compared to the upper
transition zones of existing cup carriers having single or dual sloped linear
stabilizing walls,
thereby allowing the stabilizing wall to undergo inward deflection further
from the center of the
socket and, thus, enabling the socket to accommodate larger cups.
The embodiment of cup carrier 10 of the present invention shown in Fig. 4 has
a
stabilizing wall 24 that extends downwardly and inwardly in a parabolic curve-
linear profile
with a relatively shallow tangent angle toward the top, then having the
tangent angle gradually
getting steeper. This design extends the stabilizing wall 24 further into the
top portion of socket
12, thereby enabling the stabilizing wall 22 to contact smaller diameter cups
56 at a relatively
higher point on the side of cup 56. This configuration provides increased
stability of cup 56
within socket 12. As can been seen in Fig. 4, the contact point 58 for the cup
56 will depend on
the diameter and slope of the cup's walls and where the wall engages curved
portion 42 of
stabilizing wall 24. Thus, the higher up on the cup's wall, the better.
Additionally, the
configuration allows the stabilizing wall 24 to be in contact with cup 56 from
the contact point
58 down to the lower edge 48 to further increase stability. All the while, as
illustrated in Fig. 5,
socket 12 has the ability to receive and secure larger cups, such as "step-
walled" cups 60.
Fig. 5 illustrates socket 12 of an embodiment of the present invention
receiving a larger
cup 60. When larger cup 60, such as a 32-ounce "step-walled" cup, is inserted
into socket 12, it
is contacted by the entire curved portion 42 of the stabilizing wall 24
substantially along its
length from the point of contact down to lower edge 48. Because the curved
portion 42 initially
has a relatively shallow angle, it exerts more gripping force on the cup 60
when it is deflected
outwardly by the cup's sidewall. This is especially advantageous in the case
of "step-walled"
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cups because, as mentioned above, these types of cups 60 only provide a small
gripping area,
while raising the height of the liquid load, thus making the cups 60 top-heavy
and more
susceptible to tipping when full of fluid.
In another embodiment not shown, the construction and curvature of the
stabilizing wall
24 of the socket 12 allows the stabilizing wall 24 to flex so that the cup
wall will run tangent to
the curve of the stabilizing wall for each of a wide range of cup sizes,
automatically adjusting to
the appropriate angle to be in optimal. contact with the cups depending on the
diameter of the
cup 56 or 60.
Additionally, in yet another embodiment, stabilizing walls 24 of the present
invention
may be similar to those disclosed in the issued `396 patent except for that
they may include
three, four, five or more portions having different angles, as opposed to just
two angles as shown
and described in the `396 patent to simulate and replicate the behavior of
curved portion 42.
In addition, as can be seen in Figs. 1-3, one embodiment of cup carrier 10
includes
"thumb holds" or "thumb positioners" 50 recessed or indented into the upper
surface 52 of at
least a portion (i.e., one or more) of each stabilizing post 14. Thumb holds
50 provide a user
with a secure location to grip cup carrier 10 with his/her thumb(s). The
recessed thumb holds 50
assist in preventing the user's thumb from sliding off of the stabilizing post
14, as can happen
when the stabilizing post 14 has a flat upper surface 52. The thumb holds 50
also present the
user with a more comfortable and ergonomic way to grip and hold cup carrier
10. For example,
as illustrated in Fig. 6, a user may grab cup carrier 10 such that the palm of
the user's hand
surrounds a portion of the carrier's peripheral rim 18 and the user's thumb 54
is located within
the recessed thumb hold 50. Additionally, the user may also find it
comfortable and stable to
place the user's index (i.e., pointer) finger underneath and proximate the
thumb hold 50.
Further, as shown in Fig. 6, an embodiment of the cup carrier 10 of the
present invention
includes a smoothly contoured or curved gutter 82. Gutter 82 is generally
between peripheral
rim 18 and stabilizing post 14 and spans between sockets 12. As seen in Fig.
7, there are four
gutters 82 corresponding to the four stabilizing posts in this embodiment of
the present
invention. Alternatively, gutter 82 may have a similar configuration, but with
angular walls
having more pronounced corners transitions.
As shown in Figs. 7-8, in an alternative embodiment of cup carrier 10 of the
present
invention, the thumb holds 50 may be comprised of one or more protrusions 68
extending from
the upper surface 52 of stabilizing post 14 instead of, or in addition to, the
thumb holds 50 being
recesses. For example, one or more stabilizing posts 14 may include a
protrusion 68 extending
from the outer portion of its upper surface 52 closest to the cup carrier's
peripheral ring 18. This
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provides a structure for the thumb 54 to rest against providing a vertical
barrier to prevent the
thumb 54 from slipping off post 14 when a user is carrying full cups in cup
carrier 10. In
addition, an embodiment of the cup carrier of the present invention includes
raised corner
portions 70. The raised corner portions 70 provide a thumb hold in each
corner, as well as
increase the stiffness of the corner section. The raised corner portions may
be included with
either embodiment of the thumb holds 50 (the recess or protrusions 68).
The indented thumb holds 50 or protuberances 68 may be of any desired
ornamental size,
shape and contour. The specific size, shape and contour of the thumb holds 50
as shown in Figs.
1-3, or protuberances 68 shown in Figs. 7-8 may improve the aesthetic
appearance of the tray,
and also provides for the functional advantages as discussed above.
As illustrated in the figures, one embodiment of cup carrier 10 of the present
invention is
comprised exclusively of softly curved contours at all wall transitions.
Unlike the prior art cup
carriers, an embodiment of cup carrier 10 includes only a relatively small
number of corners or
sharp edges. In fact, the only area in which this embodiment of cup carrier 10
includes any
substantially non-rounded corners is at the bottom of socket 12 where the
socket floor 28 meets
the socket's sidewall 30, as is necessary to accommodate most cups, which have
a flat bottom
wall.
Among the other advantages described below, cup carrier 10 made of molded
fiber or the
like having curved contour at plane transitions can more effectively be
pressed (as compared to a
cup carrier having sharper corners and edges), which results in shorter drying
times. This, in
turn, allows the equipment forming the cup carriers to operate at faster
speeds and leads to a
larger output of cup carriers produced over a given duration of time.
Additionally, the curved contours of cup carrier 10 facilitate de-nesting. As
is known in
the art, once they are formed, a plurality of cup carriers 10 are placed one
on top of the other in a
stack and then compressed to reduce the height of the stack for shipping. This
procedure can
sometimes cause two or more cup carriers 10 to become inadvertently stuck
together when a
user, such as a fast food restaurant employee, attempts to separate a single
cup carrier 10 from
the stack. By having fewer corners or sharp intersection lines, the curved
contours of cup carrier
10 reduces the chances that two cup carriers will become stuck together and
thereby facilitates
the de-nesting from a stack.
Moreover, the curved contours of cup carrier 10 have numerous other advantages
over
the prior art including increased strength and better cup stability, improved
shape retention, and
the elimination of corners and edges that can create weak spots or stress
concentrations in the
walls of cup carrier 10 that make it susceptible to buckling.
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In addition to the description above, the socket configurations can
alternatively be
defined, in part, by two independent diameters - the diameter D1 at the upper
edges 26 of the
stabilizing walls 24, and the diameter D2 at the lower edges 48 of the
stabilizing walls 24 (see
Fig. 2).
As mentioned above, the upper edges 26 of the three stabilizing walls 24
define the size
of the socket 12 opening, and thus the diameter of the widest cup that socket
12 can
accommodate. As illustrated in Fig. 2, the diameter D1 of a circle drawn
tangent to the edges 26
defines the size of the socket 12 opening. Diameter D1 may be between about
two inches (2")
and about four inches (4"), or alternatively between about two-and-one-half
inches (2.5") and
about three-and-one-half inches (3.5"). In one embodiment, diameter D1 may be
about three
inches (3").
Another diameter D2 is formed by a circle drawn tangent to the lower edges 48
of the
stabilizing walls 24. Diameter D2 is equal to or smaller than diameter D1 and
may be between
about one inch (1") and about three inches (3"), or alternatively between
about one-and-one-half
inches (1.5") and about two-and-one-half inches (2.5"). In one embodiment,
diameter D2 may
be about two inches (2"). The socket configuration can be further defined by
the ratio of the
diameters D2 and D1. For example, the ratio of diameter D2 to diameter D1 can
be between
about 0.5 and 0.8, and in one embodiment is about 0.67.
As illustrated in Fig. 3, the socket configurations can be further defined by
the distances
and ratios between the cup-contacting surface 28 or 40 and the lower edges 48
of the stabilizing
walls 24, and the upper edges 26 of the stabilizing walls 24. The distance D3
between the cup-
contacting surface and the lower edges 34 can be between about zero inches
(0") and about one
inch (1"), and in one embodiment is about one-half inch (0.5"). The distance
D4 between the
cup-contacting surface and the upper edges 26 can be between about one inch
(1") and about
three inches (3"), and in one embodiment is about one-and-eight-tenths inches
(1.8"). The ratio
of distance D3 to distance D4 can be between about zero (0) and 0.6, and in
one embodiment is
about 0.3. The depth of socket 12 remains such that the carrier 10 can be
produced using pre-
existing molding machines. The overall height D5 of the carrier 10 can be, for
example, about
two inches (2"). However, it will be understood that the height D5 can
certainly be more or less
than that.
In addition, as best shown in Figs. 2 and 6, the outer peripheral rim or
flange may be
inwardly arced or curved. An arced portion 62 may have a relatively large
radius or may be
comprised of a plurality of large radiuses. Inwardly arced portion 62 creates
a stiffer outer rim
that provides cup carrier 10 with additional strength and stiffness. Further,
as shown in Fig. 6,
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an outer flange 80 of rim 18 may be angled inward toward cup carrier along a
portion of the rim
that may or may coincide with the inwardly arched portion. Additionally, as
illustrated in Fig. 8,
a portion of or the entire peripheral rim 18 may include a wider portion 64 as
another element
that improves the bending or torsional stiffness of cup carrier 10.
As depicted in Fig. 7, cup carrier 10 may also include extended buttresses 66
extending
from the sockets' sidewalls 30 to improve shape retention of the socket.
Further, in order to provide increased strength and rigidity, the carrier 10
may include a
uniquely designed center cavity 16. As best shown in Fig. 4, the carrier's
center cavity 16 may
have a stepped sidewall configuration. As illustrated, the cavity 16 includes
a generally vertical
upper sidewall 72, a generally horizontal intermediate wall 74, a generally
vertical lower
sidewall 76, and a bottom wall 78. This configuration provides a structure
that increases the
torsion, shear and bending stiffness of cup carrier 10 thereby increasing the
resistance to
buckling and failure. Fig. 5 shows another embodiment that does not include a
stepped sidewall
that is also within the scope of the present invention. Notwithstanding this
difference, Figs. 4
and 5 primarily illustrate cup carrier 10 receiving cups of two different
sizes.
All of the features of cup carrier 10, including but not limited to, the
sockets, posts,
recessed thumb holds, curved stabilizing walls, soft curved contours, outer
peripheral rim,
extended buttresses, and center cavity may be of any desired ornamental size,
shape and contour.
The specific size, shape and contour of these features as shown in the figures
improves the
aesthetic appearance of the tray, and also provides for the functional
advantages as discussed
above.
To demonstrate the unexpected benefits of the improvements of the cup carrier
of the
present invention over those cup carriers known in the art, testing of a
variety of physical
characteristics and key performance qualities were performed. Cup carriers V
and W are
products of Huhtamaki America, cup carrier X is a product of Pactiv Corp., cup
carrier Y is a
product of Cascade, and cup carrier Z is a product of PrimeLink. Testing was
performed to
compare the weight of embodiments of cup carrier 10 against the weights of
existing carriers.
Lighter weight carriers require less material and energy to manufacture, dry,
ship, and dispose
of. The carriers were weighed after conditioning for at least 24 hours in a
standard atmosphere
control laboratory. The average weights of the various styles of cup carriers
described above are
listed below in Table A.
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Table A - Tray Weight
Conditioned
Weight (g)
Embodiment 1 - (Present 32.1
Cup Carrier)
Embodiment 2 - (Present 36.6
Cup Carrier)
Cup carrier V 34.1
Cup carrier W 33.7
Cup carrier X 35.1
Cup carrier Y 37.1
Cup carrier Z 36.7
As mentioned above, in some instances, cup carrier 10 is used to carry four
large cups 60
having capacities of thirty-two ounces (32 oz.) or more. In such instances,
carriers can be prone
to buckling about their center sections. For example, the carriers undergo
significant torsion and
bending stresses when loaded with full cups, especially when a user is
attempting to hold the
carrier with one hand. In such instances, material failures or buckling can
occur about the
carrier's center well or cavity.
To compare the rigidity of the embodiments of the new cup carrier 10 against
existing
cup carriers in the market place, a rigidity test was performed. The rigidity
test measures the
force required to bend a cantilevered rim of the cup carriers down by one-half
inch (1/2") while
the cup carrier is supported at the bottom of the center and at the top of the
opposite rim. The
load was applied to the rim of the carrier and the higher the number, the more
rigid the carrier.
The results of the rigidity test are presented in Table B below.
20
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Table B - Rigidity
Deflection
Force (gf)
Embodiment 1 - (Present 638
Cup Carrier)
Embodiment 2 - (Present 803
Cup Carrier)
Cup carrier V 548
Cup carrier W 498
Cup carrier X 277
Cup carrier Y 405
Cup carrier Z 274
Thus, the two embodiments of cup carrier 10 of the present invention
demonstrated
higher rigidity over the existing cup carriers. In particular, embodiment 1
has the lowest weight,
but the second highest rigidity, thus, obtaining better performance than
existing cup carriers with
lower material and shipping costs.
Another test to compare the strength and rigidity of cup carrier 10 against
that of existing
cup carriers, a deflection test was performed whereby the carriers were tested
for their ability to
support 32-ounce cups filled with liquid. During the test, one side of the
carrier was clamped to
a device in order to simulate being held by a hand. The two unsupported cup-
holding sockets
(i.e., those sockets furthest from the clamping device) were loaded with 32-
ounce "step-walled"
cups filled with liquid. The 32-ounce "step-walled" cups are considered to be
highly demanding
large cups, for the reasons already noted above. Once the load was applied,
the deflection of
each carrier was measured at thirty (30) seconds and at one-hundred-eighty
(180) seconds
wherein the cup carriers effectively act as cantilevered beams. If, during the
thirty (30) second
or one-hundred-eighty (180) second time period, the carrier failed, the result
was noted as
"Failed" and no measurement was taken. However, if the load was supported the
full thirty (30)
or one-hundred-eight seconds, the tester measured the distance that the
unsupported edge of the
carrier had deflected down under the sustained load. Carriers with lower
deflections were
judged to be stronger. In cases where one type of carrier passed some, but not
all, of the tests,
the tester only measured the deflection when it passed. The results of these
tests are recorded
below in Table C.
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Table C - Rigidity Test
% Fail (30s) Deflection % Fail Deflection
(mm)(30s) (180s) (mm) (180s)
Embodiment 1 - (Present 0 12 0 14
Cup Carrier)
Embodiment 2 - (Present 0 11 0 13
Cup Carrier)
Cup carrier V 100% N/A 100% N/A
Cup carrier W 67% N/A 100% N/A
Cup carrier X 80% N/A 100% N/A
Cup carrier Y 0 8 0 11
Cup carrier Z 90% N/A 100% N/A
The data illustrates that embodiment 2 of new carrier 10 had the second lowest
failure
rate (it never failed), and the second lowest deflection (13 mm) of all the
cup carriers tested.
Only carrier Y had lower deflection; however, is also the heaviest cup carrier
and, therefore
costs more to manufacture and transport. Further, embodiment 1 of the new
carrier is the
lightest weight, yet has comparable deflection properties as the two
substantially heavier
carriers. From the test data in Tables A-C it can be seen that the cup carrier
of the present
invention is not only stronger per unit weight overall, but can also can be
made lighter weight
than every existing carrier tested, yet still obtain better performance
characteristics.
To compare the cup-holding ability of cup carrier 10 against that of its
proprietary
existing cup carriers (cup carriers V and W) and cup carrier Y, the only other
brand to withstand
the deflection test, a tipping angle test was performed. All of the other cup
carriers have
sidewalls with a unitary angle or slope. Cups filled with a liquid were placed
in the cup-holding
sockets of the carriers. Each carrier was loaded with two thirty-two ounce (32
oz.) step walled
cups and two twelve ounce (12 oz.) coffee cups. Each of the loaded carriers
was then tilted until
at least one of the cups became dislodged. The angle at which the cup became
dislodged was
measured and recorded up to forty-five degrees (45 ). If no cups were
dislodged by the time the
carrier was tipped to 45 , then the test was stopped, and the result of 45
was recorded. The
results of these tipping tests are recorded below in Table D.
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Table D - Maximum Secure Tipping Angle
Tipping Angle
Embodiment 1 - (Present Cup Carrier) 400
Embodiment 2 - (Present Cup Carrier) 40
Cup carrier V 30
Cup carrier W 33)
Cup carrier Y 350
The results of the tipping test illustrates that the cup carrier of the
present invention
provides increased resistance to a cup tipping over when compared to all of
the other tested
existing cup carriers. In general, the performance of the cup carrier of the
present invention
exceeded that of every other carrier. From these tests, it is seen that cup
carrier 10 offers a
significant improvement in the strength of the cup carrier and an advantage in
the range of cup
sizes that can be securely held without tipping when manufactured at a weight
comparable to the
competition. Moreover, the features of cup carrier 10 provides substantial
improvement over the
existing cup carriers as the cup carrier of the present invention can be
realized the added
efficiency of reducing the weight of each carrier by over 10% and still have
equivalent or, in
most cases, superior performance characteristics.
From the foregoing, it may be seen that the cup carrier of the present
invention is
particularly well suited for the proposed usages thereof. Furthermore, since
certain changes may
be made in the above invention without departing from the scope hereof, it is
intended that all
matter contained in the above description or shown in the accompanying drawing
be interpreted
as illustrative and not in a limiting sense. It is also to be understood that
the following claims
are to cover certain generic and specific features described herein.
17
