GB2448694A

GB2448694A - Stackable cup with insert containing food product

Info

Publication number: GB2448694A
Application number: GB0707826A
Authority: GB
Inventors: Stephen Knipe
Original assignee: HUHTAMAKI
Current assignee: HUHTAMAKI
Priority date: 2007-04-23
Filing date: 2007-04-23
Publication date: 2008-10-29
Also published as: GB0707826D0

Abstract

A stackable container assembly for storing a product is described. The assembly has a container 12 having a base portion 32 and wall portions 30, and an insert 10 associated with the base portion 32, the insert 10 being arranged to form a chamber for storage of the product in the container 12, wherein the insert 10 includes a retaining portion for retaining a further container so as to form a stack. In some examples, the further container seals the chamber and the use of a separate seal can be avoided. The insert may include 10 an opening for the product to be filled into the chamber. The product may be coffee or other dried food product, and the container used as a coffee cup.

Description

Containers for Storing Products This invention relates to containers

for products. Aspects of the invention relate to stackable containers for storing products. Examples of the invention find particular, but not exclusive application in the storage of comestible products, in particular beverage products.

Products, for example comestible products, may conveniently be pre-packed into containers for subsequent use. The containers may also be used for the subsequent serving of the comestible product to a consumer; such an arrangement is of particular application to the vending of food and beverage products.

An example of such an arrangement is in containers for the vending of beverages, for example coffee, Instant coffee is stored in powdered or granulated form in the base of a container; at the point of vending, hot water is added to the powdered or granulated coffee in the container to make the beverage which is then served to the consumer in the container.

Many other beverages and food products can be stored and prepared in a similar way.

An important issue for containers storing products is to prevent spillage of the product from the container and/or, in particular for comestible products, to protect the product from environmental effects such as would spoil the product and/or reduce its shelf life.

To this end, known storage containers are provided with a seal to seal the product in the container.

Thus, known storage containers include a seal, for example a foil, to close the container and protect its contents.

It is known for a plastics cup to be moulded at the base to form a chamber for containing a product. W02004/024602 shows such an arrangement which has a seal provided to seal the chamber. However, special moulded cups are required, adding to cost of manufacture.

W02004/0741 11 describes an arrangement in which a coffee cup includes a separate container for dried coffee. The separate container may be filled with the coffee, sealed and then inserted into the coffee cup. The seal provided is a foil seal having an elongate tag which is pulled at the point of serving to remove the seal and expose the coffee product.

In both of these known arrangements a seal is applied to contain the product.

However, the use of such a seal adds to the expense of the container, and to complexity of manufacture. Furthermore, the seal needs to be removed at point of serving the product, leading to waste and additional time taken in preparing the product for the consumer.

Also, there are benefits in storage and transportation of the containers for them to be stackable. Where the volume of the product in the container permits, there is also benefit in the containers being nestable. However, the inserts or other arrangement for containing the product can lead to unstable stacking or nesting of containers.

It is an object of examples of the present invention to mitigate one or more of the problems identified above.

According to an aspect of the invention there is provided a stackable container assembly for storing a product, the assembly comprising: a container having a base portion and wall portions, and an insert associated with the base portion, the insert being arranged to form a chamber for storage of the product in the container, wherein the insert includes a retaining portion, the retaining portion being arranged for retaining a further container of a further container assembly so as to form a stack of container assemblies.

By use of the retaining portion, a stack of containers can be formed. Preferably the retaining portion is adapted to hold the further container in the insert. Preferably the arrangement is such that a base of the further container is held in the insert.

Preferably the insert includes an open,ng for the product to be filled into the chamber, the retaining portion being associated with the opening such that the further container retained by the retaining portion substantially closes the opening.

Preferably the further container substantially seals the opening. Thus the use of a separate seal to close the opening can be avoided. In some examples, it is preferred that no separate seal is provided.

Preferably the chamber for the product is formed by the insert, the base portion of the container and the base portion of the further container.

Preferably the insert is arranged so that the base portion of the container and the base portion of the further container are at a predetermined distance. Preferably the stacking pitch of the containers is controlled by the insert. By selecting an insert of suitable size and shape, the desired stacking pitch of the containers can be achieved.

The stacking pitch of the containers preferably dictates the size of the chamber for the product.

Preferably the insert includes a stacking ledge arranged such that the further container stands on the ledge. The inclusion of a stacking ledge allows for correct placement of the further container and assists in the sealing function. This can be used to set the stacking pitch of the containers and hence the size of the chamber. The ledge may optionally used for attaching a seal to seal the opening, for example a foil seal.

Preferably the retaining portion includes a retaining neck, for example for receiving a base portion of the further container. In this way, the container may be securely retained by the insert. This can facilitate the formation of a more stable stack of containers as well as improving the sealing of the chamber.

Preferably the retaining portion includes a plurality of retaining ribs. Such ribs can provide a stabilising and/or holding function. Retaining ribs may be provided to improve the retention of the further container in the insert and/or to improve the retention of the insert within the container. The rib structure can allow the use of material for the insert to be reduced.

Preferably the insert has a generally circular shape. In preferred arrangements, the container has a generally circular shape comprising a substantially circular base, The container may comprise a cup. Thus the insert is preferably shaped to be used in association with a cup of standard shape. The insert may be tapered to correspond generally to the shape of the cup.

A preferred insert for a circular container comprises annular stacking ledge, a circular stabilising neck and, optionally, radial ribs, which may include internally extending ribs for retaining the further container in the insert.

In preferred arrangements, the container has a wall and the insert includes an engagement portion, for example a rim, for engaging with the wall for holding the insert in the container. The engagement may be such that the insert may be held in the container solely by means of the rim. Alternatively, or in addition, further means may be provided to hold the insert in the container. In examples described herein, the engagement comprises frictional engagement.

In preferred arrangements, the shape of the insert is such that it can be push-fitted into the container.

By including the engagement portion, more accurate placing of the insert in the container may be achieved, which can also facilitate the formation of a uniform and stable stack of container assemblies.

Preferably the engagement portion comprises a rim having a circumference to fit the wall of the container, for example a cup. Alternatively, or in addition, the insert may be attached to the container, for example by welding, for example ultrasonic welding, or by use of an adhesive, or other suitable method.

Preferably an interior surface of the container forms a part of the chamber for the product. Preferably the insert includes no base. Thus less material is required to form the insert, In examples described, a function of the insert is to hold the containers apart at a predetermined pitch. Thus the chamber for the product can be formed by the spaces between the stacked containers. Preferably the insert has the general form of a ring.

According to a further aspect of the invention there is provided a container assembly comprising a container having a base and upstanding walls, and further comprising an insert located at the base of the container within the container walls to define a chamber within the container assembly, the chamber being defined by the insert and the base of the container. Thus the base of the container forms a part of the chamber for the product.

The invention further provides a container assembly according to any preceding claim, comprising a further container stacked onto the assembly such that the chamber is further defined by the base of the further container.

In contrast to known arrangements, the product may in this way be in contact with the base of the container and/or the outside of a further container stacked onto the first.

The container may comprise a cup. in preferred examples, the cup comprises a paper, card or similar material, although it is envisaged that the invention finds application in respect of containers made of other materials, for example plastics materials.

Examples of the invention find particular application for disposable containers. The outer surface of the cup may include a heat insulating sleeve, for example a corrugated sleeve, and the dimensions of the insert may be adjusted accordingly. Preferably the containers are nestable.

The container may further comprise a comestible product in the chamber. The invention finds particular application where the product is a comestible product, for example a food or beverage product. However, it is envisaged that other products might be stored in containers of the present invention. For example the product may comprise a pharmaceutical product, or other product for example a paint or adhesive product.

The invention finds particular application where the product is a dried or concentrated form of the product and/or is a component or ingredient of a product. The container may be adapted for the preparation of the product in the container, for example by the mixing of a liquid (for example water) with the dried or concentrated product and/or the addition of further ingredients.

Examples of products for use with the containers described herein include instant coffee granules, powdered tea, mixtures of coffee or tea with powdered milk and/or sugar, powdered chocolate drink and dried soup mixture.

The invention also provides an insert for use in a container assembly described herein.

Also provided by the invention is an insert for use in stacking of a plurality of containers, the insert being adapted to be inserted into the containers such that when the containers are stacked, there is a predetermined stacking pitch between the containers.

The invention further provides an insert for a container, the insert being adapted for insertion into the base of a first container, the insert including a retaining portion for retaining a second container stacked onto the first container, the insert having a body portion for containing the product between the first and second containers.

Preferably the insert further comprises a ledge for receiving a further container stacked onto the insert. The location of the ledge thus determines the stacking pitch of the containers.

Preferably the insert further includes a stabilising neck for retaining a container and/or retaining ribs for retaining a container in the insert and/or for retaining the insert in a container. As described above, the insert may include internally extending ribs for retaining a container in the insert. Additionally, or alternatively, the insert may include externally extending ribs for retaining the insert in a container.

Preferably the insert comprises a wall extending between a lower opening and an upper opening. The lower opening is preferably adapted for engagement with the container, preferably the base of the container. The upper opening is preferably associated with the retaining portion. Preferably the insert includes no base portion.

Thus, unlike prior art insert devices, in such cases the insert must be positioned in engagement with the container before it is filled.

The insert may comprise plastics material. Thus the insert may be injection moulded.

Furthermore, if required, a seal may be attached to the insert. The insert may comprise biodegradable material.

The insert may comprise a ridge of material for attachment of the insert to the container. Where the insert is to be attached to the container, for example by ultrasonic welding, a ridge of material may be provided at the point of attachment to assist efficient welding. For example, the bottom edge of the insert may include a ridge for attaching the insert to the base of the container.

A further aspect of the invention provides a method of filling a product into a container assembly including a container and an insert in the container, the insert and the container forming a chamber for the product, the chamber having an opening, the method comprising: filling product into the chamber through the opening, and stacking a further container into the container assembly to close the opening.

Also provided is a method of manufacture of a container assembly, the method comprising the steps of: inserting an insert into the container, and attaching the insert toan interior surface of the container, wherein the insert and the interior surface of the container define a chamber for a product.

The invention extends to methods, products and/or apparatus substantially as herein described with reference to the accompanying drawings.

Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. In particular, method aspects may be applied to apparatus aspects, and vice versa.

Preferred features of the present invention will now be described, purely by way of example, with reference to the accompanying drawings, in which: Figure 1 shows a perspective view of an insert for a cup; Figure 2 shows a perspective view of a vertical cross section of an arrangement in which two cups each having an insert inside are stacked together.

Figure 1 shows an insert 10 for a beverage container comprising a cup 12. The insert lOis in the form of a ring being generally circular and includes a lower body portion 14 and an upper rim portion 16 concentric with the lower body portion 14 and having a greater diameter.

The exterior surface 18 of the rim 16 has a greater diameter than the exterior surface of the body portion 14 and the external diameter of the rim 16 and the height of the body 14 are chosen so that the rim 16 engages an interior surface of the cup 12 as described further below. The body portion 14 and rim 16 are tapered to correspond to the taper of the cup 12.

The interior surface of the rim 16 is stepped forming a lower neck portion 22 and an upper neck portion 24. The interior diameter of the lower neck portion 22 is greater than that of the body, and where the lower neck portion 22 meets the body 14 there is an annular stacking ledge 20. Similarly, the interior diameter of the upper neck portion 24 is greater than that of the body, and where the upper neck portion meets the lower neck portion 22, there is an annular step 26. The upper neck portion 24 includes eight stabilising ribs 24 equally spaced and extending radially inwards from the interior surface of the upper neck portion 24. The interior of the rim 16 forms an opening into which a cup may be inserted as described in more detail below. It is to be noted that the body portion 14 includes no base.

The inserts 10 are nestable for efficient storage and transportation.

The insert 10 comprises plastics material, for example polypropylene and the insert may conveniently be formed by injection moulding in one piece. It will be understood that other materials may be used and other methods of manufacture as appropriate.

Where the cup is to contain a hot beverage, the insert will be chosen so as to have a suitable heat and liquid resistance. The insert may comprise biodegradable material.

Figure 2 shows a perspective view of a vertical section through a stack of two paper cups 12 each cup including an insert 10.

As can be seen from Figure 2, the cups are of standard design, each including a side wall 30 and a circular base 32, the side wall 30 being flared above the base and being generally symmetrical about an axis perpendicular to the base 32. The upper edge of the side waIl 30 is rolled externally in a known way to form the lip of the cup. The base 32 is raised above the bottom edge of the wall 30 to form a generally cylindrical skirt 34.

It will be understood that when the empty cups are stacked, the skirt 34 of an upper cup sits on the base 32 of a lower cup so that the usual stacking pitch of the cups is approximately equal to the depth of the skirt.

The cup 12 is manufactured in a manner known in the art. The cup comprises card coated on one side or both sides with LDPE or a biocoating eg PLA which, in the forming process, adheres a lap joint in the side waIl 30 and adheres the base 32 to the interior of the side wall 30.

The use of the inserts to alter the stacking pitch of a stack of cups will now be described.

As shown in Figure 2, an insert 10 has been inserted into each cup 12. The insert 10 has been push fitted into the cup so that the lower edge of the body 14 abuts the base 32 of the cup and the exterior surface 18 of the rim 16 engages the inner wall of the cup. The Figure 3 shows how the stacking pitch of the cups is changed when an insert is located in the lower cup. The insert 10 is held in the cup 12 by the frictional engagement between the rim 16 and the inner wall of the cup.

The skirt 34 of the upper cup 12 sits on the stacking ledge 20 and the lower section of the wall, including the skirt section, is held in the supporting neck 22. The ribs 28 engage the outer wall of the cup providing further support. Thus the upper cup is held securely in the upper opening of the insert 10 defined by the rim 16, locking the cups together, and the chamber defined by the body 14 of the insert 10, and the bases of the two cups is substantially sealed.

The manufacture of the cup/insert assembly and the filling of the product into the cups will now be described. It will be understood that the manufacture of the cup/insert assembly could be carried out separately and stacks of cups already including the inserts could be supplied for filling, or the empty cups and separate inserts could be supplied for assembly directly before filling.

For the assembly, the cups and inserts are supplied in nested form. An insert is push fitted into each cup and the insert is ultrasonically welded to the cup. An ultrasonic horn is inserted into the cup inside the insert and the ridge 14 at the lower edge of the insert is welded to the base of the cup. The interior surface of the cup may include a plastics coating to facilitate the welding operation.

The cups including the inserts are then transported to the filling station where a metered dose of the product, for example instant coffee, is filled into the insert in each cup.

The filled cups are then transported to the stacking station where stacks of about 10 to cups are formed. These stacks are then subject to further packaging and transport to the consumer outlet.

It will be seen that the compartment of the uppermost container of the stack will not be sealed by a further container. Thus the uppermost container may remain empty in that it contains no product or may be provided with a seal or lid, as appropriate.

For serving the product to the consumer, a container is removed from the base of the stack. The product is therefore exposed. As appropriate, hot water is added to the container; the water mixes with the product, for example to form a coffee beverage which is then served to the consumer. A lid may be applied to the container before serving to the customer. Where the product is a beverage, the lid may comprise a drink-through lid comprising an outlet through which the beverage can be consumed without removal of the lid.

It will be seen that the insert may therefore remain in the container on serving of the product to the consumer.

It will be understood that variations on the example described above will be possible.

For example, the invention may be applied in respect of a wide variety of shapes and sizes of container. Most cups currently are generally circular, but an insert could have a different shape so as to be accommodated in different shapes of cup.

The dimensions of the insert will be chosen with regard to the size of the cup and also the amount of product to be included and thus the necessary size of the chamber.

Inserts for a particular size of cup could be provided in a range of heights to accommodate different amounts of product. For example, where the product is a beverage, the amount of product could be as little as 3g to make a shot of coffee, to over 20g for a chocolate drink. In preferred arrangements, the insert extends to up to about a quarter to a half of the height of the container, preferably a third to a half. If the insert is too large, the stack of containers may be destabilised.

If a foil seal is to be applied, the depth of the stacking ledge may be increased, for example to about 2mm to allow for the application of the seal.

The shape of the insert may be chosen to minimise the amount of material used. For example, there may be a groove provided in the upper shelf 26.

In some cases, sufficient retention of the container in the insert will be provided by the lower neck portion 22 that the upper neck portion 24 with the ribs 24 may not be required. In this case the rim 16 may be shorter, leading to a reduction in the material used to make the insert 10.

While it will be understood that the lack of a base in the insert leads to a significant decrease in the amount of material required to make the insert, it is envisaged that in some arrangements it may be desirable for the insert to include a base.

It will be understood that the present invention has been described above purely by way of example, and modification of detail can be made within the scope of the invention.

Each feature disclosed in the description, and (where appropriate) the claims and drawings may be provided independently or in any appropriate combination.

Claims

1. A stackable container assembly for storing a product, the assembly comprising: a container having a base portion and wall portions, and an insert associated with the base portion, the insert being arranged to form a chamber for storage of the product in the container, wherein the insert includes a retaining portion, the retaining portion being arranged for retaining a further container of a further container assembly so as to form a stack of container assemblies.

2. An assembly according to claim 1, wherein the insert includes an opening for the product to be filled into the chamber, the retaining portion being associated with the opening such that the further container retained by the retaining portion substantially closes the opening.

3. An assembly according to claim I or claim 2, wherein the insert is arranged so that the base portion of the container and the base portion of the further container are at a predetermined distance.

4. An assembly according to any of claims I to 3, wherein the insert includes a stacking ledge arranged such that the further container stands on the ledge.

5. An assembly according to any preceding claim, wherein the retaining portion includes a retaining neck for receiving a base portion of the further container.

6. An assembly according to any preceding claim, wherein the retaining portion includes a plurality of retaining ribs.

7. An assembly according to any preceding claim, wherein the insert has a generally circular shape.

8. An assembly according to any preceding claim, wherein the container has a wall and the insert includes an engagement portion for engaging with the wall for holding the insert in the container.

9. A container assembly according to any preceding claim, wherein an interior surface of the container forms a part of the chamber for the product.

10. A container assembly comprising a container having a base and upstanding walls, and further comprising an insert located at the base of the container within the container walls to define a chamber within the container assembly, the chamber being defined by the insert and the base of the container.

11. A container assembly according to any preceding claim, comprising a further container stacked onto the assembly such that the chamber is further defined by the base of the further container.

12. A container assembly according to any preceding claim, wherein the container comprises a cup.

13. A container assembly according to any preceding claim further comprising a comestible product in the chamber.

14. An insert for use in a container assembly according to any preceding claim.

15. An insert for use in stacking of a plurality of containers, the insert being adapted to be inserted into the containers such that when the containers are stacked, there is a predetermined stacking pitch between the containers.

16. An insert for a container, the insert being adapted for insertion into the base of a first container, the insert including a retaining portion for retaining a second container stacked onto the first container, the insert having a body portion for containing the product between the first and second containers.

17. An insert according to any of claims 14 to 16, further comprising a ledge for receiving a further container stacked onto the insert.

18. An insert according to any of claims l4to 17 further including a stabitising neck for retaining a container.

19. An insert according to any of claims 14 to 18 further including retaining ribs for retaining a container in the insert and/or for retaining the insert in a container.

20. An insert according to any of claims 14 to 19, wherein the insert comprises a wall extending between a lower opening and an upper opening.

21. A container assembly according to any of claims 1 to 13, or an insert according to any of claims 14 to 19, wherein the insert comprises plastics material.

22, A container assembly or insert according to claim 21, wherein the insert comprises biodegradable material.

23. A container assembly or insert according to claim 21 or claim 22 wherein the insert comprises a ridge of material for attachment of the insert to the container.

24. Method of filling a product into a container assembly including a container and an insert in the container, the insert and the container forming a chamber for the product, the chamber having an opening, the method comprising: filling product into the chamber through the opening, and stacking a further container into the container assembly to close the opening.

25. A method of manufacture of a container assembly, the method comprising the steps of: inserting an insert into the container, and attaching the insert to an interior surface of the container, wherein the insert and the interior surface of the container define a chamber for a product.

26. An insert for a container being substantially as herein described having reference to and as illustrated by Figures 1 and 2.

27. A container assembly being substantially as herein described having reference to and as illustrated by Figures 1 and 2.

28. A stack of container assemblies being substantially as herein described having reference to and as illustrated by Figures 1 and 2

29. A method of making a container assembly, being substantially as herein described having reference to Figure 1 or Figure 2.

30. A method forming a stack of container assemblies, being substantially as herein described with reference to Figure 1 or Figure 2.