CA3023375A1 - Improved carrier for secure cup delivery - Google Patents

Abstract

The invention relates to a cup carrier with features for securing the contents of the caps during delivery from a food source to a. customer.
The cup carrier is made from a blank sheet that is foldable around at least one filled cup to provide an enclosed and sealed space. At least one seal is positioned on the blank sheet to seal to another section to hold the carrier in its assembled shape after being folded. Once assembled and sealed, the contents of the cup(s) are secure from tampering because the enclosed and sealed space that surrounds the tops of the cups cannot be opened without visible damage to the seal or the cup carrier. Disclosed embodiments of the blank sheet can also comprise features such as crease lines, adjustable elements, and pre-positioned seals that facilitate a disclosed method of the quick assembly, and adaptability to different cup sizes.

Description

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

- 2 -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.

- 3 -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

- 4 -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

- 5 -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.

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 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.

[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 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

- 9 -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.

- 10 -[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

- 11 -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.

- 12 -[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.

- 13 -[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.

- 14 -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.

- 15 -[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

- 16 -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

- 17 -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-

- 18 -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

- 19 -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

- 20 -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

-21-200. 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

- 22 -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.

_ 73 _ [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 - '74 -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 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 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 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 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 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 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 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.

Claims (25)

What is claimed is:

1. A single blank sheet that is foldable into a carrier for secure delivery of a cup, the single blank sheet comprising:
a plurality of sections divided by pre-creased lines to facilitate folding for assembly of the carrier; wherein:
one of the plurality of sections is a receiving section that has a hole cut-out sized smaller than a base of the cup to receive the cup, the base of the cup having a smaller lateral cross sectional area than that of the top of the cup, the hole cut-out being sized to have a lateral open cross sectional area smaller than the top of the cup, and the other sections are foldable around the top of the cup to form an enclosed space; and at least one seal positioned on the single blank sheet to hold the single blank sheet in its assembled shape after being folded into the carrier, whereby opening the carrier or otherwise attempting access into the enclosed space causes visible damage to the at least seal or the carrier.

2. The single blank sheet of claim 1 wherein the at least one seal is an adhesive strip that is bonded to the single blank sheet and covered with a removeable non-stick cover.

3. The single blank sheet of claim 1 wherein the hole cut-out has tabs extending into the hole cut-out and the tabs are bendable to adjust the size of the opening through the hole cut-out to accommodate different cup sizes.

4. The single blank sheet of claim 1 wherein 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.

5. The single blank sheet of claim 4 wherein the enclosed space has a height above the hole cut-outs that enables the carrier to carry cups of different sizes at the same time.

6. The single blank sheet of claim 5 wherein when the carrier is carrying the cups of different sizes, the height above the hole cut-outs is dimensioned to allow the carrier and cups to be set down on a flat surface with the bottoms of at least two cups of different sizes resting on the flat surface.

7. The single blank sheet of claim 1 wherein the carrier is sized to carry a predetermined range of cup sizes, and when assembled, the height above the hole cut-outs is large enough to accommodate all of the cups in the predetermined range of cup sizes, and wherein the height above the hole cut-outs is also less than a height of the shortest cup in the predetermined range of cup sizes.

8. The single blank sheet of claim 1 wherein the pre-creased lines comprise more than one set of creases so that the carrier is foldable in more than one configuration with different heights for the enclosed space as a function of the set of creases that are selected when the carrier is assembled.

9. The single blank sheet of claim 1 wherein when the carrier is assembled the enclosed 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.

10. The single blank sheet of claim 9 further comprising corner seals positioned on the single blank sheet for sealing along the vertical corners of the rectangular prism.

11. The single blank sheet of claim 1 wherein the carrier is assembled, the enclosed space defines a shape in the form of a triangular prism with a flat bottom and the plurality of sections comprise two sloped side walls and two triangle-shaped opposing end walls.

12. The single blank sheet of claim 11 further comprising edge seals along the end wall edges of the triangular prism in addition to the at least one seal along the peaked top edge of the triangular prism.

13. A carrier for secure delivery of a cup, the carrier comprising:
a single blank sheet foldable to define an enclosed space surrounding the top of the cup, the enclosed space having an interior height enabling 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, and the enclosed space having 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 a lateral cross-sectional area of the top of the smallest cup in the predetermined range of cup sizes; and at least one seal that joins one section of the single blank sheet to another section to prevent the enclosed space from being opened or otherwise accessed without visible damage to the at least one seal or the carrier.

14. The carrier of claim 13 wherein the at least one seal is a tamper proof label that is applied to the carrier after it has been assembled.

15. The carrier for secure cup delivery of claim 13 wherein the carrier securely holds a plurality of cups of different sizes at the same time

16. The carrier for secure cup delivery of claim 15 wherein the enclosed space is in the shape of a rectangular prism.

17. The carrier for secure cup delivery of claim 15 wherein the enclosed space is in the shape of a triangular prism with a flat bottom and triangular-shaped end walls.

18. The carrier of claim 15 wherein the height of the enclosed space above the hole cut-out is a minimum of 5 centimeters.

19. A method of assembling a carrier from a sheet blank for secure cup delivery, the method comprising:
filling a cup with product;
placing a cover on the cup;
positioning the bottom of the cup inside a hole cut-out in the sheet blank;
lifting the sheet blank until the sides of the hole cut-out contact the cup and the cup is supported thereby;
folding the sheet blank along pre-creased lines to assemble the carrier to form an enclosed space around the top of the cup;
applying at least one seal to prevent the carrier from being opened to access the enclosed space without visibly damaging the at least one seal or the carrier.

20. The method of claim 19 wherein the cup is one of a plurality of cups and the carrier has a plurality of hole cut-oats for carrying the plurality of cups and the enclosed space is sized to enclose the tops of each one of the plurality of cups.

21. The method of claim 19 wherein the pre-creased lines include more than one set of pre-creased lines to enable the carrier to be assembled with more than one height for the enclosed space, so that the carrier assembly is adaptable for different cup sizes as needed.

22. The method of claim 19 further comprising 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,

23. The method of claim 22 wherein the adapter ring has pre-creased lines that define sections that are foldable to extend into the hole cut-out, the method further comprising folding along the pre-creased lines of the adapter ring, so that the folded sections keep the adapter ring centered in the hole cut-out.

24. The method of claim 19 further comprising adapting the carrier to carry cups that are shorter than an interior height above the hole cut-outs of the 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-cut.

25. The. method of claim 24 further comprising folding the spacer from a pre-creased spacer sheet blank.