GB2467612A

GB2467612A - Lid with protective cover

Info

Publication number: GB2467612A
Application number: GB0907791A
Authority: GB
Inventors: Douglas Hussey; Edward Thomas Paine
Original assignee: Individual
Current assignee: Individual
Priority date: 2009-02-03
Filing date: 2009-05-06
Publication date: 2010-08-11
Also published as: GB0907791D0; GB0902003D0

Abstract

The invention provides a method of manufacturing a lid (10) such as a coffee cup lid for a container for edible fluids such as tea, coffee, fruit juices and other drinks such as milk shakes including thin soup or gruel. The top (12) of lid (10) includes a drinking area (11) formed by an internal boundary wall (19) and by part of sidewall (16). Drinks opening 18 is located within a receptacle (23) formed within the drinking area (11). The manufacturing process may involve applying a spray of liquid antiseptic material into the receptacle (23) so that it covers the drinks opening (18). The antiseptic material has the capability of changing to form a protective layer or film covering the drinks opening (18). A spray of dried powder material may be used instead of a liquid spray. A further part of the production process involves forming gaps (20,21) in the stepped wall (15) which surrounds the circular periphery of lid (10) on either side of the drinks opening (18). During the application of the sprayed material onto the receptacle (23) the gaps (20, 21) are filled with the material so that an outer surface of the material is formed on sidewall (16). This exposed surface of the material can be prised upwardly to assist the removal of the protective cover by the person preparing to drink from the container. Part of the production process involves the use of retractable spray pipe (28) side support (29) and a vacuum holder (26) for the lid (10). The antiseptic property of the material effects cleaning of the drinks opening (18) and neutralizes any germs present thereon.

Description

Method of Manufacturing a lid for a Container for Edible Fluids and a Lid Manufactured by said Method This invention relates to a method of manufacturing a lid for a container for edible fluids and to a lid manufactured by said method. It is generally acknowledged that in the field of manufacturing lids for containers for edible fluids, for example, coffee cup lids, there are two main methods of manufacture, namely, injection moulding and thermoforming. The main difference between injection moulding and thermforming can be taken to be that the injection moulding process can form articles having varying thickness whereas the thermoforming process can only make parts having a thickness equal to or because of stretching, less than the thickness of the basic sheet material. The injection mould comprises a three dimensional cavity that is filled with molten plastics material to form the lid. The mould can be made to form almost any desired three dimensional shape. However, the ability of the injection moulding technique to provide complex shapes is disadvantageous when it comes to production rates. The mould must be closed, filled with flowable molten plastics material, which then must be cooled sufficiently to retain its shape prior to opening of the mould. In contrast to this the thermoforming technique uses a web of plastics material that is heated to or beyond its glass state which permits the web to be shaped but does not reqtire a long cooling period which is required by the injection mould system. The net result is that the thermoforming technique has much faster production rates than injection moulding. Despite this in this specification the preferred method of lid manufacture is by injection moulding. In our co-pending patent application GB 0819803.3 (hereinafter referred to as aforesaid application) we highlighted the problem of inadvertent transfer of germs to the drinks opening on the lid by the hands of the person dispensing the drinks when that person uses his hands to press down the lid onto the container top to seal it. In the aforesaid application we proposed solving this problem by including a de-contamination step for the ancillary access facility which was defined as an opening in the lid or an area easily removable to form a drinks opening and then protecting the drinks opening from future contamination by providing a separate cover to be applied to and protect the drinks opening. This method of manufacture was criticised on the basis that it required the separate and additonal production of the protective cover and it was felt that this would compromise the production rate of lids. An example of a separate protective cover is disclosed in US patent 7111749 BI (Paul Akers) where a cover piece 12 is adhesively attached to lid 10. A further example of prior art is US 5692616 ( Dennis Baker) wherein a lid 10 is enclosed within a protective enveloping sheet 30 made of cellophane. In yet another example of prior art US 2004/0084452 Al ( Wu-Chang Hsieh) a protective lid 2 is placed on top of another lid I. Clearly the additional costs of applying these separate covers would increase costs and as far as applicants are aware none of these prior art methods have been accepted in the market place. An object of this invention is to improve this aspect of the manufacture of lids for edible fluids. According to one aspect of the present invention there is provided a method of manufacturing a lid for a container for edible fluids, the lid having an ancillary access facility, the method comprising the steps of applying flowable material to the ancillary access facility wherein the flowable material subsequently changes to provide a tough waterproof cover over the ancillary access facility and wherein the protective cover may subsequently be removed to allow access to the ancillary access facility According to a further aspect of the present invention there is provided a lid for a container for edible fluids, the lid having an outer peripheral rim and being arranged to seal edible fluids within the container due to the frictional engagement of the rim when pressed down onto the container by the person dispensing the edible fluids, the lid including an ancillary access facility allowing access to the contents of the container without removal of the lid, a part of the lid being adapted to receive flowable material, the flowable material providing a protective cover over the ancillary access facility. The invention will now be described by way of example only and with reference to the undernoted drawings wherein: Figure 1 illustrates a perspective view looking down on a lid in accordance with the invention.

Figure 2 illustrates a part-sectional elevation through the drinking area of the lid of Figure 1 utilising a liquid spray.

Figure 3 if lustrates a sectional elevation through the drinking area of the lid of Figure lwherein a dry powder spray is used.

Figure 4 illustrates a further example of a lid made in accordance with the invention.

Figure 5 illustrates a sectional elevation through the lid of Figure 4 Figure 6 illustrates a diagrammatic representation of injection moulding apparatus used in the practise of the invention.

In Figure 1 reference numeral 10 denotes a lid for a container for edible fluids, for example, a coffee cup lid in accordance with the invention. It will be understood the container, preferably circular but other shapes could be used, will have the usual tapered body and be arranged to have the usual friction fit with the lid to seal the container. The container body may be of liquid proof paper construction with a lid of thin plastics material suitable for sealing the edible fluids within the container body in a manner well known in the art. In this specification, as in the aforesaid application, the term "edible fluids" is meant to include drinks such as tea, coffee, other beverages such as milk shakes, fruit juices and is also intended to include edible fluids stich as thin soup or gruel. In this context the container body may be made of cellular material such as polystyrene or other foam materials. As illustrated in Figure 1 lid 10 comprises a flat top portion 12 with a pressed out depressed area 13 which strengthens the lid structure. An inner wall member 14 which may have a slight upward taper extends between depressed area 13 and the top part 12 and forms a stepped wall portion 15 around the circular peripheiy of lid 10. From top part 12 a depending outer sidewall 16 angles outwardly and downwardly to join outwardly and downwardly extending peripheral rim 17 which is dimensioned to provide a friction fit to seal around the top of the container in a manner well known in the art. Reference numeral 11 denotes generally a drinking area containing an ancillary access facility in the form of a drinks opening 18 and is bounded by a curvilinear inner wall portion 19 which has a slight upward and backward taper and the outer wall 16 of the lid. As is evident from Figure 1 stepped wall portion 15 is somewhat offset such that the width of the stepped wall portion 15 in the region 25 of drinks opening 18 is minimal. Stepped wall portion 15 also contains two recesses or cut outs 20, 21 to form a gap in the stepped wall portion for reasons later to be explained. An important part of the invention is a protective cover 22 shown dotted in Figure 2 formed in an area of the lid adapted to receive flowable material, for example, the drinking area 11 within a receptacle 23 defined by inner wall 19 and outer wall 16 and a base portion 24 which depends from depressed area 13 The width of the top of the wall in the area 25, see Figure 2, between the drinks opening 18 and outer wall 16 is made minimal so that it will not unduly interfere with a person drinking from opening 18 bearing in mind that the top of wall 16 which will coincide with top part 12 will be slightly above the drinks opening 18 in order to contain protective cover 22. The distance between the cut outs 20, 21 will correspond generally to the size of a person's mouth arranged uniformly around drinks opening 18. Protective cover 22 is produced within drinking area 11 by means of a spray of liquid antiseptic material applied to receptacle 23 as part of the production process and which will then be allowed to settle and change by hardening to take up the shape of receptacle 23 and thus will cover, seal and protect drinking opening 18. Drinking area 11 may have been cleaned or dc-contaminated prior to the application of the sprayed on antiseptic protective cover 22. On the other hand it may be considered that the application of the antiseptic spray is all the cleaning effort that is required so that a separate dc-contaminating or cleaning step would not be required and could be eliminated from the production process. Once the antiseptic liquid material has been sprayed on it has the -10 capability of providing a tough protective cover 22 that is antiseptic, flexible and waterproof.

Such material is sold under the name of New-Skin ( ) Liquid Bandage and for larger areas the use of New Skin ( ) Spray is recommended. The material is sold by MIEDTECH ( ) in Jackson, WI, 83001, USA (tel 1-800-443-4908). The active ingredient of this material being 8 -Hydroxyquinoline (1%). During the process of spraying the drinks area lithe liquid -15 antiseptic material will fill up cutouts 20,21, see Figure 1 and provided a suitable support or barrier tool 29, see Figure 3, is arranged around sidewall 16 during this phase of the production process anexposed side surface area of the antiseptic material will be obtained. This surface area will then be contactable by the fingers of the person intended on consuming the drink to pry up and assist the removal of protective cover 22 to allow consumption of the contents of the container bearing in mind the thickness of the protective cover may be of the order of a thin film or slightly thicker layer.Backward sloping wall 19 may also assist the peeling away of protective cover 22. An alternative to the use of a liquid spray is explained with reference to Figure 3. Figure 3 illustrates the use of Savion Antiseptic Powder Spray which also has the capability of forming an antiseptic protective layer 22A. Savion is a trademark of and may be obtained from Novartis Consumer Health UK Ltd, Wimblehurst Road, Horshain, W. Sussex RHI2 5AB. The main ingredient of Savion Antiseptic Dry Spray is Povidone Iodine 1%.

Because the dry powder may enter through the drinks opening 18 whilst being sprayed onto receptacle 23 a retractable (as indicated by the double arrows) support member / vacuum holder 26 can be used to temporarily close off or block drinks opening 18 during the spraying process.

The top 27 of support member 26 is contoured to correspond to the shape of the underside of lid 10 including an upstanding portion 30 intended to fit within and block drinks opening 18.

Such use of a support member / vacuum holder 26 could also be used if the liquid spray does not sufficiently coalesce so as to be self supporting as it is sprayed over drinks opening 18. A

retractable spray

S

pipe 28 and side support tool 29 for cutouts 20,21 are shown diagrammatically in Figure 3 as part of the production process. If it is desired that the top wall 16 should not be above drinks opening 18 as seen in the sectional views of Figure 2 and 3 than a gap 31 (shown dotted in Figure 1) similar to gaps 20, 21 could be formed in sidewall 16 opposite to drinks opening 18 and with a retractable side support tool 32 positioned around sidewall 16 opposite to drinks opening 18 forming a barrier the material would be made to flow into gap 31. The top surface of gap 31 would then be arranged to be level with drinks opening 18. Also, if desired curvilinear support tool 31 could be extended to stretch from gap 20 to gap 21 so there would be one gap and drinks opening 18 would be flush with the resulting level of top edge surface of sidewall 16 throughout this area. Figures 4 and 5 illustrate embodiments of the invention wherein stepped wall 1 5A transitions down at an angle from an uppermost wall surface 1 2A to a level with base portion 24, see Figure 5. A retractable tool 29A, see Figure 5, with a stepped or L shaped face is presented to side surface 16 so that flowable material will fill the gap there between so that a protective cover 22A may be formed at an angle to base 24 and thus provides protection to the drinks opening 18 over base 24 and down the side surface 16 for a distance to provide adequate cover for a person's mouth. An alternative to forming protective cover 22, 22A by spray application is an overmoulding process of a standard injection moulding process. A typical injection moulding apparatus used to produce lids 10 is illustrated diagrammatically at 40 in Figure 6 and comprises a storage hopper 41 for suitable polymeric resin material 42 which is fed by a ram usually archimedes screw 43 into a heated barrel 44. The material is then heated to a liquid flowable state and is forced fed into mould cavity 45 comprising movable platens 46,47 containing the desired shape of the component, in this case lid 10. The mould platens 46,47 can be made using eletrical discharge machining or CNC machining. The platens 46,47 are then forced apart to dispense the formed article and the process is then repeated. It should be noted the lid 10 resulting from this basic process is minus the protective cover 22. In accordance with the invention a protective cover 22B is then formed on lid 10 by overmoulding. Essentially this means that a previously injection moulded part, for example, lid 10 is subjected to another injection moulding process to allow a new plastic layer, that is protective cover 22B, to be formed on the originally injection moulded product. 2-shot or multi-shot mould.s are designed to overrnould. This process is actually an injection moulded process performed twice. The advantage of this that two or more materials with different properties are incorporated into a single product. For example the protective cover 22B can be added to a standard lid. In addition since the material for the protective cover 22B can be made to provide an antiseptic effect this means that a de-contamination step can be eliminated from the lid production process with consequent savings on production rates. It should be noted that with conventional overmoulding processes every effort is made to achieve 100% bonding strength. With the present invention, however, the desired bond strength will be such as will allow the component parts to be easily separated because the protective cover 22B will be required to be easily removed when a person wishes to expose the drinks opening to drink therefrom. Information on how to achieve and measure maximum bond strength is given in an article entitled "Guide to Overmoulding with Melt Processible Elastomers (MPE's)" produced by Advanced Polymer Alloys, Ferro Corp. 3521 Silverside Road, Suite 2E, Wilmington DE 19810 USA with particular attention given to their products Alcryn and Duragrip. However, a variety of materials may be used including all thermoplastics, some thermosets and some elastomers. Common polymers like epoxy and phenolic are examples of thermosetting whilst nylon, polyethylene and polystyrene are thermoplastic. Other materials include polyurethane (PU); styrene-ethylene/butylene-styrene copolymer (SEBS), thermoplastic rubber (TPR)and thermo plastic vulcanite (TPR). Drinks opening 18 will be formed in the usual manner with a punch and die. Accordingly it can be seen that various methods of providing a protective covering over the drinks opening in accordance with the invention have been described.

Claims

Claims 1. A method of manufacturing a lid for a container for edible fluids, the lid having an ancillary access facility, the method comprsing the steps of applying flowable material to the ancillary access facility wherein the flowable material subsequently changes to provide a tough waterproof cover over the ancillary access facility and wherein the protective cover may be subsequently removed to allow access to the ancillary access facility.
2. A method of manufacturing a lid for a container for edible fluids according to claim I wherein the lid is adapted to receive the flowable material.
3. A method of manufacturing a lid for a container for edible fluids according to claim 2 wherein the lid includes a receptacle for receipt of the flowable material.
4. A lid for a container according to claim 1 wherein the lid includes a receptacle and a part of the lid provides a part of the receptacle for the flowable material and the remaining part of the receptacle is provided by way of retractable outside support means.
5. A lid for a container for edible fluids according claim 4 wherein the protective cover includes a side portion protecting the underside of the mouth.
6. A method of maufacturng a container for edible fluids according to claim I wherein the flowable material is applied as a liquid spray.
7 A method of manufacturing a lid for a container for edible fluids according to claim 1 wherein the flowable material is applied as a spray of powder.
8 A method of manufacturng a containerfor edible fluids accordng to claim 6 wherein the main ingredient of the flowable material is 8-Hydroxyquinoline (1%).
9. A method of manufacturing a container for edible fluids according to claim 7 wherein the main ingredient of the flowable material is Povidone 1%.
10. A method of manufacturing a container for edible fluids according to claim 3 wherein the receptacle includes an ancillary access facility in the form of a drinks opening.
11. A method of manufacturing a container for edible fluids according to claim 10 wherein during the production process a support member for the lid is provided during the application of the flowable material to the receptacle and the support member includes an upstanding portion enterable within the drinks opening thus preventing applied material from entering the drinks opening.
12. A method of manufacturing a lid for a container for edible fluids according to claim 2 wherein the lid includes a stepped wall member around the circular periphery of the lid and cut outs of the stepped wall portion are formed to provide a gap or gaps therein and wherein the flowable material flows into and fills the gap or gaps.
13. A method of manufacturing a lid for a container for edible fluids according to claim 12 wherein a side support barrier surface is placed across the gaps such that a side surface of the material is provided in the gaps and upon removal of the side support barrier the side surface of material may be contacted for removing the protective cover by a person about to drink from the drinks opening.
14. A methd of manufacturing a lid for a container for edible fluids according to claim 1 wherein the lid is produced by way of an injection moulding process and the protective cover is added by a separate process of overmoulding.
15. A method of manufacturing a lid for a container for edible fluids according to claim 14 wherein the bonding between the lid and the protective cover is arranged to be less than the theoretical maximum thereby making it relatively easy.for the protective cover to be removed under finger pressure thereby giving access to the drinks opening.17. A method of manufacturing a lid for a container for edible fluids according to claim I wherein the protective cover provides an antiseptic effect thereby netralising any germs present around the drinks opening.18. A method of manufacturing a lid for a container for edible fluids substantially as herein described with reference to any one of Figures 1, Figure 2, Figure 3, Figure 4, Figure 5 or Figure 6 of the accompanying drawings.19. A lid for a container for edible fluids, the lid having an outer peripipheral rim and being arranged to seal edible fluids within the container due to the frictional engagement of the rim when pressed down onto the container by the person dispensing the edible fluids, the lid having an ancillary access facility allowing access to the container contents without removal of the lid, a part of the lid being adapted to receive flowable material, the flowable material providing a protective cover over the ancillary access facility, the ancillary access facility being located within an area of the lid adapted to receive the fiowable material 20. A lid for a container for edible fluids according to claim 19 wherein the lid includes a stepped wall member around the periphery of the lid, the stepped wall member being offset relative to the circular periphery of the lid such that the minimal thickness of the stepped wall occurs adjacent to the drinks opening.21. A lid for a container for edible fluids according to claim 20 wherein that part of the stepped wall opposite the drinks opening has been removed so that the protective cover may lie flat over the drinks opening and includes a portion extended to cover a part of the side surface of the lid and thereby the mouth of a user.22. A lid for a container for edible fluids according to claim 19 wherein the lid includes a stepped wall extending around the circular periphery of the lid and wherein the part of the lid adapted to receive flowable material comprises a receptacle and the receptacle is bounded by an internal wall and the stepped wall. 1 10AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS1. A method of manufacturing a lid for a container for edible fluids, the lid having an outer peripheral rim and being arranged to seal edible fluids within the container due to the frictional engagement of the rim when pressed down onto the container by the person dispensing the edible fluids, the lid having an ancillary access facility allowing access to the container contents without removal of the lid, the ancillary access facility being in the form of a drinks opening, the lid further including a receptacle adapted to receive flowable material, the drinks opening being formed within the receptacle, the method comprising the steps of applying flowable material to the receptacle wherein the flowable material subsequently changes to provide a tough waterproof protective cover over the drinks opening and wherein the protective cover may be subsequently removed to allow access to the drinks opening.2. A method of manufacturing a lid for a container for edible fluids according to claim 1 wherein the method includes the further step of providing a support member for the lid during the application of the flowable material to the receptacle wherein the support member includes an upstanding portion enterable within the drinksopening thus preventing applied material from entering te drinks opening.3. A method of manufacturing a lid for a container for edible fluids according to claim 1 wherein a part of the receptacle is provided by way of retractable outside support means.4. A method of manufacturing a lid for a container for edible fluids according to claim I wherein the protective cover includes a side portion protecting the underside of the mouth of a user. *...5. A method of manufacturing a lid for a container for edible fluids according to claim I wherein the flowable material is applied as a liquid spray.* 6. A method of manufacturing a lid for a container for edible fluids according to claim 1 : : wherein the flowable material is applied as a spray of powder *e.* 7. A method of manufacturing a lid for a container for edible fluids according to claim 5 wherein the main ingredient of the flowable material is 8-Hydroxyquinoline (1%) **** * ..: 8. A method of manufacturing a lid for a container for edible fluids according to claim 6 wherein the main ingredient of the flowable material is Povidine 1%.9. A method of manufacturing a lid for a container for edible fluids according to claim 1 wherein the lid includes a stepped wall member around the periphery of the lid and cut outs of the stepped wall portion are. formed to provide a gap or gaps therein and wherein the flowable material flows into and fills the gap or gaps..10. A method of manufacturing a lid for a container for edible fluids according to claim 9 wherein a side support barrier surface is placed across the gap or gaps such that a side surface of the material is provided in the gap or gaps and upon removal of the side support barrier surface the side surface of material may be contacted to facilitate removal of the protective cover by a person about to drink from the drinks openng. 11.11. A method of manufacturing a lid for a container for edible fluids according to claim I wherein the lid is produced by way of an injection moulding process and the protective cover is added by a separate process of over moulding.12. A method of manufacturing a lid for a container for edible fluids according to claim 11 wherein the bonding between the lid and the protective cover is arranged to be less than the theoretical maximum thereby making it relatively easy for the protective cover to be removed under finger pressure thereby giving access to the drinks opening.13. A method of manufacturing a lid for a container for edible fluids according to claim 1 wherein the protective cover provides an antiseptic effect thereby neutralising any germs present around the drinks opening.14. A method of manufacturing a lid for a container for edible fluids substantially as herein described with reference to any one of Figures 1 to 6 of the accompanying drawings.15. A lid for a container for edible fluids, the lid having an outer peripheral rim and being arranged to seal edible fluids within the container due to the frictional engagement of the rim when pressed down onto the container by the person dispensing the edible fluids, the lid having an ancillary access facility allowing access to the container contents without removal of the lid, a part of the lid being adapted to receive flowable material, the flowable material being capable of hardening to provide a protective cover over the ancillary access facility, the ancillary access facility being located within an area of the lid adapted to receive the flowable material, the lid including a stepped wall member around the periphery of the lid, the stepped wall member being offset relative to the circular periphery of the lid such that the minimal thickness of the stepped wall occurs adjacent to the drinks opening.* **..I
16. A lid for a container for edible fluids according to claim 15 wherein that part of the * . . stepped wall opposite the drinks opening hss been removed so that the protective cover may lie flat over the drinks opening.
17. A lid for a container according to claim 15 wherein the lid is of plain construction * :1. facilitating disposal after use.* : *
18. A lid for a container according to claim 17 wherein the lid is of plain construction insofar as the lid does not involve relatively slidable, hingeable or other moving parts.19.. A lid for a container for edible fluids substantially as herein described with reference to any one of Figures 1 to 6 of the accompanying drawings.