WO2013059011A1 - Nestable beverage container - Google Patents

Nestable beverage container Download PDF

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Publication number
WO2013059011A1
WO2013059011A1 PCT/US2012/059164 US2012059164W WO2013059011A1 WO 2013059011 A1 WO2013059011 A1 WO 2013059011A1 US 2012059164 W US2012059164 W US 2012059164W WO 2013059011 A1 WO2013059011 A1 WO 2013059011A1
Authority
WO
WIPO (PCT)
Prior art keywords
beverage container
end portion
side wall
internal volume
protrusions
Prior art date
Application number
PCT/US2012/059164
Other languages
French (fr)
Inventor
Vladislav A. Babinsky
John A. Gelardi
Wade HARRIS
Dobbie C Newman
Laurel Thomas
Original Assignee
Meadwestvaco Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Meadwestvaco Corporation filed Critical Meadwestvaco Corporation
Publication of WO2013059011A1 publication Critical patent/WO2013059011A1/en

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/22Boxes or like containers with side walls of substantial depth for enclosing contents
    • B65D1/26Thin-walled containers, e.g. formed by deep-drawing operations
    • B65D1/265Drinking cups
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D21/00Nestable, stackable or joinable containers; Containers of variable capacity
    • B65D21/02Containers specially shaped, or provided with fittings or attachments, to facilitate nesting, stacking, or joining together
    • B65D21/0233Nestable containers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/38Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
    • B65D81/3865Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation drinking cups or like containers
    • B65D81/3874Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation drinking cups or like containers formed of different materials, e.g. laminated or foam filling between walls

Definitions

  • This application relates to beverage containers and, more particularly, to nestable beverage containers.
  • Beverage containers such as disposable beverage cups, typically include a side wall extending circumferentially about a vertical axis to define an internal volume for receiving a beverage (e.g., soda).
  • a base wall or floor is typically connected to the lower end of the side wall to partially enclose the internal volume.
  • the upper end of the side wall typically defines an opening into the internal volume of the beverage container.
  • beverage containers are often designed to nest with other like beverage containers.
  • beverage containers are typically designed such that multiple beverage containers may be nested together such that each successive beverage container is received within the internal volume of the preceding beverage container.
  • the vertical axis of each beverage container is aligned with the vertical axes of the other nested beverage containers. Therefore, two nested beverage containers occupy significantly less volume than two separate beverage containers.
  • nestable beverage containers are constructed to minimize contact between the side walls of the nested containers. Instead, the beverage containers are designed such that each successive beverage container stands in the preceding beverage container (i.e., a base-to-base engagement). Unfortunately, such designs limit the overall shape and configuration of the beverage container.
  • the disclosed nestable beverage container may include a circumferential side wall that defines an internal volume and a longitudinal axis, the side wall includes an upper end portion that defines an opening into the internal volume and a sealed lower end portion, and at least one protrusion extending radially outward from the upper end portion, the protrusion being longitudinally spaced from the opening.
  • the disclosed nestable beverage container may include a side wall having an upper end portion and a lower end portion, the side wall defining an internal volume and the upper end portion defining an opening into the internal volume, a base wall connected to the lower end portion to partially enclose the internal volume, and a plurality of protrusions circumferentially spaced about the upper end portion and extending radially outward from the upper end portion.
  • the disclosed beverage container system may include a first beverage container including a first side wall that defines a first internal volume and a first longitudinal axis, the first side wall including a first upper end portion and a first lower end portion, the first upper end portion including a first rim that defines a first opening into the first internal volume, the first lower end portion being sealed, and a first plurality of protrusions extending radially outward from the first upper end portion, and a second beverage container including a second side wall that defines a second internal volume and a second longitudinal axis, the second side wall including a second upper end portion and a second lower end portion, the second upper end portion including a second rim that defines a second opening into the second internal volume, the second lower end portion being sealed, and a second plurality of protrusions extending radially outward from the second upper end portion, wherein a portion of the first beverage container is received in the second internal volume such that the first plurality of protrusions are engaged with the second second
  • Fig. 1 is a front elevational view of one aspect of the disclosed nestable beverage container
  • FIG. 2 is a front elevational view, in section, of the nestable beverage container of Fig. l ;
  • FIG. 3 is cross- sectional view of a portion of the side wall of the nestable beverage container of Fig. 2;
  • Fig. 4 is a front elevational view, in section, of the nestable beverage container of Fig. 2 nested with another nestable beverage container;
  • Fig. 5 is cross-sectional view of a portion of the nested beverage containers of Fig. 4.
  • the nestable beverage container 10 may be formed as a disposable beverage cup, such as a 12-ounce, 16- ounce, 21 -ounce or 24-ounce disposable beverage cup. While a generally frustoconical beverage container is shown, those skilled in the art will appreciate that beverage containers of various shapes may be constructed without departing from the scope of the present disclosure.
  • the nestable beverage container 10 may include a side wall 12 and a bottom wall 14 (Fig. 2).
  • the side wall 12 may include an upper end portion 16 and a lower end portion 18, and may extend circumferentially about a longitudinal axis A to define an internal volume 20 (Fig. 2) of the nestable beverage container 10.
  • the upper end portion 16 may have a greater cross- sectional area (e.g., a greater diameter) than the lower end portion 18.
  • the bottom wall 14 may be sealingly connected to the lower end portion 18 of the side wall 12 to partially enclose the internal volume 20.
  • the upper end portion 16 of the side wall 12 may include a circumferential rim 24 that defines an opening 22 (Fig. 2) into the internal volume 20.
  • the rim 24 may be formed by outwardly rolling the upper end portion 16 of the side wall 12.
  • the rim 24 may be used to secure a lid (not shown) or the like to the upper end portion 16 of the side wall 12, thereby further enclosing the internal volume 20.
  • the side wall 12 may be formed as a single-walled structure (not shown).
  • the side wall 12 may be formed as a layered structure that includes a first, inner layer 26 and a second, outer layer 28, as shown in greater detail in Fig. 3.
  • An adhesive 30 may connect the outer layer 28 to the inner layer 26.
  • the outer layer 28 may be spaced from the inner layer 26 to define an annular region 27 therebetween.
  • the inner layer 26 may include an inner surface 32 and an outer surface 34.
  • the inner surface 32 of the inner layer 26 may define (or may be proximate) the interior surface 36 of the side wall 12.
  • the inner surface 32 of the inner layer 26 may be coated with a moisture barrier layer 38, thereby rendering the interior surface 36 of the side wall 12 of the nestable beverage container 10 resistant to moisture penetration when the internal volume 20 of the nestable beverage container 10 is filled with a beverage (not shown).
  • the moisture barrier layer 38 may have a cross-sectional thickness ranging from about 0.5 to about 3.5 points, wherein 1 point equals 0.001 inches.
  • the moisture barrier layer 38 may be (or may include) a layer of polyethylene that has been laminated, extrusion coated or otherwise connected (e.g., with adhesives) to the inner surface 32 of the inner layer 26.
  • Other moisture barrier materials useful in the moisture barrier layer 38 are commercially available and known to the skilled artisan.
  • the inner layer 26 may be formed from a sheet of material capable of being shaped into the side wall 12.
  • the inner layer 26 may have a cross-sectional thickness Ti and a rigidity sufficient to impart the side wall 12 of the insulated beverage container 10 with sufficient structural integrity to maintain the desired shape of the insulated beverage container 10 when a beverage is placed in the internal volume 20.
  • the inner layer 26 may be formed from a recyclable material, such as paperboard.
  • the paperboard may have a cross- sectional thickness Ti of at least about 6 points, such as about 8 to about 24 points.
  • the inner layer 26 may be formed from a polymeric material, such as polycarbonate or polyethylene terephthalate.
  • the outer layer 28 may include an inner surface 40 and an outer surface 42.
  • the outer surface 42 of the outer layer 28 may define (or may be proximate) the external surface 44 of the side wall 12.
  • the outer layer 28 may be a sleeve or wrap positioned over the inner layer 26. As such, the overall surface area of the outer layer 28 may be less than the overall surface area of the inner layer 26, as shown in Figs. 1 and 2. Therefore, the outer layer 28 may cover only a portion of the inner layer 26. As one example, the outer layer 28 may cover at least 60 percent of the inner layer 26. As another example, the outer layer 28 may cover at least 80 percent of the inner layer 26. As yet another example, the outer layer 28 may cover at least 90 percent of the inner layer 26.
  • the outer layer 28 may be formed from a sheet of paperboard, which may be bleached or unbleached, and which may have a basis weight of at least about 85 pounds per 3000 square feet and a thickness T 2 of at least about 6 points.
  • the outer layer 28 may be formed from paperboard, such as linerboard or solid bleached sulfate (SBS), having a basis weight ranging from about 180 to about 270 pounds per 3000 square feet and a thickness T 2 ranging from about 8 to 36 points.
  • SBS solid bleached sulfate
  • the paperboard used to form the outer layer 28 may include various components and optional additives in addition to cellulosic fibers.
  • the outer layer 28 may optionally include one or more of the following: binders, fillers, organic pigments, inorganic pigments, hollow plastic pigments, expandable microspheres and bulking agents, such as chemical bulking agents.
  • the paperboard used to form the outer layer 28 may include ground wood particles dispersed therein. Without being limited to any particular theory, it is believed that the presence of ground wood particles in the outer layer 28 may encourage the absorption of condensation that is formed on the external surface 44 of the side wall 12 into the outer layer 28.
  • the outer layer 28 may be engineered to maximize the transfer of moisture (i.e., condensation) forming on the external surface 44 of the side wall 12 into the outer layer 28.
  • moisture i.e., condensation
  • the surface sizing and the porosity of both the inner and outer surfaces 40, 42 of the outer layer 28 may be engineered to maximize moisture (i.e., condensation) absorption and minimize the negative effects of condensate formation.
  • the surface sizing of the inner and outer surfaces 40, 42 of the outer layer 28 may be controlled such that the inner surface 40 has a Hercules sizing that is less than the Hercules sizing of the outer surface 42.
  • the surface sizing of the inner and outer surfaces 40, 42 of the outer layer 28 may be controlled such that the inner surface 40 has a sizing in the range from about 30 to about 80 Hercules units, while the outer surface 42 has a sizing in the range from about 100 to about 150 Hercules units.
  • the porosities of the inner and outer surfaces 40, 42 of the outer layer 28 may be controlled such that the inner surface 40 has a Gurley porosity that is less than the Gurley porosity of the outer surface 42 (i.e., greater pore volume on the inner surface 40 than on the outer surface 42).
  • the porosities of the inner and outer surfaces 40, 42 of the outer layer 28 may be controlled such that the inner surface 40 has a porosity of about 20 Gurley units (400 cc test), while the outer surface 42 has a porosity of about 40 Gurley units (400 cc test).
  • surface sizing may be controlled using various sizing agents, such as alkyl ketene dimer.
  • sizing agents such as alkyl ketene dimer.
  • other properties pertaining to moisture absorption, such as porosity can be achieved by modifying the paperboard making process, such as modifying the selection of the forming, pressing and drying fabrics.
  • the rate of moisture absorption can be controlled.
  • moisture absorption rates of 0.02 to 0.1 g/cm 2 /min at the outer surface 42 and 0.03 to 0.2 g/cm 2 /min at the inner surface 40 may be achieved.
  • the outer layer 28 of the side wall 12 may be connected to the inner layer 26 with an adhesive 30.
  • Other techniques for securing the outer layer 28 relative to the inner layer 26 are also contemplated. For example, mechanical fasteners or an interference fit may provide the necessary connection between the inner and outer layers 26, 28.
  • the adhesive 30 may be a thermally insulating adhesive.
  • An adhesive may be deemed thermally insulating if it has an insulating R value per unit of thickness that is greater than the insulating R value per unit of thickness of the outer layer 28.
  • the ratio of the insulating R value per unit of thickness of the adhesive 30 to the insulating R value per unit thickness of the outer layer 28 may be at least about 1.25:1, such as 1.5:1, 2:1 or even 3:1.
  • a suitable thermally insulating adhesive 30 may be formed as a composite material that includes an organic binder and a filler.
  • the organic binder may comprise 15 to 70 percent by weight of the adhesive 30 and the filler may comprise 2 to 70 percent by weight of the adhesive 30.
  • the organic binder component of the thermally insulating adhesive 30 may be any material, mixture or dispersion capable of bonding the outer layer 28 to the inner layer 26.
  • the organic binder may also have insulating properties.
  • suitable organic binders include latexes, such as styrene-butadiene latex and acrylic latex, starch, such as ungelatinized starch, polyvinyl alcohol, polyvinyl acetate, and mixtures and combinations thereof.
  • the filler component of the thermally insulating adhesive 30 may include an organic filler, an inorganic filler, or a combination of organic and inorganic fillers.
  • Organic fillers include hard organic fillers and soft organic fillers. Examples of suitable hard organic fillers include sawdust and ground wood. Examples of suitable soft organic fillers include cellulose pulp, pearl starch, synthetic fiber (e.g., rayon fiber), gluten feed, corn seed skin and kenaf core (a plant material). Examples of suitable inorganic fillers include calcium carbonate, clay, perlite, ceramic particles, gypsum and plaster.
  • organic filler may comprise 2 to 70 percent by weight of the thermally insulating adhesive 30 and inorganic filler may comprise 0 to 30 percent by weight of the thermally insulating adhesive 30.
  • All or a portion of the filler may have a relatively high particle size (e.g., 500 microns or more).
  • the use of high particle size filler material may provide the thermally insulating adhesive 30 with structure such that the thermally insulating adhesive 30 functions to further space the outer layer 28 of the side wall 12 from the inner layer 26.
  • the thermally insulating adhesive 30 may be formed as a composite material that includes an organic binder and a hard organic filler, such as sawdust, that has an average particle size of at least 500 microns, such as about 1000 to about 2000 microns.
  • the thermally insulating adhesive 30 may be a foam.
  • the foam may be formed by mechanically whipping the components of the thermally insulating adhesive 30 prior to application.
  • a foam forming agent may be included in the adhesive layer formulation to promote foam formation.
  • 10 to 60 percent of the foam of the thermally insulating adhesive 30 may be open voids, thereby facilitating the absorption of moisture from the external surface 44 of the insulated beverage container 10.
  • 10 to 30 percent of the foam of the thermally insulating adhesive 30 may be open voids.
  • the thermally insulating adhesive 30 may be formed from a binder-filler formulation having a pseudoplasticity index in the range of 0.3 to 0.5.
  • a pseudoplasticity index may provide the thermally insulating adhesive 30 with a sufficient minimum thickness, while preserving the ability to apply the formulation at a low viscosity.
  • the formulation may have a low shear viscosity in the range of 2,000 to 50,000 centipoises and a high shear viscosity in the range of 100 to 5,000 centipoises.
  • the thermally insulating adhesive 30 may additionally include a plasticizer.
  • the plasticizer may comprise 0.5 to 10 percent by weight of the thermally insulating adhesive 30. Examples of suitable plasticizers include sorbitol, Emtal emulsified fatty acids and glycerine.
  • the thermally insulating adhesive 30 may additionally include sodium silicate, which may act as a filler, but is believed to aid in binding and curing of the binder by rapidly increasing viscosity of the binder during the drying process.
  • the sodium silicate may comprise 0 to 15 percent by weight of the thermally insulating adhesive 30, such as about 1 to about 5 percent by weight of the thermally insulating adhesive 30.
  • the thermally insulating adhesive 30 may be formulated to be biodegradable.
  • the thermally insulating adhesive 30 may include styrene- butadiene or acrylic SRB latex (binder), wood flour (organic filler), Aero Whip ® (foam stabilizer available from Ashland Aqualon Functional Ingredients of Wilmington, Delaware), corn fibers (organic filler), calcium carbonate (inorganic filler) and starch (binder), wherein the components of the thermally insulating adhesive have been mechanically whipped together to form a foam.
  • suitable thermally insulating adhesives are described in greater detail in U.S. Ser. No. 61/287,990 filed on December 18, 2009, the entire contents of which are incorporated herein by reference.
  • the adhesive 30 may be positioned between the inner and outer layers 26, 28 in various ways to connect the inner layer 26 to the outer layer 28.
  • the adhesive may be applied to the inner layer 26 in a stripe or swirl pattern or as discrete dollops.
  • the adhesive 30 is a thermally insulating adhesive, such as a foam adhesive, a portion (if not all) of the annual region 27 between the inner and outer layers 26, 28 may be filled with the thermally insulating adhesive.
  • a plurality of protrusions 46 may be circumferentially spaced about the upper end portion 16 of the side wall 12.
  • the protrusions 46 may extend radially outward from the upper end portion 16 of the side wall 12 relative to the longitudinal axis A of the nestable beverage container 10.
  • the nestable beverage container 10 shown in Figs. 1 and 2 includes six protrusions 46 (only four are visible) equidistantly spaced about the circumference of the upper end portion 16 of the side wall 12.
  • protrusions 46 are design considerations that may vary without departing from the scope of the present disclosure.
  • the protrusions 46 may be integral with the outer layer 28 (or, alternatively, the inner layer 26) of the side wall 12. Integral protrusions 46 may be formed by embossing the outer layer 28. For example, a sheet of substrate material (e.g., paperboard) may be passed through an embossing press to form the protrusions 46 prior to assembling the sheet into the outer layer 28 of the side wall 12.
  • a sheet of substrate material e.g., paperboard
  • the protrusions 46 may be formed independently of the outer layer 28 of the side wall 12 and then later connected to the outer layer 28, such as with an adhesive.
  • the protrusions 46 may be longitudinally spaced a distance D from the opening 22 defined by the upper end portion 16 of the side wall 12.
  • the distance D may be sufficient to provide the desired longitudinal spacing of the nestable beverage container 10 from a subjacent beverage container 10' with which the nestable beverage container 10 is nested, as shown in Fig. 4 and described in greater detail below.
  • the distance D between the protrusions 46 and the opening 22 may be at most 20 percent of the overall height H of the nestable beverage container 10.
  • the distance D may be at most 15 percent of the overall height H of the nestable beverage container 10.
  • the distance D may be at most 10 percent of the overall height H of the nestable beverage container 10.
  • the distance D may be at most 8 percent of the overall height H of the nestable beverage container 10.
  • the distance D may be at least 5 percent and at most 20 percent of the overall height H of the nestable beverage container 10.
  • the nestable beverage container 10 may have a height H of about 16 cm and the protrusions 46 may be spaced about 1.5 cm from the opening 22 of the nestable beverage container 10.
  • the protrusions 46 may radiate outward from the outer layer 28 of the side wall 12 such that each protrusion 46 has a radial length L.
  • the radial length L may have sufficient magnitude such that the protrusions 46 of the nestable beverage container 10 form an interfering
  • the radial length L of each protrusion 46 may be at least 5 points. In a second generalization, the radial length L of each protrusion 46 may be at least 10 points. In a third generalization, the radial length L of each protrusion 46 may be at least 20 points. In a fourth generalization, the radial length L of each protrusion 46 may range from about 10 to about 30 points.
  • each protrusion 46 may have a longitudinally elongated (e.g., tear drop) shape in plan view.
  • a longitudinally elongated, tear drop shape may provide the protrusions 46 with structural reinforcement in the longitudinal direction to resist the compression force F (Fig. 5) applied by a subjacent beverage container 10' in the nested configuration.
  • protrusions 46 having different shapes will not result in a departure from the scope of the present disclosure.
  • protrusions 46 that are cylindrical, rectilinear, triangular (in plan view), diamond (in plan view) or irregular are also contemplated.
  • a single ridge may extend circumferentially about the upper end portion 16 of the side wall 12.
  • the ridge may be longitudinally spaced a distance D from the opening 22 and may have a radial length L that protrudes radially outward from the side wall 12.
  • a first beverage container 10 may be nested with a second beverage container 10' by positioning the first beverage container 10 into the internal volume 20' of the second beverage container 10'.
  • the protrusions 46 of the first beverage container 10 may engage the side wall 12' (e.g., the rim 24') of the second beverage container 10' to limit longitudinal movement of the first beverage container 10 into the second beverage container 10'. Therefore, the engagement between the protrusions 46 of the first beverage container 10 and the rim 24' of the second beverage container 10' provides longitudinal spacing of the first beverage container 10 from the second beverage container 10'.
  • Such longitudinal spacing provides for spacing between the base wall 14 of the first beverage container 10 and the base wall 14' of the second beverage container 10', as well as spacing between the side wall 12 of the first beverage container 10 and the side wall 12 ' of the second beverage container 10', thereby allowing for separation of the first beverage container 10 from the second beverage container 10' with a significantly reduced amount of pulling force.

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Abstract

A beverage container including a side wall having an upper end portion and a lower end portion, the side wall defining an internal volume and the upper end portion defining an opening into the internal volume, a base wall connected to the lower end portion to partially enclose the internal volume, and a plurality of protrusions circumferentially spaced about the upper end portion and extending radially outward from the upper end portion.

Description

NESTABLE BEVERAGE CONTAINER
FIELD
[0001] This application relates to beverage containers and, more particularly, to nestable beverage containers.
BACKGROUND
[0002] Beverage containers, such as disposable beverage cups, typically include a side wall extending circumferentially about a vertical axis to define an internal volume for receiving a beverage (e.g., soda). A base wall or floor is typically connected to the lower end of the side wall to partially enclose the internal volume. The upper end of the side wall typically defines an opening into the internal volume of the beverage container.
[0003] In an effort to reduce space, beverage containers are often designed to nest with other like beverage containers. Specifically, beverage containers are typically designed such that multiple beverage containers may be nested together such that each successive beverage container is received within the internal volume of the preceding beverage container. In the nested configuration, the vertical axis of each beverage container is aligned with the vertical axes of the other nested beverage containers. Therefore, two nested beverage containers occupy significantly less volume than two separate beverage containers.
[0004] Unfortunately, when a first beverage container is nested within the internal volume of a second beverage container, friction between the external surface of the first beverage container and the internal surface of the second beverage container resists separation of the first beverage container from the second beverage container. The friction between nested beverage containers tends to increase due to abrasion between the nested beverage containers. Such abrasion has been known to occur when the nested beverage containers are shipped.
[0005] Difficulty separating nested beverage containers often leads to user frustration and a decline in operating efficiency, particularly in high efficiency and high volume operations, such as fast food restaurants. Therefore, the ability to easily separate nested beverage containers is a desirable feature of nestable beverage containers.
[0006] In one known solution, nestable beverage containers are constructed to minimize contact between the side walls of the nested containers. Instead, the beverage containers are designed such that each successive beverage container stands in the preceding beverage container (i.e., a base-to-base engagement). Unfortunately, such designs limit the overall shape and configuration of the beverage container.
[0007] Accordingly, those skilled in the art continue with research and development efforts in the field of beverage containers.
SUMMARY
[0008] In one aspect, the disclosed nestable beverage container may include a circumferential side wall that defines an internal volume and a longitudinal axis, the side wall includes an upper end portion that defines an opening into the internal volume and a sealed lower end portion, and at least one protrusion extending radially outward from the upper end portion, the protrusion being longitudinally spaced from the opening.
[0009] In another aspect, the disclosed nestable beverage container may include a side wall having an upper end portion and a lower end portion, the side wall defining an internal volume and the upper end portion defining an opening into the internal volume, a base wall connected to the lower end portion to partially enclose the internal volume, and a plurality of protrusions circumferentially spaced about the upper end portion and extending radially outward from the upper end portion.
[0010] In yet another aspect, the disclosed beverage container system may include a first beverage container including a first side wall that defines a first internal volume and a first longitudinal axis, the first side wall including a first upper end portion and a first lower end portion, the first upper end portion including a first rim that defines a first opening into the first internal volume, the first lower end portion being sealed, and a first plurality of protrusions extending radially outward from the first upper end portion, and a second beverage container including a second side wall that defines a second internal volume and a second longitudinal axis, the second side wall including a second upper end portion and a second lower end portion, the second upper end portion including a second rim that defines a second opening into the second internal volume, the second lower end portion being sealed, and a second plurality of protrusions extending radially outward from the second upper end portion, wherein a portion of the first beverage container is received in the second internal volume such that the first plurality of protrusions are engaged with the second rim.
[0011] Other aspects of the disclosed nestable beverage container and associated beverage container system will become apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Fig. 1 is a front elevational view of one aspect of the disclosed nestable beverage container;
[0013] Fig. 2 is a front elevational view, in section, of the nestable beverage container of Fig. l ;
[0014] Fig. 3 is cross- sectional view of a portion of the side wall of the nestable beverage container of Fig. 2;
[0015] Fig. 4 is a front elevational view, in section, of the nestable beverage container of Fig. 2 nested with another nestable beverage container; and
[0016] Fig. 5 is cross-sectional view of a portion of the nested beverage containers of Fig. 4.
DETAILED DESCRIPTION
[0017] Referring to Figs. 1 and 2, one aspect of the disclosed nestable beverage container, generally designated 10, may be formed as a disposable beverage cup, such as a 12-ounce, 16- ounce, 21 -ounce or 24-ounce disposable beverage cup. While a generally frustoconical beverage container is shown, those skilled in the art will appreciate that beverage containers of various shapes may be constructed without departing from the scope of the present disclosure. [0018] The nestable beverage container 10 may include a side wall 12 and a bottom wall 14 (Fig. 2). The side wall 12 may include an upper end portion 16 and a lower end portion 18, and may extend circumferentially about a longitudinal axis A to define an internal volume 20 (Fig. 2) of the nestable beverage container 10. The upper end portion 16 may have a greater cross- sectional area (e.g., a greater diameter) than the lower end portion 18. The bottom wall 14 may be sealingly connected to the lower end portion 18 of the side wall 12 to partially enclose the internal volume 20. The upper end portion 16 of the side wall 12 may include a circumferential rim 24 that defines an opening 22 (Fig. 2) into the internal volume 20.
[0019] Optionally, the rim 24 may be formed by outwardly rolling the upper end portion 16 of the side wall 12. The rim 24 may be used to secure a lid (not shown) or the like to the upper end portion 16 of the side wall 12, thereby further enclosing the internal volume 20.
[0020] In a first implementation, the side wall 12 may be formed as a single-walled structure (not shown).
[0021] In a second implementation, the side wall 12 may be formed as a layered structure that includes a first, inner layer 26 and a second, outer layer 28, as shown in greater detail in Fig. 3. An adhesive 30 may connect the outer layer 28 to the inner layer 26. The outer layer 28 may be spaced from the inner layer 26 to define an annular region 27 therebetween.
[0022] The inner layer 26 may include an inner surface 32 and an outer surface 34. The inner surface 32 of the inner layer 26 may define (or may be proximate) the interior surface 36 of the side wall 12. Optionally, the inner surface 32 of the inner layer 26 may be coated with a moisture barrier layer 38, thereby rendering the interior surface 36 of the side wall 12 of the nestable beverage container 10 resistant to moisture penetration when the internal volume 20 of the nestable beverage container 10 is filled with a beverage (not shown). The moisture barrier layer 38 may have a cross-sectional thickness ranging from about 0.5 to about 3.5 points, wherein 1 point equals 0.001 inches. For example, the moisture barrier layer 38 may be (or may include) a layer of polyethylene that has been laminated, extrusion coated or otherwise connected (e.g., with adhesives) to the inner surface 32 of the inner layer 26. Other moisture barrier materials useful in the moisture barrier layer 38 are commercially available and known to the skilled artisan. [0023] The inner layer 26 may be formed from a sheet of material capable of being shaped into the side wall 12. The inner layer 26 may have a cross-sectional thickness Ti and a rigidity sufficient to impart the side wall 12 of the insulated beverage container 10 with sufficient structural integrity to maintain the desired shape of the insulated beverage container 10 when a beverage is placed in the internal volume 20. In one construction, the inner layer 26 may be formed from a recyclable material, such as paperboard. The paperboard may have a cross- sectional thickness Ti of at least about 6 points, such as about 8 to about 24 points. In another construction, the inner layer 26 may be formed from a polymeric material, such as polycarbonate or polyethylene terephthalate.
[0024] The outer layer 28 may include an inner surface 40 and an outer surface 42. The outer surface 42 of the outer layer 28 may define (or may be proximate) the external surface 44 of the side wall 12.
[0025] The outer layer 28 may be a sleeve or wrap positioned over the inner layer 26. As such, the overall surface area of the outer layer 28 may be less than the overall surface area of the inner layer 26, as shown in Figs. 1 and 2. Therefore, the outer layer 28 may cover only a portion of the inner layer 26. As one example, the outer layer 28 may cover at least 60 percent of the inner layer 26. As another example, the outer layer 28 may cover at least 80 percent of the inner layer 26. As yet another example, the outer layer 28 may cover at least 90 percent of the inner layer 26.
[0026] The outer layer 28 may be formed from a sheet of paperboard, which may be bleached or unbleached, and which may have a basis weight of at least about 85 pounds per 3000 square feet and a thickness T2 of at least about 6 points. For example, the outer layer 28 may be formed from paperboard, such as linerboard or solid bleached sulfate (SBS), having a basis weight ranging from about 180 to about 270 pounds per 3000 square feet and a thickness T2 ranging from about 8 to 36 points.
[0027] Optionally, the paperboard used to form the outer layer 28 may include various components and optional additives in addition to cellulosic fibers. For example, the outer layer 28 may optionally include one or more of the following: binders, fillers, organic pigments, inorganic pigments, hollow plastic pigments, expandable microspheres and bulking agents, such as chemical bulking agents.
[0028] In a first optional aspect, the paperboard used to form the outer layer 28 may include ground wood particles dispersed therein. Without being limited to any particular theory, it is believed that the presence of ground wood particles in the outer layer 28 may encourage the absorption of condensation that is formed on the external surface 44 of the side wall 12 into the outer layer 28.
[0029] In a second optional aspect, the outer layer 28 may be engineered to maximize the transfer of moisture (i.e., condensation) forming on the external surface 44 of the side wall 12 into the outer layer 28. For example, the surface sizing and the porosity of both the inner and outer surfaces 40, 42 of the outer layer 28 may be engineered to maximize moisture (i.e., condensation) absorption and minimize the negative effects of condensate formation.
[0030] In one implementation of the second optional aspect, the surface sizing of the inner and outer surfaces 40, 42 of the outer layer 28 may be controlled such that the inner surface 40 has a Hercules sizing that is less than the Hercules sizing of the outer surface 42. For example, the surface sizing of the inner and outer surfaces 40, 42 of the outer layer 28 may be controlled such that the inner surface 40 has a sizing in the range from about 30 to about 80 Hercules units, while the outer surface 42 has a sizing in the range from about 100 to about 150 Hercules units.
[0031] In another implementation of the second optional aspect, the porosities of the inner and outer surfaces 40, 42 of the outer layer 28 may be controlled such that the inner surface 40 has a Gurley porosity that is less than the Gurley porosity of the outer surface 42 (i.e., greater pore volume on the inner surface 40 than on the outer surface 42). For example, the porosities of the inner and outer surfaces 40, 42 of the outer layer 28 may be controlled such that the inner surface 40 has a porosity of about 20 Gurley units (400 cc test), while the outer surface 42 has a porosity of about 40 Gurley units (400 cc test).
[0032] Those skilled in the art will appreciate that surface sizing may be controlled using various sizing agents, such as alkyl ketene dimer. Furthermore, those skilled in the art will appreciate that other properties pertaining to moisture absorption, such as porosity, can be achieved by modifying the paperboard making process, such as modifying the selection of the forming, pressing and drying fabrics.
[0033] Accordingly, by modifying the surface sizing and porosity of both the inner and outer surfaces 40, 42 of the outer layer 28, the rate of moisture absorption can be controlled. For example, moisture absorption rates of 0.02 to 0.1 g/cm2/min at the outer surface 42 and 0.03 to 0.2 g/cm2/min at the inner surface 40 may be achieved.
[0034] As noted above, the outer layer 28 of the side wall 12 may be connected to the inner layer 26 with an adhesive 30. Other techniques for securing the outer layer 28 relative to the inner layer 26 are also contemplated. For example, mechanical fasteners or an interference fit may provide the necessary connection between the inner and outer layers 26, 28.
[0035] Those skilled in the art will appreciate that various adhesives may be used to connect the outer layer 28 to the inner layer 26. However, in one particular embodiment, the adhesive 30 may be a thermally insulating adhesive. An adhesive may be deemed thermally insulating if it has an insulating R value per unit of thickness that is greater than the insulating R value per unit of thickness of the outer layer 28. For example, the ratio of the insulating R value per unit of thickness of the adhesive 30 to the insulating R value per unit thickness of the outer layer 28 may be at least about 1.25:1, such as 1.5:1, 2:1 or even 3:1.
[0036] A suitable thermally insulating adhesive 30 may be formed as a composite material that includes an organic binder and a filler. The organic binder may comprise 15 to 70 percent by weight of the adhesive 30 and the filler may comprise 2 to 70 percent by weight of the adhesive 30.
[0037] The organic binder component of the thermally insulating adhesive 30 may be any material, mixture or dispersion capable of bonding the outer layer 28 to the inner layer 26. The organic binder may also have insulating properties. Examples of suitable organic binders include latexes, such as styrene-butadiene latex and acrylic latex, starch, such as ungelatinized starch, polyvinyl alcohol, polyvinyl acetate, and mixtures and combinations thereof.
[0038] The filler component of the thermally insulating adhesive 30 may include an organic filler, an inorganic filler, or a combination of organic and inorganic fillers. Organic fillers include hard organic fillers and soft organic fillers. Examples of suitable hard organic fillers include sawdust and ground wood. Examples of suitable soft organic fillers include cellulose pulp, pearl starch, synthetic fiber (e.g., rayon fiber), gluten feed, corn seed skin and kenaf core (a plant material). Examples of suitable inorganic fillers include calcium carbonate, clay, perlite, ceramic particles, gypsum and plaster. For example, organic filler may comprise 2 to 70 percent by weight of the thermally insulating adhesive 30 and inorganic filler may comprise 0 to 30 percent by weight of the thermally insulating adhesive 30.
[0039] All or a portion of the filler may have a relatively high particle size (e.g., 500 microns or more). The use of high particle size filler material may provide the thermally insulating adhesive 30 with structure such that the thermally insulating adhesive 30 functions to further space the outer layer 28 of the side wall 12 from the inner layer 26. For example, the thermally insulating adhesive 30 may be formed as a composite material that includes an organic binder and a hard organic filler, such as sawdust, that has an average particle size of at least 500 microns, such as about 1000 to about 2000 microns.
[0040] In one particular expression, the thermally insulating adhesive 30 may be a foam. The foam may be formed by mechanically whipping the components of the thermally insulating adhesive 30 prior to application. Optionally, a foam forming agent may be included in the adhesive layer formulation to promote foam formation. As one example, 10 to 60 percent of the foam of the thermally insulating adhesive 30 may be open voids, thereby facilitating the absorption of moisture from the external surface 44 of the insulated beverage container 10. As another example, 10 to 30 percent of the foam of the thermally insulating adhesive 30 may be open voids.
[0041] In another particular expression, the thermally insulating adhesive 30 may be formed from a binder-filler formulation having a pseudoplasticity index in the range of 0.3 to 0.5. Such a pseudoplasticity index may provide the thermally insulating adhesive 30 with a sufficient minimum thickness, while preserving the ability to apply the formulation at a low viscosity. For example, the formulation may have a low shear viscosity in the range of 2,000 to 50,000 centipoises and a high shear viscosity in the range of 100 to 5,000 centipoises. [0042] As one option, the thermally insulating adhesive 30 may additionally include a plasticizer. The plasticizer may comprise 0.5 to 10 percent by weight of the thermally insulating adhesive 30. Examples of suitable plasticizers include sorbitol, Emtal emulsified fatty acids and glycerine.
[0043] As another option, the thermally insulating adhesive 30 may additionally include sodium silicate, which may act as a filler, but is believed to aid in binding and curing of the binder by rapidly increasing viscosity of the binder during the drying process. The sodium silicate may comprise 0 to 15 percent by weight of the thermally insulating adhesive 30, such as about 1 to about 5 percent by weight of the thermally insulating adhesive 30.
[0044] As yet another option, the thermally insulating adhesive 30 may be formulated to be biodegradable.
[0045] As a specific example, the thermally insulating adhesive 30 may include styrene- butadiene or acrylic SRB latex (binder), wood flour (organic filler), Aero Whip® (foam stabilizer available from Ashland Aqualon Functional Ingredients of Wilmington, Delaware), corn fibers (organic filler), calcium carbonate (inorganic filler) and starch (binder), wherein the components of the thermally insulating adhesive have been mechanically whipped together to form a foam. Other examples of suitable thermally insulating adhesives are described in greater detail in U.S. Ser. No. 61/287,990 filed on December 18, 2009, the entire contents of which are incorporated herein by reference.
[0046] The adhesive 30 may be positioned between the inner and outer layers 26, 28 in various ways to connect the inner layer 26 to the outer layer 28. For example, the adhesive may be applied to the inner layer 26 in a stripe or swirl pattern or as discrete dollops. When the adhesive 30 is a thermally insulating adhesive, such as a foam adhesive, a portion (if not all) of the annual region 27 between the inner and outer layers 26, 28 may be filled with the thermally insulating adhesive.
[0047] As shown in Figs. 1 and 2, a plurality of protrusions 46 may be circumferentially spaced about the upper end portion 16 of the side wall 12. The protrusions 46 may extend radially outward from the upper end portion 16 of the side wall 12 relative to the longitudinal axis A of the nestable beverage container 10.
[0048] The nestable beverage container 10 shown in Figs. 1 and 2 includes six protrusions 46 (only four are visible) equidistantly spaced about the circumference of the upper end portion 16 of the side wall 12. However, those skilled in the art will appreciate that the number and spacing of the protrusions 46 are design considerations that may vary without departing from the scope of the present disclosure.
[0049] In one construction, the protrusions 46 may be integral with the outer layer 28 (or, alternatively, the inner layer 26) of the side wall 12. Integral protrusions 46 may be formed by embossing the outer layer 28. For example, a sheet of substrate material (e.g., paperboard) may be passed through an embossing press to form the protrusions 46 prior to assembling the sheet into the outer layer 28 of the side wall 12.
[0050] In another construction, the protrusions 46 may be formed independently of the outer layer 28 of the side wall 12 and then later connected to the outer layer 28, such as with an adhesive.
[0051] The protrusions 46 may be longitudinally spaced a distance D from the opening 22 defined by the upper end portion 16 of the side wall 12. The distance D may be sufficient to provide the desired longitudinal spacing of the nestable beverage container 10 from a subjacent beverage container 10' with which the nestable beverage container 10 is nested, as shown in Fig. 4 and described in greater detail below.
[0052] In a first expression, the distance D between the protrusions 46 and the opening 22 may be at most 20 percent of the overall height H of the nestable beverage container 10. In a second expression, the distance D may be at most 15 percent of the overall height H of the nestable beverage container 10. In a third expression, the distance D may be at most 10 percent of the overall height H of the nestable beverage container 10. In a fourth expression, the distance D may be at most 8 percent of the overall height H of the nestable beverage container 10. In a fifth expression, the distance D may be at least 5 percent and at most 20 percent of the overall height H of the nestable beverage container 10. As a specific, non-limiting example, the nestable beverage container 10 may have a height H of about 16 cm and the protrusions 46 may be spaced about 1.5 cm from the opening 22 of the nestable beverage container 10.
[0053] The protrusions 46 may radiate outward from the outer layer 28 of the side wall 12 such that each protrusion 46 has a radial length L. The radial length L may have sufficient magnitude such that the protrusions 46 of the nestable beverage container 10 form an interfering
engagement with the rim 24' of a subjacent beverage container 10', as shown in Fig. 5 and described in greater detail below.
[0054] In a first generalization, the radial length L of each protrusion 46 may be at least 5 points. In a second generalization, the radial length L of each protrusion 46 may be at least 10 points. In a third generalization, the radial length L of each protrusion 46 may be at least 20 points. In a fourth generalization, the radial length L of each protrusion 46 may range from about 10 to about 30 points.
[0055] Referring to Fig. 1, each protrusion 46 may have a longitudinally elongated (e.g., tear drop) shape in plan view. Those skilled in the art will appreciate that such an elongated, tear drop shape may provide the protrusions 46 with structural reinforcement in the longitudinal direction to resist the compression force F (Fig. 5) applied by a subjacent beverage container 10' in the nested configuration. However, the use of protrusions 46 having different shapes will not result in a departure from the scope of the present disclosure. For example, protrusions 46 that are cylindrical, rectilinear, triangular (in plan view), diamond (in plan view) or irregular are also contemplated.
[0056] In an alternative aspect, as opposed to multiple protrusions, a single ridge (not shown) may extend circumferentially about the upper end portion 16 of the side wall 12. The ridge may be longitudinally spaced a distance D from the opening 22 and may have a radial length L that protrudes radially outward from the side wall 12.
[0057] Accordingly, as shown in Figs. 4 and 5, a first beverage container 10 may be nested with a second beverage container 10' by positioning the first beverage container 10 into the internal volume 20' of the second beverage container 10'. Once nested, the protrusions 46 of the first beverage container 10 may engage the side wall 12' (e.g., the rim 24') of the second beverage container 10' to limit longitudinal movement of the first beverage container 10 into the second beverage container 10'. Therefore, the engagement between the protrusions 46 of the first beverage container 10 and the rim 24' of the second beverage container 10' provides longitudinal spacing of the first beverage container 10 from the second beverage container 10'. Such longitudinal spacing provides for spacing between the base wall 14 of the first beverage container 10 and the base wall 14' of the second beverage container 10', as well as spacing between the side wall 12 of the first beverage container 10 and the side wall 12 ' of the second beverage container 10', thereby allowing for separation of the first beverage container 10 from the second beverage container 10' with a significantly reduced amount of pulling force.
[0058] Although various aspects of the disclosed nestable beverage container have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.
[0059] What is claimed is:

Claims

1. A beverage container comprising:
a circumferential side wall that defines an internal volume and a longitudinal axis, said side wall comprising an upper end portion that defines an opening into said internal volume and a sealed lower end portion; and
at least one protrusion extending radially outward from said upper end portion, said protrusion being longitudinally spaced from said opening.
2. The beverage container of claim 1 wherein said upper end portion has a greater diameter than said lower end portion.
3. The beverage container of claim 1 comprising a plurality of said protrusions extending radially outward from said upper end portion.
4. The beverage container of claim 3 wherein said plurality of protrusions are circumferentially and equidistantly spaced about said upper end portion.
5. The beverage container of claim 1 wherein said protrusion is integral with said side wall.
6. The beverage container of claim 1 wherein said side wall comprises an inner layer and an outer layer.
7. The beverage container of claim 6 wherein said protrusion is integral with said outer layer.
8. The beverage container of claim 6 wherein said side wall further comprises an adhesive between said inner layer and said outer layer.
9. The beverage contamer of claim 8 wherein said adhesive is a foam comprising a filler and a binder.
10. The beverage container of claim 1 wherein said side wall has a height along said longitudinal axis, and wherein said protrusion is longitudinally spaced a distance from said opening, said distance being at least 5 percent of said height.
11. The beverage container of claim 10 wherein said distance is at most 20 percent of said height.
12. The beverage container of claim 10 wherein said distance is at most 10 percent of said height.
13. The beverage container of claim 1 wherein said protrusion extends a radial length from said side wall, wherein said radial length is at least 10 points.
14. The beverage container of claim 1 wherein said protrusion is elongated relative to said longitudinal axis.
15. A beverage container comprising:
a side wall having an upper end portion and a lower end portion, said side wall defining an internal volume and said upper end portion defining an opening into said internal volume; a base wall connected to said lower end portion to partially enclose said internal volume; and
a plurality of protrusions circumferentially spaced about said upper end portion and extending radially outward from said upper end portion.
16. The beverage container of claim 15 wherein said plurality of protrusions are equidistantly spaced about said upper end portion.
17. The beverage container of claim 15 wherein said plurality of protrusions are integral with said side wall.
18. The beverage container of claim 15 wherein said side wall has a height along said longitudinal axis, and wherein said plurality of protrusions are longitudinally spaced a distance from said opening, said distance being at least 5 percent of said height and at most 20 percent of said height.
19. The beverage container of claim 15 wherein each protrusion of said plurality of protrusions extends from said side wall by a radial length, wherein said radial length is at least 10 points.
20. A beverage container system comprising:
a first beverage container comprising:
a first side wall that defines a first internal volume and a first longitudinal axis, said first side wall comprising a first upper end portion and a first lower end portion, said first upper end portion comprising a first rim that defines a first opening into said first internal volume, said first lower end portion being sealed; and
a first plurality of protrusions extending radially outward from said first upper end portion; and
a second beverage container comprising:
a second side wall that defines a second internal volume and a second longitudinal axis, said second side wall comprising a second upper end portion and a second lower end portion, said second upper end portion comprising a second rim that defines a second opening into said second internal volume, said second lower end portion being sealed; and
a second plurality of protrusions extending radially outward from said second upper end portion,
wherein a portion of said first beverage container is received in said second internal volume such that said first plurality of protrusions are engaged with said second rim.
PCT/US2012/059164 2011-10-18 2012-10-08 Nestable beverage container WO2013059011A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201161548285P 2011-10-18 2011-10-18
US61/548,285 2011-10-18

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3208631A (en) * 1957-11-29 1965-09-28 Illinois Tool Works Nestable cup
US5628453A (en) * 1996-01-16 1997-05-13 Packaging Resources, Inc. Cup with thermally insulated side wall
JP2000302132A (en) * 1999-04-21 2000-10-31 Tomohisa Ogawa Paper cup

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3208631A (en) * 1957-11-29 1965-09-28 Illinois Tool Works Nestable cup
US5628453A (en) * 1996-01-16 1997-05-13 Packaging Resources, Inc. Cup with thermally insulated side wall
JP2000302132A (en) * 1999-04-21 2000-10-31 Tomohisa Ogawa Paper cup

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