EP3206958A1 - Double-walled paper cup and method of manufacture thereof - Google Patents
Double-walled paper cup and method of manufacture thereofInfo
- Publication number
- EP3206958A1 EP3206958A1 EP15778987.6A EP15778987A EP3206958A1 EP 3206958 A1 EP3206958 A1 EP 3206958A1 EP 15778987 A EP15778987 A EP 15778987A EP 3206958 A1 EP3206958 A1 EP 3206958A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- outer sleeve
- cup
- inner cup
- contact strip
- glue
- Prior art date
- Legal status (The legal status 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 status listed.)
- Granted
Links
- 238000000034 method Methods 0.000 title claims abstract description 112
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 39
- 239000003292 glue Substances 0.000 claims abstract description 184
- 239000012943 hotmelt Substances 0.000 claims abstract description 86
- 230000008569 process Effects 0.000 claims abstract description 66
- 238000004026 adhesive bonding Methods 0.000 claims description 13
- 238000003780 insertion Methods 0.000 claims description 4
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- 239000000853 adhesive Substances 0.000 claims description 3
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- 239000000123 paper Substances 0.000 description 37
- 238000012546 transfer Methods 0.000 description 14
- 230000015572 biosynthetic process Effects 0.000 description 8
- 239000007788 liquid Substances 0.000 description 8
- 239000004831 Hot glue Substances 0.000 description 7
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- 238000001035 drying Methods 0.000 description 4
- 238000002844 melting Methods 0.000 description 4
- 230000008018 melting Effects 0.000 description 4
- 239000011087 paperboard Substances 0.000 description 4
- 239000004447 silicone coating Substances 0.000 description 4
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- 125000006850 spacer group Chemical group 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 230000007423 decrease Effects 0.000 description 3
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- 239000004698 Polyethylene Substances 0.000 description 2
- 239000002537 cosmetic Substances 0.000 description 2
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- 235000020965 cold beverage Nutrition 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS 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
- B65D81/00—Containers, 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
- B65D81/38—Containers, 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
- B65D81/3865—Containers, 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
- B65D81/3869—Containers, 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 with double walls, i.e. hollow
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS 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
- B65D3/00—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines
- B65D3/02—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines characterised by shape
- B65D3/06—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines characterised by shape essentially conical or frusto-conical
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS 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
- B65D3/00—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines
- B65D3/22—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines with double walls; with walls incorporating air-chambers; with walls made of laminated material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS 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
- B65D81/00—Containers, 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
- B65D81/38—Containers, 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
- B65D81/3865—Containers, 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
Definitions
- the invention relates to a double-walled cup made of a paper material, for example, paper or cardboard.
- a paper cup having an inner cup and an outer sleeve attached thereto is disclosed.
- the outer sleeve is configured to reduce the heat transfer from the inner cup to the outer sleeve.
- the present invention further relates to a method of manufacturing the double-walled cup.
- Paper cups for hot and cold beverages are widely used. These cups are either single-walled paper cups or double-walled paper cups and generally have a frusto-conical shape having an increasing diameter from the bottom towards the top. Double-walled cups are generally used for hot beverages such as coffee.
- FIG. 1 is a side view of a conventional double-walled cup.
- the double- walled cup includes an inner cup 100 for holding liquid and an outer sleeve 101 .
- the outer sleeve 101 includes a bottom curl 102 that keeps a portion of the outer sleeve 101 separated from the inner cup 100.
- outer sleeve 101 may contact the inner cup 100 at a section 103 near the top of the inner cup 100. Furthermore the gap between the outer sleeve 101 and the inner cup 100 decreases from the bottom curl 102 to the top section 103. The outer sleeve 101 may be attached to the inner cup 100 at the top section 103.
- FIG. 2 illustrates such a double-walled cup.
- the double-walled paper cup comprises an outer sleeve 201 and an inner cup 200 which fits into the outer sleeve 201 .
- An upper portion of the outer sleeve 201 is curled inwards to form a top curl 203 and a lower portion of the outer sleeve 201 is curled inwards to form a bottom curl 202.
- a gap 205 is formed between the outer sleeve 201 and the outer wall of the inner cup 200.
- the top curl 203 is provided at an upper portion of the sleeve 201 .
- the top curl 203 may be virtually identical to the bottom curl 202.
- the top curl 203 may be configured in the same manner as the bottom curl 202.
- the provision of the top curl 203 ensures a uniform gap between the outer sleeve 201 and inner cup 200.
- the top curl 203 may contact a lip 204 of the inner cup 200.
- the top curl 203 of the outer sleeve 201 may interfere with the lip 204 of the inner cup 200, which may make it difficult for for a lid to be fitted onto the cup as described below.
- the increased uniform gap between the inner sleeve 201 and the inner cup 200 provides improved insulation when compared to the double-walled cup 100 of Figure 1 .
- the provision of the top curl 203 may impinge on the lip 204 of the inner cup 200.
- the top curl 203 may push the outer sleeve 201 away from the inner cup 200 such that the size of the lip 204 on the inner cup 200 is reduced.
- This reduced lip size may be insufficient to keep a standard lid securely in place.
- a suitably configured lip is essential to ensure that a lid remains securely in place on the cup. Any reduction in the lip size makes it more likely that the lid will become detached from the cup during use. Such detachment is potentially dangerous and could lead to scalding.
- the shape of the top curl 203 only provides a minimal area of contact between the outer sleeve 201 and the inner cup 200.
- the outer sleeve 201 of the double-walled cup of Figure 2 only contacts the inner cup 20 at two points, a small portion of each of the top and bottom curls 203 and 202.
- the outer sleeve 201 may be attached to the inner cup 200 at these two points, a sufficient attachment area is not provided to ensure a robust connection between the inner cup 200 and the outer sleeve 201 .
- top curl 203 only allows about 1 mm contact between the inner cup 200 and the outer sleeve 201 . Since even the most accurate hot melt gluing systems have a tolerance of 3 mm, mass production of such cups may be difficult.
- the circular nature of the top curl 203 means contact with the inner cup 200 is minimal. Specifically, it can be observed that the outer surface of the inner cup 200 is tangential to the top curl 203. This minimal contact area may lead to problems with robustly securing the outer sleeve 201 to the inner cup 200.
- paper cups are usually manufactured using one of two adhesive processes, namely cold glue and hot melt glue processes.
- the outer sleeve such as that shown with reference to Figure 2 is generally secured to the inner sleeve using either a cold glue or hot glue process.
- Cold glue is a room temperature glue that requires no heat to set. In time the agent that keeps the glue from turning solid evaporates, turning the glue hard and a solid bond is formed. The disadvantage is that this may take a minimum of about 25 minutes to start to properly bond, making it unstable in high speed manufacturing (180 pieces per minute). Once set the process is irreversible Hot melt is glue that is solid up to a "set" temperature and liquid once the glue achieves this temperature.
- Hot melt glue may be applied using heated tanks and heated guns to maintain the glue above the set temperature. Once the glue leaves the gun and is applied to a surface it quickly cools and forms a bond between two surfaces. Hot melt glue is stable for use in high speed machinery (180 pieces per minute). This bond is reversible if the same heat is applied to the material, and will become liquid again.
- the hot melt glue used in paper cups has a melting point of about 130 degrees Celsius. Although this melting point is much higher than liquid coffee/tea at a maximum of about 95 degrees Celsius, the glue does start to soften even at these temperatures. Even though the hot melt glue appears solid at about 70 - 80 degrees Celsius, the bonds are significantly weakened to the point where slight external pressure can break them. However, since even the most accurate hot melt gluing systems have a margin of error of 3 mm, using a hot melt gluing system to mass produce the conventional cup of Figure 2 may be difficult. For example, it may be difficult to accurately apply a sufficient volume of glue to the top curl 203 to ensure a secure attachment to the inner cup 200.
- the cold glue process is a less accurate method of gluing when compared to the hot glue process. This process relies on using centripetal force from a spinning wheel to apply a "splash" of glue around the inside of a sleeve before contact with an inner cup.
- a cold glue process may be used to apply glue to the top section 103 of Figure 1 before sliding the outer sleeve 101 onto the inner cup 100.
- Cold glue is very inexpensive which is advantageous as it may be liberally applied to the outer sleeve before contact with the inner cup.
- a significant amount of the cold glue may be required to keep the outer sleeve attached to the inner cup while the manufacturing process is being completed. For example, counting, moving, packing etc. of the double-walled cups may be performed whilst the cold glue is drying. However, once dry in about 10-15 minutes, the cold glue provides a very secure bond. The bond created is not affected by heat or external environmental factors in any significant way. In order to remove the outer sleeve from the inner cup, it may be necessary to tear the manufactured double-walled cup apart.
- the double-walled cup of Figure 1 may have more than 10 mm of contact area at the top section 103. It may be necessary to add a drying time pause in the manufacturing process to ensure the glue has sufficiently dried before continuing with a subsequent step of the process. It will be appreciated that such a pause in the manufacturing process is not desirable as it would greatly decrease the manufacturing output.
- the glue used in this process is extremely accurate and very fast setting. There are no issues with accurately applying hot melt glue. Furthermore, the fact that hot melt glue sets relatively quickly means there is little chance of an outer sleeve becoming separated from an inner cup during any subsequent steps of the manufacturing process. Specifically, once the outer sleeve is glued to the inner cup using the hot melt process a robust connection is quickly established and maintained between the outer sleeve and the inner cup.
- Hot melt glue has a melting point of about 130 degrees Celsius which is significantly above the boiling point of water.
- the glue bonds created by the hot glue process start to melt and soften.
- Such melting transforms a seemingly indestructible outer sleeve inner cup connection to a less secure connection. It is very possible that the outer sleeve may detach from the inner cup under such circumstances. That is, if force is applied to pull the outer sleeve away from the inner cup, it is possible to detach the outer sleeve from the inner cup.
- the use of a hot melt process to attach the outer sleeve to the inner cup has inherent problems.
- One way to overcome the structural stability problems associated with a hot melt process is to increase the volume of glue used to create a connection between the outer sleeve and the inner cup.
- the use of an increased volume of hot glue ensures that even if the glue softens while the double-walled cup is holding a hot beverage, the connection is still sufficient to securely hold the outer sleeve to the inner cup.
- the hot glue may be up to ten times the cost of cold glue, which greatly increases the manufacturing cost. The following table outlines the advantages and disadvantages of the cold and hot glue processes.
- the minimal contact area between the top curl 203 and the inner cup 200 may lead to further issues.
- the glued or contact area between the inner cup 200 and outer sleeve 201 would be only about 1 mm wide. This area may be too small to provide a robust connection between the inner cup 200 and the outer sleeve 201 . Such a connection may lead to the outer sleeve 201 becoming detached from the inner cup 200 whilst in use.
- a further drawback of the double-walled cup of Figure 2 is that secure attachment of a lid to the cup may be compromised by the provision of the top curl 203.
- a lid slips over the lip 204 of the cup and is snap-fitted in place under the lip 204. Specifically, as the lid is pushed over the lip 204, it deforms to a slightly larger diameter and once past the lip 204, returns or snaps back to its original diameter.
- the lip 204 may be formed from a rolled or curled section of the inner cup 200. However, the ability of the lid to return to its original diameter is inhibited by the top curl 203 adjacent to the lip 204 of the double-walled cup.
- the lip 204 is generally curled the same way as the top curl 203 on the outer sleeve 201 is always curled as much as possible. Therefore, although the top curl 203 of Figure 2 is shown as being much smaller than the lip 204, in practice both will likely be of very similar size. This may lead to a significant impact on the capability of the lip 204 to securely retain the lid.
- a double-walled paper cup as detailed in claim 1 .
- a method of manufacturing a double-walled paper cup is provided in claim 18.
- a double-walled paper cup according to claim 46 is provided in the dependent claims.
- Figure 1 is a side view of a conventional double-walled cup
- Figure 2 is a side view of a another conventional double-walled cup
- Figure 3 is a side view of a double-walled cup in accordance with an embodiment of the present disclosure
- Figure 4 is a flow diagram illustrating a method of manufacturing a double- walled cup, in accordance with an embodiment of the present disclosure
- Figure 5 is a flow diagram illustrating a method of manufacturing a double- walled cup, in accordance with an embodiment of the present disclosure.
- Figure 6 is a flow diagram illustrating a more detailed method of manufacturing a double-walled cup, in accordance with an embodiment of the present disclosure.
- the present disclosure provides a double-walled paper cup comprising: an inner cup; and an outer sleeve configured to circumferentially envelop the inner cup and to be attached at top and bottom circumferential edges thereof to the inner cup; wherein the top edge of the outer sleeve is folded inwards on itself to form a contact strip for attachment to a portion of the inner cup adjacent to a lip of the inner cup, the contact strip defining a gap between the inner cup and outer sleeve.
- the present disclosure achieves inproved heat insulation by defining an air gap between the inner cup and outer sleeve. This is achieved by using a fold system on the outer sleeve to define the air gap.
- the bottom edge of the outer sleeve may also be configured to provide a gap between the outer sleeve and the inner cup at the bottom of the cup as is known in the art.
- the top edge of the outer sleeve is folded inwardly on itself to define a gap between the outer sleeve and the inner cup at the top of the cup. In this manner a continuous gap is created between the inner cup and outer sleeve from the bottom to the top of the outer sleeve.
- the contact strip formed by folding the top edge of the outer sleeve inwardly on itself forms a sufficient area for securely attaching the outer sleeve to the inner cup.
- the continous gap reduces heat transfer from the inner cup to the outer sleeve and reduces the possibility of scalding especially when boiling water is held within the cup.
- the top edge of the outer sleeve is the portion of the outer sleeve that is adjacent to the lip of the inner cup
- the bottom edge of the outer sleeve is the portion of the outer sleeve that is adjacent to the base of the inner cup.
- the double-walled cup comprises an outer sleeve 301 circumferentially enveloping an inner cup 300.
- the inner cup 300 comprises a lip 304.
- the double-walled cup may have a frusto-conical shape having an increasing diameter from the bottom towards the top.
- Each of the outer sleeve 301 and inner cup 300 may be constructed from any suitable paper or cardboard. It will be understood that the term 'double-walled paper cup' in the context of the present disclosure is intended to comprise any suitable paper or cardboard.
- the paper or cardboard may be coated with either PE (polyethylene) or PLA (polyatic acid).
- a bottom curl 302 may be provided at a bottom edge of the outer sleeve 301 .
- the bottom curl 302 acts as a spacer to create an air gap between the planar region of the outer sleeve 301 and the inner cup 300.
- the gap formed at the bottom of the cup between the outer sleeve 301 and inner cup 300 may be at least 3 mm in width.
- an air gap is similar to the use of an insulating material. If an air gap is created between two layers, the air trapped between the two layers, air being a poor conductor of heat, acts as a barrier to heat transfer. Heat is transferred across an air space by a combination of conduction, convection and radiation. Heat transfer from a liquid held within the inner cup 300 to the outer sleeve 301 is primarily a result of conduction. As is known to those skilled in the art, heat transfer by conduction is inversely proportional to the width of the air gap. The width and uniformity of the air gap is a very important design parameter that governs its effectiveness by controlling the heat transfer coefficient as in the case of insulation.
- a contact strip 303 is provided at the top edge of the outer sleeve 301 .
- the contact strip 303 may be formed by folding the top edge of the outer sleeve 301 inwards on itself. That is, the top edge of the outer sleeve 301 may be folded onto an inner surface of the outer sleeve 301 to form the contact strip 303. . Accordingly, it will be appreciated that the contact strip 303 has a thickness that is at least double the thickness of the outer sleeve 301 .
- the inwardly folded top edge of the outer sleeve 301 may be attached to the inner surface of the outer sleeve 301 by adhesive such as glue or any other suitable means.
- an approximately 5 mm portion of the top edge of the outer sleeve 301 may be folded to create the contact strip 303.
- the portion of the top edge of the outer sleeve 301 that is folded substantially constitutes the width of the contact strip 303.
- the width of the contact strip 303 refers to the axial distance by which the top edge of the outer sleeve 301 is folded.
- the outer sleeve 301 is thus configured to be attached to the inner cup 300 along the contact strip 303. Such a configuration allows for the outer sleeve 301 to be attached to the inner cup 300 along the entire width of the contact strip 303.
- the contact strip 303 acts as a spacer between the outer sleeve 301 and the inner cup 300. It will be understood that the spacer is effectively the thickness of the outer sleeve 301 .
- the spacer creates an air gap between the outer sleeve 301 and the inner cup 300 at the top of the outer sleeve 301 , the air gap being substantially equal to the thickness of the outer sleeve 301 .
- the outer sleeve 301 may have a uniform thickness. In one embodiment, the thickness of the outer sleeve 301 may be about 1 mm. Thus, the air gap formed may also be about 1 mm in width.
- the air gap may decrease from the bottom curl 302 to the contact strip 303. Nonetheless, it is the provision of a continuous air gap between the outer sleeve 301 and the inner cup 300 that provides heat insulating properties.
- the contact strip 303 of the present disclosure does not affect the ability of the lip 304 to hold a lid in place.
- the contact strip 303 may be formed by folding a portion or strip at the top of the outer sleeve 301 inwards such that the strip is co-planar with the inner surface of the outer sleeve 301 . Therefore the outer sleeve 301 is separated from the inner cup 300 by a distance of at least the thickness of the outer sleeve 301 . The thickness of the lip 304 is thus only reduced by approximately the thickness of the contact strip 303, which in one embodiment is about 1 mm.
- the lip 304 may have a thickness of about 5 or 6 mm, this is a minimal impact on the size and therefore functionality of the lip 304.
- the lip 304 of the double-walled cup is configured to securely hold a lid in place.
- the contact strip 303 of the double-walled cup of the present invention provides a sufficiently large contact area between the outer sleeve 301 and the inner cup 300 to provide a secure attachment therebetween.
- the contact strip 303 provides a co-planar contact area between the inner cup 300 and the outer sleeve 301 .
- the contact strip 303 provides a contact area in the form of a strip that extends around the circumference of the outer sleeve 301 .
- the total contact area between the outer sleeve 301 and the inner cup 300 may be the width of the contact strip 303 multiplied by the circumference of the contact strip 303.
- the width of the contact strip 303 may be approximately 5 mm or less.
- the contact area provided by the contact strip 303 in accordance with an exemplary arrangement of the present disclosure provides ample room for attachment of the outer sleeve 301 to the inner cup 300.
- the margin of error for a hot melt process is generally only 3 mm.
- provision of a strip attachment means allows for a sufficient bonding area between the surface of the inner cup 300 and the outer sleeve 301 to keep the bond stable under normal use. That is, the contact area or strip is configured to ensure that a secure bond may be achieved between the outer sleeve 301 and the inner cup 300.
- the double-walled paper cup of the present disclosure may be manufactured using either a hot or cold glue process. However, it has been found that a process that involves a combination of both hot and cold gluing processes provides optimal results.
- a method of manufacturing a double-walled paper cup comprises: forming an inner cup; forming an outer sleeve configured to circumferentially envelop the inner cup, comprising folding a top edge of the outer sleeve inwards on itself to form a contact strip for attachment to a portion of the inner cup adjacent to a lip of the inner cup, the contact strip defining a gap between the inner cup and outer sleeve; and attaching the outer sleeve at top and bottom circumferential edges thereof to the inner cup.
- Figure 4 is a flow diagram illustrating a method 400 of manufacturing a double-walled cup, in accordance with an embodiment of the present disclosure.
- the method 400 includes forming an inner cup 401 ; forming an outer sleeve configured to circumferentially envelop the inner cup 402, comprising folding a top edge of the outer sleeve inwards on itself to form a contact strip for attachment to a portion of the inner cup adjacent to a lip of the inner cup, the contact strip defining a gap between the inner cup and outer sleeve; and attaching the outer sleeve at top and bottom circumferential edges thereof to the inner cup 403.
- the inventors have found that using a two-stage gluing process involving both cold glue and hot melt glue provides optimal results in manufacturing such double-walled paper cups. Such a two stage process relies on using two gluing stations in the manufacturing process where both cold glue and hot melt processes are performed, respectfully.
- the hot melt glue securely holds the outer sleeve to the inner cup during the manufacturing process and ensures a stable connection whilst manufacturing. Furthermore, the use of cold glue ensures an extremely robust connection during use of the double-walled cup, i.e., while the double-walled cup is holding a hot beverage.
- Figure 5 is a flowchart illustrating a method 500 of manufacturing a double- walled paper cup, in accordance with an embodiment of the present disclosure.
- the process may be used to manufacture the double-walled cup as illustrated in Figure 3.
- the method of manufacturing the double-walled paper cup according to the present embodiment comprises using a cold glue process and a hot melt glue process to attach the outer sleeve and the inner cup together.
- the method may include applying the cold glue to the contact strip of the outer sleeve before the hot melt glue.
- the method may comprise inserting the inner cup into the outer sleeve so as to attach the outer sleeve and the inner cup together.
- the method 500 of manufacturing the double-walled paper cup of the present disclosure may include forming the outer sleeve 501 , applying cold glue to the contact strip of the outer sleeve 502, applying hot melt glue to the contact strip of the outer sleeve 503, positioning the outer sleeve and the inner cup in relation to each other 504, and attaching the outer sleeve and the inner cup together 505.
- the first step may involve formation of the outer sleeve 501 .
- the outer sleeve may be formed from a printed flat or blank.
- the sleeve may be manufactured by folding or curling a blank and gluing two ends of the blank together to form an outer sleeve having a frusto-conical shape as illustrated in Figure 3.
- the outer sleeve may then be transferred to a first turntable for further processing.
- a bottom curl may be formed at the bottom of the outer sleeve. That is, a bottom curl may be formed at the end of the outer sleeve that has the smaller diameter.
- the formation of a curl in the outer sleeve requires at least two stages. The next stage of the bottom curl formation involves tightening the bottom curl.
- a curl may be formed in the outer sleeve by performing at least two curling stages and in addition clamping the outer sleeve in different ways during the different curling stages.
- the aim is to prevent the buckling of the outer sleeve wall during the curling stages such that the outer sleeve is clamped during the different curling stages in each case just below the upper rim of the cup sleeve or the already partially completed top curl. Due to this repeated clamping, the top curl may be dependably shaped without any fear of bulging or buckling of the outer sleeve.
- the step of forming the outer sleeve 501 may include formation of the contact strip on the outer sleeve. Unlike the bottom curl, the contact strip may be formed in one step. The outer sleeve may be held securely just below the top of the outer sleeve to prevent buckling. A uniform strip or section of the outer sleeve may then be folded inwards as described above to form the contact strip.
- the outer sleeve may be transferred to a second turntable and a silicone coating may be applied to the outer sleeve.
- the method for applying the silicone coating may be chosen as appropriate by those skilled in the art.
- the purpose of the silicone coating is to lubricate the paper before curling so as to prevent scraping or marking.
- the silicone coating also helps to form the lip as there are spinning wheels used to fold and curl lips.
- the silicone acts as a lubricant so the paper can be formed without damaging the surface of the print and the paper.
- the gluing process may comprise the application of cold glue first 502 and then hot melt glue 503 due to the extremely short setting time of the hot melt glue.
- cold glue may be applied to at last a portion of the contact strip 502.
- a cold glue process known to those skilled in the art may be used to apply cold glue to the contact strip on the inner surface or inner circumference of the outer sleeve.
- the cold glue may not be applied to the entire area of the contact strip. Rather, cold glue may be applied to the contact strip of the outer sleeve so as to form at least one discontinuous portion of cold glue on the contact strip. In this regard, multiple spots of cold glue may be applied at regular intervals to the contact strip.
- hot melt glue process performed after the cold melt process hot melt glue may be applied to at least a portion of the contact strip not covered with cold glue.
- a glue gun may be used to apply two spots of cold glue in total to the contact strip.
- the spots of cold glue may be applied directly opposite each other i.e., at 180 degrees to each other along the circumference of the outer sleeve.
- Two spots of hot melt glue may be subsequently applied to the contact strip at opposite sides thereof. In this manner, all four spots of glue are spaced evenly apart on the contact strip. Specifically in this example, each spot of glue may be separated by 90 degrees on the circumference of the outer sleeve.
- Each of the spots of cold glue may be approximately 2 mm x 4 mm in size.
- a discontinuous series of cold glue portions may be formed on the contact strip 303.
- two spots of cold glue may be applied and a blank space, approximately equal to the area of the two spots, left before the application of two more spots of glue.
- the contact strip may have cold glue applied to about 50% of its area. The remaining area is left with no portions of cold glue.
- the use of two spots of cold glue should not be considered limiting; a single spot of cold glue may be applied and a space (approximately the same size of the glued area) may be left before application of another spot of cold glue.
- cold glue may be applied to a larger continuous area of the contact strip.
- hot melt glue may be applied to the inner surface of the contact strip using a hot melt process 503.
- the hot melt glue may be applied to the remaining portions of the contact strip not covered with cold glue.
- one or more spots of hot melt glue may be applied to the inner surface of the contact strip.
- the contact strip may have glue applied to substantially all portions thereof, e.g., alternating areas of hot melt glue and cold melt glue.
- Each of the spots of hot melt glue may be approximately 2 mm x 4 mm in size.
- cold glue may be applied first 502 and then hot melt glue 503 due to the extremely short setting time of hot melt glue.
- the outer sleeve should be attached to the inner cup as soon as possible after application of the hot melt glue thereto. Otherwise, if the hot melt glue is applied to the contact strip first (before the cold glue), the hot melt glue may have already dried by the time the time the outer sleeve comes in contact with the inner cup. Furthermore, due to the rapid drying of the hot melt glue, it is important that the application of the hot melt glue may be the last step in the manufacturing step before the outer sleeve comes into contact with the inner cup.
- only cold glue may be applied to the inner surface of the contact strip of the outer sleeve. That is, the cold glue process may comprise applying cold glue around at least a portion of the inner surface of the contact strip as described above. In this regard, one or more spots of cold glue may be applied to the contact strip. In another embodiment, multiple spots of cold glue may be applied at regular intervals to the contact strip. The method may alternatively comprise applying cold glue continuously along the contact strip.
- the next step in the process may be positioning the outer sleeve and inner cup in relation to each other 504.
- the inner cup may be manufactured using a separate process and provided to the aforementioned second turntable as needed.
- the inner cup may be inserted into the outer sleeve. It will be understood that due to the outer sleeve having a frusto-conical shape having an increasing diameter from the bottom towards the top, the inner cup may be effectively inserted into only one end of the outer sleeve, namely the end with the greatest diameter.
- the insertion of the inner cup into the outer sleeve may comprise inserting the base portion of the cup through the end of the outer sleeve with the greatest diameter until both ends of the outer sleeve fit around the inner cup.
- the insertion of the inner cup into the outer sleeve may comprise a downward motion.
- the outer sleeve circumferentially envelops the inner cup.
- the next step in the manufacturing method comprises attaching the outer sleeve to the inner cup 505. This step may involve pressing the contact strip firmly against the outer wall of the inner cup 505. This ensures that a continuous contact is achieved at all points. A roller device may be used to achieve this.
- pressure may be applied to the inner wall of the inner cup to oppose a corresponding force applied to the contact strip.
- the bottom curl of the outer sleeve may also be attached to the inner cup.
- the bottom curl of the outer sleeve may be attached to the inner cup using a hot melt glue process.
- hot melt glue may be applied to the bottom circumferential portion of the inner cup.
- the glue is placed on the bottom circumferential portion of the outer sleeve first before the inner cup is pushed down. At the base of the cup this has the potential to cause cosmetic problems as the glue tends to be pushed down past the bottom curl as the inner cup pushes through.
- hot melt glue may be applied to the inner cup before it is inserted into the outer sleeve. This has the effect of pushing the glue up rather than away from the visible portion of the base of the cup, preventing cosmetic damage.
- one or more spots of hot melt glue may be applied to the bottom circumferential portion of the inner cup corresponding to the bottom curl of the outer sleeve.
- Each of the one or more spots may be approximately 2 mm x 4 mm in size.
- the one or more spots may be applied at different positions on the bottom circumferential portion of the inner cup.
- two spots of hot melt glue may be applied at different positions on the bottom circumferential portion of the inner cup.
- two spots of hot melt glue may be applied at positions 180 degrees apart on the bottom circumferential portion of the inner cup.
- the one or more spots of hot melt glue spread upon contact with the outer sleeve.
- the mechanism for attaching the bottom curl of the outer sleeve to the inner cup strengthens the bond. This ensures that a strong bond is formed between the outer sleeve and inner cup.
- the paper configuration is not strong enough to ensure that the outer sleeve stays glued whilst downward pressure is applied as the inner cup is pushed downward. This is because the paper simply unravels at the contact strip, tearing very easily. This is not a problem related to the glue, but is caused because the paper is made in layers and can be easily separated if pressure in the right direction is applied.
- the application of hot melt glue on the inner cup means the paper does not unravel and the outer sleeve is secured to the inner cup no matter what downward pressure.
- the process of manufacture is configured so that the hot melt glue is applied to the inner cup before being inserted into the outer sleeve. In this manner, glue is prevented from reaching below the bottom curl.
- the hot melt glue may be applied to the inner cup before being transferred to a joining station where it is inserted into the outer sleeve.
- the rate of application of hot melt glue to inner cups may be 180 cups per minute. Thus, the hot melt glue does not have time to cool before being inserted into the outer sleeve.
- the gluing process comprises a cold glue process and a hot melt glue process.
- cold glue and hot melt glue may be applied to the contact strip of the outer sleeve in order to attach the contact strip of the outer sleeve to the inner cup.
- hot melt glue may not be applied to the contact strip at all.
- the bottom curl of the outer sleeve may be attached to the inner cup using a hot melt glue process as described above.
- the final step in the method may be the ejection of the completed double- walled cup for further processing such as packaging, etc.
- the above method may take place on a single "double-walling" machine having two turntables.
- Such a machine may be configured to carry out all of the steps described above and shown in Figure 5.
- a second outer sleeve may be supplied to the first turntable. In this way, a continuous and rapid method of manufacturing the double-walled cups can be ensured.
- FIG. 6 is a flow diagram illustrating a more detailed method 600 of manufacturing a double-walled cup, in accordance with an embodiment of the present disclosure.
- the process 600 comprises the outer sleeve formation 601 , transfer of the outer sleeve to a first turntable for further processing 602, formation of a bottom curl 603, tightening of the bottom curl 604, creation of the contact strip 605, transfer of the outer sleeve to a second turntable 606, silicone application to the outer sleeve 607, cold glue application 608, hot melt glue application 609, attachment of inner cup and outer sleeve 610, pressing the outer wall and inner cup together 61 1 , and ejection 612.
- the gluing process involving both the application of hot and cold glue is critical to the manufacturing process.
- cold glue and hot melt glue in this order, a rapid connection is established ensuring a continuous manufacturing process while also ensuring the long term structural integrity of the double- walled cup.
- hot melt glue to the bottom circumferential portion of the inner cup before the inner cup is inserted into the outer sleeve, the outer sleeve can be secured to the inner cup irrespective of downward pressure and glue is prevented from reaching below the bottom curl.
- hot melt glue may not be applied to the contact strip at all.
- the present disclosure also provides a double-walled paper cup which is manufactured using any of the above-described processes. That is, the present disclosure provides a double-walled paper cup which is manufactured using a cold glue process and a hot melt glue process. Both cold glue and hot melt glue may be applied to a contact strip of the outer sleeve in order to attach the contact strip of the outer sleeve to the inner cup. Alternatively, only cold glue may be applied to the contact strip of the outer sleeve in order to attach the contact strip of the outer sleeve to the inner cup. That is, hot melt glue may not be applied to the contact strip at all. A bottom curl of the outer sleeve may be attached to the inner cup using a hot melt glue process as described above.
- the words comprises/comprising when used in this specification are to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers , steps, components or groups thereof.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Making Paper Articles (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1418161.4A GB2531277A (en) | 2014-10-14 | 2014-10-14 | Double-walled paper cup and method of manufacture thereof |
PCT/EP2015/073774 WO2016059111A1 (en) | 2014-10-14 | 2015-10-14 | Double-walled paper cup and method of manufacture thereof |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3206958A1 true EP3206958A1 (en) | 2017-08-23 |
EP3206958B1 EP3206958B1 (en) | 2019-11-06 |
Family
ID=52001386
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP15778987.6A Active EP3206958B1 (en) | 2014-10-14 | 2015-10-14 | Double-walled paper cup and method of manufacture thereof |
Country Status (4)
Country | Link |
---|---|
US (1) | US20170233166A1 (en) |
EP (1) | EP3206958B1 (en) |
GB (1) | GB2531277A (en) |
WO (1) | WO2016059111A1 (en) |
Families Citing this family (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN112046888A (en) * | 2020-10-01 | 2020-12-08 | 湖北克拉弗特实业有限公司 | Paper-plastic cup |
EP4029413A1 (en) | 2021-01-16 | 2022-07-20 | Nilofer Christensen | Single use coffee cup with seed paper |
Family Cites Families (29)
Publication number | Priority date | Publication date | Assignee | Title |
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US1771765A (en) * | 1925-01-24 | 1930-07-29 | Kalix Cup Company | Waterproof paper receptacle |
DE2642046C3 (en) * | 1976-09-18 | 1982-12-23 | Kronseder, Hermann, 8404 Wörth | Labeling device for vessels |
US5988493A (en) * | 1998-04-06 | 1999-11-23 | Sonoco Development, Inc. | Composite container for vacuum packaging of products |
DE19840841B4 (en) * | 1998-09-07 | 2007-02-08 | Michael Hörauf Maschinenfabrik GmbH & Co. KG | Heat-insulating mug |
TW504479B (en) * | 1998-09-30 | 2002-10-01 | Dainippon Printing Co Ltd | Heat insulating container |
JP3773366B2 (en) * | 1998-10-30 | 2006-05-10 | 大日本印刷株式会社 | Heat insulating container |
JP2000177724A (en) * | 1998-10-09 | 2000-06-27 | Dainippon Printing Co Ltd | Heat-insulating paper cup |
US6085970A (en) | 1998-11-30 | 2000-07-11 | Insulair, Inc. | Insulated cup and method of manufacture |
ES2222327T3 (en) * | 2001-01-30 | 2005-02-01 | Seda S.P.A. | DOUBLE WALL CONTAINER. |
US9630740B2 (en) * | 2004-04-06 | 2017-04-25 | Wm. Wrigley Jr. Company | Comestible product dispensers and methods of making and using same |
US9168714B2 (en) * | 2005-06-30 | 2015-10-27 | Dixie Consumer Products Llc | Methods for making paperboard blanks and paperboard products therefrom |
SI1785370T2 (en) * | 2005-11-11 | 2014-05-30 | Seda S.P.A. | Insulated cup |
DE102007030864A1 (en) * | 2006-07-17 | 2008-01-24 | Ptm Packaging Tools Machinery Pte.Ltd. | Paper beaker has an outer roll at the mouth, higher than the base structure, to reduce stress when inserted into each other for stacking |
WO2008009371A1 (en) * | 2006-07-17 | 2008-01-24 | Ptm Packaging Tools Machinery Pte. Ltd. | Method and device for the production of a cup |
US20080128481A1 (en) | 2006-12-05 | 2008-06-05 | Robertson Ronald D | Stackable storage container with insulating sleeve |
CN201099401Y (en) * | 2007-08-27 | 2008-08-13 | 李美香 | Scald-proof paper container |
JP5256709B2 (en) * | 2007-11-28 | 2013-08-07 | 凸版印刷株式会社 | Insulated container |
DE102008014878A1 (en) * | 2008-03-12 | 2009-09-17 | Ptm Packaging Tools Machinery Pte.Ltd. | Double-walled cup |
AT506750B1 (en) * | 2008-04-24 | 2011-02-15 | Rundpack Ag | METHOD FOR PRODUCING A COMBINED PACKAGING CONTAINER AND A COATED EXTERNAL PART |
JP2009286402A (en) * | 2008-05-27 | 2009-12-10 | Toppan Printing Co Ltd | Heat insulating cup |
DE102008026984A1 (en) * | 2008-05-28 | 2009-12-03 | Ptm Packaging Tools Machinery Pte.Ltd. | Outer jacket for a double-walled cup and method of manufacture |
GB2467099A (en) * | 2008-11-12 | 2010-07-21 | Chesapeake Plc | Method of making a tubular container |
CN201398774Y (en) * | 2009-04-10 | 2010-02-10 | 黄文聪 | Disposable paper plastic vacuum cup |
US20120000923A1 (en) * | 2010-07-02 | 2012-01-05 | Wade Antoine Powell | Rapid-flow and smooth-spouted container lid |
FR2972958B1 (en) * | 2011-03-25 | 2014-06-13 | Marie Claude Dropsy | METHOD FOR MANUFACTURING A BI-COMPONENT TRAY |
US20140061215A1 (en) * | 2011-05-05 | 2014-03-06 | Rich Cup Bio-Chemical Technology Co., Ltd. | Lid |
JP5889024B2 (en) | 2012-02-07 | 2016-03-22 | 東罐興業株式会社 | Container and container manufacturing method |
US20150108146A1 (en) * | 2013-10-22 | 2015-04-23 | Meadwestvaco Corporation | Beverage Container |
DE102014211275A1 (en) * | 2014-06-12 | 2015-12-17 | Ptm Packaging Tools Machinery Pte. Ltd. | Cup and method of making a cup |
-
2014
- 2014-10-14 GB GB1418161.4A patent/GB2531277A/en not_active Withdrawn
-
2015
- 2015-10-14 EP EP15778987.6A patent/EP3206958B1/en active Active
- 2015-10-14 WO PCT/EP2015/073774 patent/WO2016059111A1/en active Application Filing
- 2015-10-14 US US15/519,026 patent/US20170233166A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
GB2531277A (en) | 2016-04-20 |
EP3206958B1 (en) | 2019-11-06 |
GB201418161D0 (en) | 2014-11-26 |
US20170233166A1 (en) | 2017-08-17 |
WO2016059111A1 (en) | 2016-04-21 |
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