Reusable cup

Abstract

The present invention relates to a reusable cup comprising a cup body formed from a liquid impervious, flexible material, the cup having an upper portion, a middle portion and a base portion, and having foldable pre-forms arranged so as to define at least a first folding hinge around a first circumferential location interposed between the middle portion and the upper portion, and a second folding hinge around a second circumferential location, separate from the first circumferential location, interposed between the base portion and the middle portion, an outer peripheral band is formed around the middle portion of the cup to provide a central band, wherein the cup body is foldable into itself, at the circumferential locations, so as to adopt a nested, concentric form.

Claims

1. A reusable cup comprising: a cup body formed from a liquid impervious, flexible material, the cup body including an upper portion, a middle portion and a base portion and has foldable pre-forms arranged so as to define at least: a first folding hinge around a first circumferential location interposed between the middle portion and the upper portion, and a second folding hinge around a second circumferential location, separate from the first circumferential location, interposed between the base portion and the middle portion; and an outer peripheral band formed around the middle portion of the cup body to provide a central band; wherein the central band has at least one of indentations, undulations and crenellations formed thereon so as to provide thermal insulation; the cup body is foldable into itself, at the first circumferential location to adopt a first, partially nested, concentric form, or at the second circumferential location to adopt a second, partially nested, concentric form, or at both the first circumferential location and the second circumferential location to adopt a third, nested, concentric form, to provide any of at least three different deployed functional forms, each of the three different deployed functional forms having a different functional capacity of the cup; and the cup has a fourth, fully nested, concentric form for storage.

2. The reusable cup according to claim 1 wherein: the base portion of the cup body folds up and into the middle portion of the cup, and the top portion of the cup body folds over an exterior of the middle portion of the cup body.

3. The reusable cup according to claim 1 wherein when the cup is folded the cup body is folded back on itself so that in cross section an S-form is defined at each of the first folding hinge and the second folding hinge.

4. The reusable cup according to claim 1, further comprising: frusto conical sections between the top portion and the middle portion of the cup body, and between the middle portion and the base portion of the cup body.

5. The reusable cup according to claim 1 wherein an inner surface of the central band has a relieved form or pattern produced thereon in order to improve insulation.

6. The reusable cup according to claim 1 further comprising a plurality of grooves formed on the central band at depths of at least 1 mm and with a minimum spacing of 0.6 mm.

7. The reusable cup according to claim 1 further comprising a lower outer peripheral band formed around the base portion of the cup.

8. The reusable cup according to claim 7 wherein the lower outer peripheral band includes a stand.

9. The reusable cup according to claim 8 further comprising a lip formed around the stand which provides a larger footprint for stability.

10. The reusable cup according to claim 1 further comprising an upper outer peripheral band formed around the upper portion of the cup.

11. The reusable cup according to claim 10 wherein the upper outer peripheral band defines a surface and a perimeter on which and around which a lid fits.

12. The reusable cup according to claim 10 further comprising an external thread formed on the upper outer peripheral band.

13. The reusable cup according to claim 10 wherein an excess liquid impervious, flexible material is provided around an upper periphery of the cup between the upper outer peripheral band and the cup body of the flexible material and provides a surface against which a lid may abut to seal the cup.

14. The reusable cup according to claim 1 wherein the liquid impervious, flexible material has a Shore hardness in excess of 20 Shore A.

15. The reusable cup according to claim 1 wherein a thickness of the liquid, impervious flexible material is between 1 mm and 2 mm.

16. The reusable cup according to claim 1 wherein a Shore hardness of the central band is between 50 Shore D and 70 Shore D.

17. The reusable cup according to claim 1 wherein a thickness of the central band is between 0.1 and 0.3 mm.

18. The reusable cup according to claim 1 wherein a width of the central band is between 15 mm and 70 mm.

19. The reusable cup according to claim 1 wherein a radius of the cup at the central band is between 18 mm and 34 mm.

20. The reusable cup according to claim 1 wherein the central band is adapted to act as a guide for the upper portion of flexible impervious material to fold against.

21. The reusable cup according to claim 1 wherein respective capacities of the at least three different deployed functional forms are 175 ml, 300 ml and 475 ml.

22. The reusable cup according to claim 1 further comprising a lid with a threaded portion.

23. The reusable cup according to claim 1 wherein the liquid impervious, flexible material is a thermoplastic elastomer.

24. The reusable cup according to claim 23 wherein the thermoplastic elastomer is a styrene-ethylene-butadiene-styrene (SEBS) based thermoplastic elastomer or silicone.

25. The reusable cup according to claim 1 wherein the outer peripheral band is formed from polypropylene or glass filled thermoplastic or thermo set plastics.

26. The reusable cup according to claim 1 further comprising: a lid, wherein the lid has a positive engagement means which engages when the lid is sealed around the cup.

27. The reusable cup according to claim 26, wherein the lid further has a threaded portion so that is can be screwed onto a thread defined in an upper peripheral band formed around the upper portion of the cup.

28. The reusable cup according to claim 26 wherein the lid further has a tab or stopper which opens.

29. The reusable cup according to claim 28 further comprising an air pressure hole.

30. A reusable cup according to claim 28 wherein the stopper clicks into place to spread rubber material under pressure against a drinking aperture.

31. A reusable cup according to claim 30 wherein the stopper is hinged so that when open it is held back.

32. A reusable cup according to claim 28 wherein the stopper has a soft rubber component, with a substantially rectangular cross section, disposed around an edge which compresses against a drinking aperture forming a spill-proof seal.

33. A reusable cup according to claim 30 wherein the lid is raised slightly at the drinking point for directing liquid to the user's mouth.

34. The reusable cup according to claim 28 further comprising a slot located proximal to an interior wall of the cup so as to ensure that all contents of the cup can be consumed by minimizing residue retained in the cup.

35. The reusable cup according to claim 28 further comprising a clip provided on the lid so as to engage with an exterior of the lid.

36. The reusable cup according to claim 1 further comprising an RFID chip.

37. A method of manufacturing the reusable cup according to claim 11 comprising the steps of: introducing a flexible rubber into a cavity injection mold, receiving a molded cup body, the cup body has three peripheral sections or bands which are bonded to the cup body at regions that are connected by tapering portions of the cup body.

38. A method of manufacturing the reusable cup according to claim 1 wherein peripheral sections or relatively rigid bands are bonded to an outer surface of the cup body.

39. A method of manufacturing the reusable cup according to claim 1 wherein a blowing agent is introduced into one or more polyurethane band(s) so as to improve its thermal insulating properties.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 shows a sectional view of a first embodiment of the cup in a fully deployed configuration;

(2) FIG. 2 shows a sectional view of the first embodiment of the cup in a partially collapsed configuration with the upper and lower folding hinges partially folded;

(3) FIG. 3 shows a sectional view of the first embodiment of the cup in a partially collapsed configuration with the upper folding hinge partially folded and the lower folding hinge deployed;

(4) FIG. 4 shows a sectional view of the first embodiment of the cup in a fully collapsed configuration with the upper and lower folding hinges fully collapsed;

(5) FIG. 5 is a sectional view of the first embodiment cup in a fully collapsed configuration showing only lid and peripheral bands;

(6) FIG. 6 is a sectional view through the lid for the first embodiment of the cup;

(7) FIGS. 7a and 7b show above plan and under plan views of the lid for the first embodiment of the cup;

(8) FIG. 8a shows an above view of a lid for a second embodiment of the cup with the stopper open;

(9) FIG. 8b shows a below view of the lid for the second embodiment of the cup;

(10) FIG. 9 shows a plurality of the cups of the second embodiment in the fully collapsed configuration stacked on top of each other;

(11) FIG. 10 shows an above view of the lid for the second embodiment of the cup with the stopper closed;

(12) FIG. 11 shows a side view of the second embodiment of the cup in a fully deployed configuration;

(13) FIG. 12 shows a side view of the second embodiment of the cup in a partially collapsed configuration with the upper folding hinge partially collapsed and the lower folding hinge deployed;

(14) FIG. 13 shows a side view of the second embodiment of the cup in a partially collapsed configuration with the upper and lower folding hinges partially collapsed;

(15) FIG. 14 shows a side view of the second embodiment of the cup in a fully collapsed configuration with the upper and lower folding hinges fully collapsed;

(16) FIG. 15 shows an overall view of the second embodiment of the cup in a fully deployed configuration;

(17) FIG. 16 shows an overall view of the second embodiment of the cup without the lid in a partially collapsed configuration with the upper folding hinge collapsed and the lower folding hinge deployed;

(18) FIG. 17 shows an overall view of the second embodiment of the cup without the lid in a partially collapsed configuration with the upper folding hinge deployed and the lower folding hinge collapsed; and

(19) FIG. 18 shows a section view of the second embodiment of the cup.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION

(20) Referring to the Figures generally there are shown two embodiments of a reusable cup 10. FIGS. 1 to 7 show the first embodiment of the cup and its lid. FIGS. 8 to 17 show the second embodiment of the cup and its lid. FIGS. 1 to 4 show how the cup 10 is deployed in different configurations by virtue of folding hinges 12a and 12b and 13a and 13b, which are interposed between middle 15 and upper 17 portion of the cup 10 and bottom 19 and middle 15 portions, respectively.

(21) Cup 10 comprises a liquid impervious, flexible material 21 having foldable pre-forms arranged to define at least two sets of hinges 12a and 12b, and 13a and 13b around separate circumferential locations on the cup body whereby the material 21 from which the cup body is formed is foldable into itself, at the circumferential locations, so as to adopt the form of two nested, concentric forms (FIG. 4), shown as S-shaped forms in section in FIG. 1.

(22) The flexible material 21, which is typically a thermo plastic elastomer (TPE), from which the cup 10 is formed, is food safe, ideally approved by the United States Federal Drug Administration (FDA), mechanically strong and stable. Other synthetic plastics material may be used as the cup body provided they possess the necessary features of food safety, flexibility, thermal insulation and durability to repeated folding.

(23) Peripheral bands 14, 16 and 18 are bonded to an outer surface of the flexible material 21 which is heat resistant and liquid proof. The peripheral bands 14, 16, 18 are formed from FDA-approved polypropylene. Bonding of different materials forming the cup is achieved by moulding the thermo plastic elastomer directly onto the polypropylene. The heat within the thermo plastic elastomer melts the surface of the polypropylene allowing cross linking and thereby creating a strong bond. Alternatively, it is possible to join the parts with a suitable adhesive but this may require surface treatment such as plasma or chemical primer.

(24) The cup is free from bisphenol (BPA) and requires no phthalates or glues in the assembly of the cup. This allows the cup to adhere to food safety standards.

(25) Band 14 is a base portion, band 16 is a central band and band 18 is an upper band. Sufficient excess flexible material 21 is provided around an upper periphery 24 at a lip or collar region of a bond zone between the body of the flexible material 21 and the upper band 18 so as to provide a surface against which a lid 30 may abut and seal the cup 10.

(26) An additional fillet of flexible material 21 is provided at hinges 12a and 12b, and 13a and 13b so as to ensure that folding of the cup body material 21 is permitted without risk of tearing. The hinges 12a and 12b and 13a and 13b define hinges which optimise the balance between thicknesses of material 21 required in order to retain an overall cup shape of the cup 10 whilst being sufficiently thin and durable in order to permit repeated folding.

(27) An advantage of the central band 16, which is effectively of the form of a part of a cylinder, provided around the external surface of the middle region of the cup 10, is that it acts as a thermal barrier and so enables the user to grasp the cup 10 with relatively hot contents safely. The central band 16 is ideally at least 20 mm deep, preferably at least 30 mm deep, so as to provide a surface onto which branding may be placed as well as providing a large area for holding the cup.

(28) Also the central portion or band 16 offers a large surface area onto which the cup body may be bonded so improving strength and enabling tapering sections 22 and 24 of the body 21 to be defined between the upper and middle portions; and middle and lower portions of the cup 10. Not only is this aesthetically and ergonomically pleasing but it also increases stability and strength of the cup 10. The thickness of the central band 16 may be thicker than the other bands so providing an additional layer of insulating material.

(29) Another advantage of the cup is that it has few separate parts. Prior art cups had more parts which are liable to fail, be lost or require additional assembly costs and cleaning.

(30) Due to the tapering nature of frusto-conical connecting sections 22 and 24 the cup 10 adopts a form that is convenient to grasp whilst maintaining its overall cup shape state whilst standing on its base 14. The cup 10 requires sufficient stiffness in order to ensure that, even when filled with a hot liquid, it retains its form. Therefore, the conical angle of the frusto-conical sections 22 and 24 cannot be so shallow as to compromise strength and stability of the deployed cup 10; neither can they be so steep as to prevent or inhibit folding of the hinges 12a and 12b and 13a and 13b. It has been found that a range of conical angles between 10° and 20° is ideal to meet these objectives. This range of angles enables the cup 10 to retain a shape that is similar to an existing cup whilst still permitting the cup 10 to be folded.

(31) A lid 30 is shown in FIGS. 6 and 7. FIG. 6 shows a sectional view of the lid 30. FIGS. 7a and 7b show above plan and under plan views of the lid 30.

(32) A drinking aperture 32 is suitably shaped and dimensioned to allow liquid contents (not shown) to flow at a comfortable and safe rate. The lid 30 seals the cup 10 and prevents leaks when stored. The edge 34 of the lid 30 is angled so as to assist to channel the liquid contents to the user's mouth and form a seal with the lips.

(33) Referring to FIGS. 6, 7a and 7b there are shown views of the lid 30 with a hinged pivot type stopper 60, with a stay open latch 62 and an elastomer spout seal 64. The stopper 60 has a positive click detent 62a and 62b which is ideally audible so as to seal firmly and retain it when open. The stopper 60 is hinged so that when open it is held back so allowing the user to drink without interference from the stopper.

(34) By adding a flanged or a winged base 50 the surface area is improved so making the cup more stable. Also when the base unit is in “stored” configuration the “wings” protect the softer thermoplastics elastomer material from accidental damage. The base 50 has three small pillars 52, 54 and 56 formed thereon in order to support it during the injection as well as stabilise the cup 10 in use. A mould tool (not shown) may be textured with a knurled, contoured, fluted or any other desired finish.

(35) A method of manufacturing the reusable cup comprises the steps of: introducing a flexible rubber into a cavity injection mould, receiving a moulded cup body, the cup body has three peripheral sections or bands which are bonded to the cup body at regions that are connected by tapering portions of the cup body. Ideally the peripheral sections or bands are bonded to an outer surface of the cup body.

(36) The preferred method of manufacture is a two shot injection moulding using a rotary turn table configuration. The three polypropylene bands are formed within the injection mould tool using core A. The mould opens leaving the rings in the cavity. The mould cavity indexes to align with core B. Mould tool closes and the thermo plastic elastomer is injected in through a hole in band 21 and across its inner surface. Three pips support the surface of 21 to ensure the thermo plastic elastomer flows through the hole and not across the back of band 21.

(37) Once a sufficient amount of thermo plastic elastomer has passed through the hole, band 21 is pushed back against the mould surface and the three pips are no longer required. The continuing flow of the thermo plastic elastomer over the pips erodes them, this means they can no longer break through the thermo plastic elastomer and be visible from the inside of the cup, thereby leaving an unbroken and continuous internal surface which is easier to clean.

(38) A blowing agent can be introduced into one or more of the polypropylene band(s) so as to improve its thermal insulating properties and provide a comfortable grip for a user to hold.

(39) An inner surface of the middle band has a relieved form or pattern produced thereon in order to improve insulation.

(40) The materials forming the cup are dishwasher safe for ease of maintenance and the interior is smooth so that no recesses are provided for material or liquid to egress into or for any residue, such as milk or sugar, to accumulate at corners or inaccessible regions, for example in crevices or between different components.

(41) The materials, from which the cup is formed, as well as pigments, may be chosen such that they can be used in a microwave oven.

(42) It is appreciated therefore that the reusable cup not only overcomes the problem of wastage of precious environmental resources, but also provides a unique foldable cup that can be carried in a pocket or purse and used to collect beverages, and folded away when empty, without risk of leakages or spillage from the folded cup.

(43) It is presented as an eye-appealing receptacle which may be adorned with colours, icons or logos of particular sports teams, personalities or corporations. Ideally such icons or logos or trade marks may be printed or placed on the central band.

(44) FIGS. 8 to 17 show the second embodiment of the cup 100, including a second embodiment lid 200. The second embodiment cup comprises a cup body formed from a liquid impervious flexible material. The cup body comprises an upper cylindrical portion 110, a central cylindrical portion 114 with a radius less than that of the upper portion and a base portion 118 which is also cylindrical, with a radius less than that of the central portion. The base portion 118 has a closed end, defining the base of the cup volume.

(45) The cup body further comprise a frusto-conical upper folding hinge 112 and a frusto-conical lower folding hinge 116. The upper portion 110 is connected to the central portion 114 by the upper folding hinge 112. The central portion 114 is connected to the base portion by the lower folding hinge 116.

(46) An upper band 120 is formed around the upper portion 110. A central band 125 is formed around the central portion 114. A base band 130 is formed around the base portion 118.

(47) In use the frusto-conical folding hinges 112, 116 are configured to be collapsed by folding them in on themselves. By collapsing the end deploying the folding hinges, the cup 100 can be collapsed for storage, or can have its capacity varied.

(48) In the large volume fully deployed configuration (shown in FIG. 11) both hinges 112, 116 are deployed fully thereby maximising the volume of the cup (to hold 475 ml beverages).

(49) In the medium volume partially deployed configuration (shown in FIG. 17) the lower hinge 116 is collapsed, but the upper hinge 112 is deployed. This configuration is dimensioned to hold 300 ml beverages.

(50) In the small volume partially deployed configuration (shown in FIG. 16) the lower hinge 116 is deployed, but the upper hinge 112 is collapsed. This configuration is dimensioned to hold 175 ml beverages.

(51) In the fully collapsed configuration (shown in FIG. 14 and in FIG. 11), both hinges 112, 116 are collapsed. This configuration could hold a very small beverage and saves volume for transporting the cup when not in use.

(52) When each hinge 112, 116 collapses, it folds around two circumferences, one at the top of the hinge, at the boundary with the cylindrical portion above the hinge, and one at the bottom of the hinge at the boundary with the cylindrical portion below the hinge. The bottom circumferential location of each hinge folds about the top of the band formed about the cylindrical portion below the hinge,

(53) Therefore, when the hinges are collapsed they have S-shaped cross sections, and the portion above the hinge and below the hinge adopt a nested concertina arrangement. The hinge portions of the cup body being turned inside out between the circumferential folding points when they are collapsed.

(54) The upper 110, central 114 and base 118 portions, and upper 112 and lower 116 folding hinges are all formed from a single continuous piece of impervious flexible material such as TPE or silicone. The boundaries between the portions and the hinges being at the circumferential folding points and being determined by the change in the slope of the cup body.

(55) The circumferential folding points, the portions, the folding hinges and the segments surrounded by bands ideally all have equal thicknesses.

(56) The peripheral bands are formed from rigid plastics. Preferably polypropylene. They therefore provide structure to the cup, preventing the cup body from being compressed. Furthermore, the bands act as guides which ensure the folding hinges fold correctly.

(57) The upper peripheral band 120 has a quarter turn external thread formed on its outer surface for the attachment of the lid 200.

(58) The base peripheral band 130 extends below the bottom of the flexible cup body and therefore defines a rigid circular base upon which the cup is supported. Four radially extending flanges 132 protrude outwards from the bottom edge of the base portion of the cup 100, increasing the footprint of the cup and therefore its stability. The footprint of the base is dimensioned such that it fits within a central flat portion of the lid 200 which is surrounded by the ridge. This facilitates stacking of the cups, as seen in FIG. 11.

(59) The lid 200 comprises a raised rim 205 which protrudes vertically above the surface of the lid 200. The drinking slot 210 is formed in the top of the rim 205. The rim slopes upwards towards the drinking slot 210, protruding further from the lid 200, the closer it is to the drinking slot 210 (this may be seen in FIGS. 12 to 15). The rim 205 has a slightly smaller radius than the aperture of the flexible cup body, such that the drinking slot 210 is above the volume of the cup but is adjacent to an edge of the cup volume, this advantageously reduces liquid residue build-up.

(60) The lid has an internal screw thread 220, which in use meshes with the external screw thread 122 of the upper band 120, thereby attaching the lid 200 to the upper band 120.

(61) The lid further comprises a stopper mechanism. The stopper mechanism comprising an arm 250 connected to the lid by hinges 255. The arm 250 rotates between a closed configuration where it is pressed into an indent 280 formed in the lid, and a continuum of open configurations, where it is rotated out of the indent 280.

(62) The stopper mechanism comprises a bung 270 located on the underside of the arm 250 adjacent the opposite end of the arm 250 from the hinges 255. When arm is in the closed configuration the, stopper is pressed into the drinking slot 210. The stopper 270 is dimensioned such that it seals the drinking slot 210.

(63) The lid comprises an air pressure hole 215 located near its centre. When the arm 250 is in the closed configuration a hole sealing post 265 presses against the air pressure hole 215, thereby sealing it.

(64) The arm further comprises a pair of clips 260 which produce an audible click when the arm is moved between the closed and one of the open configurations, and which act to hold the arm in the closed configuration, thereby preventing the drinking slot and air pressure hole from becoming unsealed accidentally. The clips 250 may each comprise a protrusion from the wall of the indent 280 which interlocks with a groove, indent or slot in the side of the arm 250 when the stopper is in a closed configuration.

(65) When in the closed configuration, the end of the arm 250 furthest from the hinges 255 protrudes beyond the raised rim 205 of the lid. This facilitates the opening of the stopper mechanism and allows the bung 270 to fit more tightly into the drinking slot 210 (This may be seen in FIG. 10).

(66) The arm further comprises a pair of protrusions 275 on the end of the arm 250 adjacent the hinges 255. When the arm 250 is pivoted such that it extends vertically from the lid and as it is pivoted any further from the closed configuration, these protrusions are in contact with the lid 200. The friction due to the protrusions increases the angular moment required to pivot the arm 250, and therefore act retain the arm 250 in a wide open position, this ensures that the arm does not fall into contact with a user's face while they are drinking.

(67) The central band 125 has a plurality of ridges formed thereon. A series of parallel horizontal ridges 140 are formed on the outer surface of the central band. These exterior ridges provide grip to a user and thermal insulation between the contents of cup and the user's hand by creating air pockets. A second series of wider and shallower vertical parallel ridges are formed on the inner surface of the central band, these provide thermal insulation by creating air pockets between the central band 125 and the central portion 114. The ridges cover the entire surface of both the inside and the outside of the central band 125, except for any regions of the band where names or logos are printed or embossed.

(68) The upper portion 110 of the flexible cup shape extends vertically above the upper edge of the upper band 120, thereby forming a raised flexible rim. The raised flexible rim extends radially outwards such that it covers the upper edge of the upper band 120. This rim is compressed between the upper band 120 and the lid 200 when the lid is screwed onto the upper band 120, thereby providing a good seal between the upper portion 110 and the lid 120.

(69) The upper portion 110 and the central portion 114 may have additional radially extending lips formed thereon (not shown). A first lip may be formed towards and parallel to the lower edge of the upper portion 110, and the bottom edge of the upper band 120 abuts this lip. Therefore, this lip and the raised flexible rim cover the top and bottom edges of the upper band 120 and fix its vertical position on the flexible cup body. A second lip may be formed around the top of the central portion 114 such that it abuts and covers the upper edge of the central band 125, and a third lip may be formed towards the bottom edge of the central portion 114 such that it abuts and covers the bottom edge of the central band 125. The second and third protruding lips define the location of the central band.

(70) The lid 200 may comprise an internal downwards extending ridge 290 with a radius very slightly smaller than the radius of the aperture of the flexible cup body and arranged such that when the lid is attached to the cup the ridge projects downwards from the inner surface of the lid and presses against the inner wall of the flexible cup body. This ridge improves the seal between the lid 200 and the flexible cup body.

(71) The bands 120, 125, 130 may be bonded to the outer surface of the flexible cup body.

(72) It will also be appreciated that the invention has been described by way of examples only and variation to the aforementioned examples may be made, such as by combining features of the two embodiments, without departing from the scope of the invention, as defined by the appended claims