SEALED CONTAINER FOR BEVERAGES

Abstract

A sealed container (1) for beverages, especially pressurised beverages, comprises a cup (2) with an open top (3) and a lip (4) circumscribing the open top, and a sealing lid (5) heat welded to the lip (4). The paperboard lid comprises a micron-sized pressure release aperture (6) providing pressure regulation within the cup when the beverage is disturbed. The container includes a removable transport cap (13) for sealing engagement with the top of the cup (2) having a top panel (14) and a skirt (16) circumscribing the top panel, in which the top panel includes a first annular sealing head (19) configured to abut the sealing lid (5) when the plastic lid is engaged on the top of the cup. 12. A welding machine (33) for sealing the sealing lid (5) to the lip (4) of the cup (5) is also described.

Claims

1. A kit for assembling a sealed container containing a beverage, the kit comprising: a paperboard cup (2) with an open top (3) and a lip (4) circumscribing the open top; a paperboard sealing lid (5) dimensioned to be welded to the lip of the cup continuously around the lip to seal the paperboard cup; a removable transport cap (13) for sealing engagement with the top of the cup (2) configured to define a headspace chamber (25) between the sealing lid (5) and the transport cap (13) for receipt and retainment of fluid exiting the cup (2) and a welding machine (33) comprising a welding head configured for sealing the paperboard sealing lid to the lip of the cup, wherein in use a beverage is dispensed into the cup, and the welding machine is actuated whereby the welding head welds the paperboard sealing lid to the lip of the cup continuously around the lip to provide the sealed container containing the beverage.

2. A kit as claimed in claim 1, in which the beverage is a pressurised beverage.

3. A kit as claimed in claim 1 or 2, in which the sealing lid (5) includes a pressure release aperture (6).

4. A kit as claimed in claim 3, in which the pressure release aperture has an area of about 0.1 mm.sup.2 to about 10 mm.sup.2.

5. A kit as claimed in claim 3, in which the pressure release aperture (6) is a micron-sized pressure release aperture (6).

6. A kit as claimed in claim 5 in which the micron-sized pressure release aperture (6) has an area of about 0.05 mm.sup.2 to about 0.8 mm.sup.2.

7. A kit as claimed in any of claims 3 to 6, in which the pressure release aperture (6) is positioned about the centre of the sealing lid (5).

8. A kit according to any preceding Claim, in which the paperboard cup (2) and paperboard sealing lid (5) are formed of the same paperboard material.

9. A kit according to claim 5, in which the paperboard material is a paperboard-polyethylene laminate.

10. A kit according to any preceding Claim, in which the transport cap (13) comprises a top panel (14) having a raised central portion (20) and the headspace chamber (25) is defined between the sealing lid (5) and the raised central portion (20).

11. A kit according to claim 10, in which the top panel (14) includes a first annular sealing head (19) configured to abut the paperboard sealing lid (5) when the transport cap (13) is engaged on the top of the cup to peripherally define the headspace chamber (25).

12. A kit according to claim 11, in which the top panel (14) includes a second annular sealing head (22) at the periphery of the top panel (14).

13. A kit according to claim 12, in which the top panel (14) of the transport cap comprises a raised annular channel (24) defined by the first annular sealing head (19) and the peripheral annular sealing head (22).

14. A kit according to any of claims 10 to 13, in which the top panel (14) of the transport cap comprises an opening, or means for providing an opening, (23) for receipt of a drinking straw (26).

15. A kit according to any preceding Claim, in which the welding machine (33) is a heat-welding machine.

16. A sealed container containing a beverage, the sealed container comprising: a paperboard cup (2) with an open top (3) and a lip (4) circumscribing the open top; a beverage (32) disposed within the cup; a paperboard sealing lid (5) welded to the lip of the cup continuously around the lip to seal the paperboard cup; and a removable transport cap (13) for sealing engagement with the top of the cup (2) configured to define a headspace chamber (25) between the sealing lid (5) and the transport cap (13) for receipt and retainment of fluid exiting the cup (2).

17. A sealed container as claimed in claim 16, in which the beverage is a pressurised beverage.

18. A sealed container as claimed in claim 16 or 17, in which the sealing lid (5) includes a pressure release aperture (6).

19. A sealed container as claimed in claim 18, in which the pressure release aperture (6) has an area of about 0.1 mm.sup.2 to about 10 mm.sup.2.

20. A sealed container as claimed in any of claims 16 to 18, in which the pressure release aperture (6) is a micron-sized pressure release aperture (6).

21. A sealed container as claimed in any of claims 16 to 20, in which the pressure release aperture (6) is positioned about the centre of the sealing lid (5).

22. A sealed container according to any of claims 16 to 21, in which the paperboard cup (2) and paperboard sealing lid (5) are formed of the same paperboard material.

23. A sealed container according to claim 22, in which the paperboard material is a paperboard-polyethylene laminate.

24. A sealed container according to claims 16 to 23, in which the paperboard lid (5) comprises only one pressure release aperture (6).

25. A sealed container according to any of claims 16 to 24, in which the transport cap (13) comprises a top panel (14) having a raised central portion (20) and the headspace chamber (25) is defined between the sealing lid (5) and the raised central portion (20).

26. A sealed container according to claim 25, in which the top panel (14) includes a first annular sealing head (19) configured to abut the paperboard sealing lid (5) when the transport cap (13) is engaged on the top of the cup to peripherally define the headspace chamber (25).

27. A sealed container according to claim 26, in which the top panel (14) includes a second annular sealing head (22) at the periphery of the top panel (14).

28. A sealed container according to claim 27, in which the top panel (14) of the transport cap comprises a raised annular channel (24) defined by the first annular sealing head (19) and the peripheral annular sealing head (22).

29. A sealed container according to any of claims 25 to 28, in which the top panel (14) of the transport cap comprises an opening, or means for providing an opening, (23) for receipt of a drinking straw (26).

30. A method of providing a sealed container containing a beverage, the method comprising the steps of: providing a paperboard cup (2) with an open top (3) and a lip (4) circumscribing the open top; dispensing a beverage (32) into the cup; welding a paperboard sealing lid (5) to the lip of the cup continuously around the lip to seal the paperboard cup; and attaching a removable transport cap (13) to the top of the cup (2) covering the paperboard sealing lid to define a headspace chamber (25) between the sealing lid (5) and the transport cap (13) for receipt and retainment of fluid exiting the cup (2).

31. A method according to claim 30, in which the removable transport cap (13) is configured for sealing engagement with the top of the cup (2) and has a top panel (14) and a skirt (16) circumscribing the top panel (14), in which the top panel (14) includes a first annular sealing head (19) configured to abut the paperboard sealing lid (5) when the transport cap (13) is engaged on the top of the cup (2).

32. A welding machine (33) for welding a lid (5) to a cup (2) containing a beverage to seal the beverage in the cup, the welding machine comprising a housing (35) having: a cup holder (38) having an annual sealing head (40) defining an aperture for receipt of a cup and configured for nested engagement with a lip of the cup when the cup is placed in the cup holder; and a welding head (47) configured for movement between a first position in which the welding head is spaced apart from the annular sealing head (40) and a welding position in which the welding head abuts the annular sealing head, wherein the cup holder (38) comprises guide means (41) for guiding the correct placement of the sealing lid onto the lip of the cup.

33. A welding machine according to claim 32, in which the guide means comprises at least three guide arms (41) disposed around the welding head (47). in which each guide arm (41) has a lower part (42) that is substantially vertical and an upper part (43) that is outwardly angled.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0061] FIG. 1 is a perspective view of a container for carbonated beverages according to an embodiment of the invention;

[0062] FIG. 2 is an exploded view of the container of FIG. 1

[0063] FIG. 3 is a top view of the transportation cap;

[0064] FIG. 4 is a side elevational view of the transportation cap;

[0065] FIG. 5 is a perspective view of the transportation cap;

[0066] FIG. 6 is a sectional side view of the transportation cap taken along the lines III-III of FIG. 3;

[0067] FIG. 7 is a side elevational view of the container of FIG. 1 with a transportation cap mounted on the cup;

[0068] FIG. 8A is a sectional side view of the container taken of FIG. 7, and FIG. 8B is a detail of FIG. 8A;

[0069] FIG. 9 is a sectional side view of part of the cup and paperboard sealing lid of FIG. 1;

[0070] FIG. 10 is a partly sectional elevational view of the container of the invention in use with a straw;

[0071] FIG. 11A and FIG. 11B are sectional view of the container and lid of FIG. 7 showing how pressurised carbon dioxide within the cup can escape through the pressure release aperture in the paperboard sealing lid into the headspace between the sealing lid and the transport cap (FIG. 11A), and showing how any beverage that escapes through the pressure release aperture is maintained between the cap and the lid by the annular sealing head (FIG. 11B)

[0072] FIG. 12 is an illustration of a method of packaging a carbonate beverage suitable for the ready-to-drink/home delivery market according to a method of the invention.

[0073] FIG. 13 is a perspective view of a welding machine, showing a paperboard cup containing a beverage placed in the cup holder and a paperboard lid positioned above the top of the cup above the guide arms.

[0074] FIG. 14 is a perspective view of a welding machine of FIG. 13, showing the cup holder without the cup in place.

[0075] FIG. 15 is top plan view of part of the cup holder showing the sealing head and guide arms.

[0076] FIG. 16 is a front elevational view of a cup being filled with a beverage in a beverage filling machine.

[0077] FIG. 17 is a front plan view of a welding machine.

[0078] FIG. 18 is a side elevational view the welding machine of FIG. 17 (with a side wall of the housing removed) showing the cup holder projecting out of the housing and a cup nested in the cup holder and a cap positioned above the lip of the cup.

[0079] FIG. 19 is the same side elevational view as FIG. 18 with the cup holder retracted into the housing and the welding head lowered into the welding position.

[0080] FIG. 20A is a top plan view of the cup holder in an extended position prior to loading a cup.

[0081] FIG. 20B is the same view of the cup holder as FIG. 20A shown with a cup containing a beverage nested in the cup holder, and a lid.

[0082] FIG. 20C is the same view of the cup holder as FIG. 20B shown with the lid in position on the top of the cup.

DETAILED DESCRIPTION OF THE INVENTION

[0083] All publications, patents, patent applications and other references mentioned herein are hereby incorporated by reference in their entireties for all purposes as if each individual publication, patent or patent application were specifically and individually indicated to be incorporated by reference and the content thereof recited in full.

Definitions and General Preferences

[0084] Where used herein and unless specifically indicated otherwise, the following terms are intended to have the following meanings in addition to any broader (or narrower) meanings the terms might enjoy in the art:

[0085] Unless otherwise required by context, the use herein of the singular is to be read to include the plural and vice versa. The term a or an used in relation to an entity is to be read to refer to one or more of that entity. As such, the terms a (or an), one or more, and at least one are used interchangeably herein.

[0086] As used herein, the term comprise, or variations thereof such as comprises or comprising, are to be read to indicate the inclusion of any recited integer (e.g. a feature, element, characteristic, property, method/process step or limitation) or group of integers (e.g. features, element, characteristics, properties, method/process steps or limitations) but not the exclusion of any other integer or group of integers. Thus, as used herein the term comprising is inclusive or open-ended and does not exclude additional, unrecited integers or method/process steps.

[0087] As used herein, the term carbonated beverage refers to carbonated drinks like cola, orange, lemonade, lemon and lime, water, and other fizzy drinks. However, it will be appreciated that the container and methods of the invention may be employed with other pressurised drinks, such as beer, cider, sparkling water and sparkling wine. In one embodiment, the beverage is a ready to consume beverage, especially a short shelf life beverage.

[0088] As used herein, the term micron-sized pressure release aperture refers to an aperture that is sufficiently small to keep liquid within the cup when the cup is shaken or falls over, yet allow a sufficient amount of pressure dissipate out of the cup to prevent rupturing of the lid during period of pressure build-up. Generally, an aperture having an area of about 0.05 to about 0.8 mm.sup.2 are suitable for this purpose, although this depends on the viscosity of the beverage. In a preferred embodiment, the aperture has an area of about 0.1 to 0.6 mm.sup.2, more preferably about 0.2 to about 0.4 mm.sup.2.

[0089] As used herein, the term paperboard as applied to paperboard cups and paperboard sealing lids refers to paperboard materials conventionally used in carbonated beverage cups, including paperboard-polymer laminates and paperboard-foil laminates. In a preferred embodiment, the paperboard laminate is a paperboard-polymer laminate, as these have been found to provide the best seal when adhered together by welding, generally heat welding. These paperboard polymer laminates generally include a layer of paperboard with a barrier layer of polymer, generally a polyethylene polymer, on one or both sides of the paper. Specific examples of paperboard laminates for use in containers of the invention include Stora Enso's Cupforma paperboard, Georgia Pacific's CPH Masterserve cupstock, Mondi Paper Miprotex Barrier Stock. Paperboard formed from any type of paper pulp may be employed, including conventional paperpulp from trees, or paperpulp from bamboo or bagasse.

[0090] As used herein, the term adhered as applied to the sealing lids and cups refers to the sealing of the lid to the lip of the cup. Various methods of sealing may be employed, for example by means of welding (i.e. induction, heat and ultrasound welding methodologies). Heat welding has been found to provide the most efficient seal between a paperboard sealing lid and paperboard cup, capable of resisting significant pressure build-up in the cup during transport and storage, while providing a material that can be easily ruptured with a straw to allow the beverage be consumed.

[0091] As used herein, the term heat welded (also referred to as heat-fused) refers to a process where the lip is welded to the lip of the cup using heat. Methods of heat welding paperboard laminate materials together are well known to those skilled in the art, and machines for this purpose are commercially available. Welding of the lid to the lip on the cup is facilitated by providing a lip with a flattened upper surface, which increases the surface area of the lip available for welding to the lid.

Exemplification

[0092] The invention will now be described with reference to specific Examples. These are merely exemplary and for illustrative purposes only: they are not intended to be limiting in any way to the scope of the monopoly claimed or to the invention described. These examples constitute the best mode currently contemplated for practicing the invention.

[0093] Referring to the drawings, and initially to FIGS. 1 and 2, there is illustrated a container for a carbonated beverage according to the invention, indicated generally by the reference numeral 1. The container comprises a paperboard laminate cup 2 (hereafter cup) having an open top 3 circumscribed by a lip 4 (FIG. 1), and a paperboard laminate sealing lid 5 that is heat-welded to the lip to seal the cup 2 (FIG. 2). The paperboard laminate sealing lid 5 (hereafter sealing lid has a single micron-sized pressure release aperture 6 disposed in the centre of the lid having a diameter of approximately 0.6 mm.

[0094] In more detail, the sealing lid and cup are formed from the same paperboard-polyethylene laminate material, specifically PE coated Paper Cup Stock. Other paperboard-polymer laminates that may be employed include Biodegradable PLA Coated Paper Cup Stock. The cup is generally frusto-connical in shape, has a volume of approximately 450 mls (16 oz), and has an upper section 2A that is double walled and a lower section 2B that is single walled. The lip 4 at the top of the cup extends laterally outwardly of the top of the cup and a top of the lip is flattened to provide an annular landing surface 9 having a width of about 5 mm to which a periphery 10 of the paperboard sealing lid 5 is heat welded.

[0095] In use, a carbonated beverage is dispensed into the cup from a drink dispenser to a pre-set volume, and the cup containing the beverage is placed in a heat-welding machine, where a sealing lid is welded to the annular surface of the lip of the cup. This provides a very strong seal that is capable of withstanding pressures in the cup of up to 3 Bar. In addition, the provision of the micron-sized aperture in the sealing lid allows a certain amount of pressure to be vented from the cup during periods of pressure build-up, for example during transport, which helps prevent rupturing of the seal.

[0096] Referring to FIGS. 3 to 6, there is illustrated a transport cap according to the invention suitable for use with a sealed container of the invention and indicated generally by the reference numeral 13. As shall be explained more fully below, the transport cap 13 is a removable transport cap 13 for sealing engagement with the top of the cup 2 and is configured to define a headspace chamber 25 between the sealing lid 5 and the transport cap 13 for receipt and retainment of fluid exiting the cup 2. The transport cap 13 is generally made from a polymer material such as PET (Polyethylene) or PS (Polystyrene), is opaque or coloured, and comprises a top panel 14 and a skirt 16 that extends downwardly from a periphery 15 of the top panel 14. The skirt comprises a series of fluted formations 17 which are conventional in friction fit lids for papers cups. The top panel 14 comprises a recessed annular sealing head 19 which defines a convex central part 20, and a second annular sealing head 22 at the periphery 15 of the top panel 14. A raised annular channel 24 is defined between the annular sealing heads 19 and 22. The convex central part 20 comprises a re-closable aperture 23 configured for receipt of a drinking straw.

[0097] FIG. 7 is a side elevational view of the transport cap 13 engaged with the cup 2 and sealing lid 5.

[0098] FIGS. 8A and 8B are sectional views of the sealed container comprising cup 3, sealing lid 5 and transport cap 13 in an engaged configuration, which shows how the recessed annular sealing head 19 of the transport cap 13 is configured to abut and seal against the sealing lid 5, and peripherally define or form the headspace 25 defined between the sealing lid 5 and central convex part 20 of the transport cap 13. This illustration also shows how the second annular sealing head 22 is configured to abut and seal against the periphery 10 of the sealing lid 5 which is heat-welded to the annular surface 9 of the lip 4. Also shown is the raised annular channel 24 defined between the sealing heads 19 and 22 which serves as a channel to collect any beverage which escapes beyond the sealing head 19 and prevent escape of the beverage. FIG. 9 is a detailed view showing how the sealing lid 5 is welded to the annular surface 9 on the lip 4 of the cup 2.

[0099] FIG. 10 illustrates the use of the carbonated beverage container of the invention, where a straw 26 with a piercing tip 27 is inserted through the re-closable aperture 23, and through the sealing lid 5, and into the beverage 28 contained within the container.

[0100] FIG. 11A and 11B are sectional views of the sealed container of FIG. 7 showing how pressurised carbon dioxide 29 within the cup forces the sealing lid 5 upwards against the sealing heads 18 and 22, and how gas can escape through the pressure release aperture 6 in the sealing lid into the headspace 25 between the sealing lid and the transport cap (FIG. 11A). FIG. 11B shows how beverage 28 that escapes through the pressure release aperture 6 is maintained between the sealing lid and the transport cap by the annular sealing head 19.

[0101] FIG. 12 illustrates a method of packaging a carbonate beverage suitable for transport according to a method of the invention. In a first step (FIG. 12A), a cup 3 is placed under the spout 30 of a carbonated beverage dispenser 31 of the type employed in fast-food outlets, and the dispenser is actuated to fill the cup with carbonated beverage 32 to a pre-set volume. The cup 3 containing the desired amount of carbonated beverage 32 is then moved to the welding machine 33 (FIG. 12B), where a welding head of the welding machine heat-welds a paper-PE laminate sealing lid 5 to the top of the cup, sealing the cup. A transport cap 13 is then placed on the top of the sealed cup and secured in place. The packaged beverage is then ready for transport.

[0102] FIGS. 13 to 20 illustrate a welding machine according to the invention, and a use of the machine to seal a lid to a beverage cup. Referring to FIGS. 13-15, the welding machine 33 comprises a housing 35 comprising side walls 36 and a front wall 37 with an opening containing a cup holder tray 38 that is horizontally adjustable between a retracted and an extended position, cup-loading, position shown in FIG. 13. Referring to FIG. 14, the cup holder tray 38 comprises an annular sealing head 40 defining an aperture for receipt of a paper cup 2 which is dimensioned such that when a cup is nested in the cup holder (FIG. 13), a lip 4 of the cup 2 rests on the annular sealing head 40. The cup holder tray 38 additionally includes guide means for guiding a sealing lid 5 into position on the lip 4 of the cup 2. The guide means comprises three guide arms 41 positioned on the cup holder tray 38 equally spaced around the sealing head 40. Each guide arm comprises a lower part 42 that is substantially horizontal and an upper part 43 that is angled outwardly, whereby the combined action of the lower parts of the three guide arms acts to centre the lid directly above the annular sealing head 40. The welding machine 33 also includes a welding head (not shown) that is disposed in the machine above the cup holder tray 38 when it is in a retracted position, and vertically adjustable from a raised (resting) position to a lowered (welding) position.

[0103] Referring to FIGS. 16 to 19, the use of the welding machine of the invention to heat-weld a paperboard sealing lid 5 to a paperboard cup 2 is described, in which parts identified with reference to the previous embodiments are assigned the same reference numerals.

[0104] FIG. 16 illustrates the cup 5 being filled with carbonated beverage by a drinks filling machine 45.

[0105] FIG. 17 illustrates the welding machine 33 with the cup holder tray 38 in a retracted position inside the housing 35 and the welding head 47 in a raised, resting, position.

[0106] FIG. 18 illustrates the welding machine 33 with the cup holder tray 38 in an extended position outside of the housing 35, and a cup 5 nested in the cup holder tray 38 and a sealing lid 5 positioned above the cup and guide arms 41 and about to be dropped on to the top of the cup where the guide arms serve to correctly position the sealing lid on the lip of the cup as described previously.

[0107] FIG. 19 illustrates a heat-welding step, showing the cup holder tray 38 in a retracted position within the housing, under the welding head which is 47 is a lowered into a welding position, abutting the annular sealing head 40 and heat-welding the paperboard lid 5 to the lip 4 of the paperboard cup 2.

[0108] FIGS. 20A to 20C are plan views of the cup holder tray 38 in an extended position outside of the housing, prior to loading of the cup (FIG. 20A), after loading of the paper cup 2 (FIG. 20B) and showing the sealing lid 5 about to be placed on the cup 2 guided by the guide arms (not shown), and after the paper cup 5 has been guided onto the lip 4 of the cup 2 and the tray has been retracted into the housing 35 (FIG. 20C).

EXAMPLE 1

[0109] 16 oz cups formed of a paperboard-PE laminate material were filled with carbonated beverage and a paperboard-PE laminate sealing lid was heat-sealed to the lip of the cup using a table top, single cavity cup heat sealing semi-automatic machine. A transport cap according to the invention was then placed on the top of the cup and secured in place. The cup was then dropped 4 feet onto a concrete surface without any loss of integrity in the heat weld between the cup and the lid, and without any spillage of beverage.

EXAMPLE 2

[0110] The same containers as employed in Example 1 were subjected to a pressure test. The first container contained a micron-sized aperture (0.60+/0.02 mm) in the centre of the paperboard laminate sealing lid 5, and the second container did not contain an aperture in the sealing lid. Steadily increasing pressure was applied to both containers. The seal in the first container remained intact up to a pressure of 2.8+/0.2 psi, whereupon the application of further pressure failed to register pressure increases in the container, indicating that the pressure was being vented through the micron-sized aperture at elevated pressure levels, preventing loss of integrity in the seal. The seal in the first container remained intact up to a pressure of 3.0+/0.2 psi, and pressure beyond this value caused the sealed rim of the container to fail. This demonstrates that the pressure release aperture functions to vent gas from the cup at elevated pressure, preventing the pressure rising to a level that causes a loss of integrity in the seal.

Equivalents

[0111] The foregoing description details presently preferred embodiments of the present invention. Numerous modifications and variations in practice thereof are expected to occur to those skilled in the art upon consideration of these descriptions. Those modifications and variations are intended to be encompassed within the claims appended hereto.