TECHNICAL FIELD

This disclosure relates to cups for containing e.g. food or drink.

BACKGROUND ART Disposable cups are commonly used for dispensing hot and cold liquids (e.g. coffee, tea, smoothies), and sometimes food (e.g. yoghurt, ice cream) to consumers. Such cups have previously been formed of polystyrene, largely due to its thermal insulation properties (which allow a cup to be handled when containing hot or cold food or liquid). However, polystyrene is also slow to biodegrade, and thus disposal of such cups could be detrimental to the environment.

Because of this issue, there is an increasing preference for disposable cups that are formed of paper instead of polystyrene. However, paper is generally inferior to polystyrene in regards to its thermal insulation. In addition to providing an insulating function, the walls of disposable cups may be used to increase the market attractiveness of the product (e.g. a drink contained in the cup). For example, the outer surfaces of such disposable cups may contain branding in the form of logos, slogans, messages, etc. The purpose of this branding may be to associate the product with a particular brand, and/or to have an effect on a consumer's perception of the product.

It is to be understood that, if any prior art is referred to herein, such reference does not constitute an admission that the prior art forms a part of the common general knowledge in the art, in Australia or any other country. SUMMARY

Disclosed herein is a cup assembly comprising an inner cup, an embossed and/or debossed outer layer formed of stretchable paper, and a middle layer disposed between a sidewall of the inner cup and the outer layer. In one embodiment the outer layer and middle layer may be bonded to one another at one or more bonded regions, and may be detached from one another at one or more free regions. It may not be necessary that the free region be completely free of bonding - rather, the term 'free region' is used to identify a region as being one that is substantially free of bonding. That is, the bonding of the outer layer and middle layer may be substantially provided at the one or more bonded regions, and any bonding in the one or more free regions may be generally insignificant in regards to the overall bonding of the outer layer and middle layer together.

In one embodiment the one or more bonded regions may be disposed at a periphery of the outer layer, and the one or more free regions may be disposed at a central portion of the outer layer. In this way, the bonding between the layers may be minimal, which may reduce heat transfer between the layers. It also means that damage or disruption to the embossed outer layer during

manufacturing may be minimal (i.e. because in some cases the layers may need to be pressed together in order to bond them which would otherwise flatten the embossed portions).

In one embodiment the middle layer and the outer layer may form a sleeve that is wrapped around the sidewall of the inner cup. The sleeve may partially or fully extend around the sidewall of the inner cup. In one embodiment the sleeve may comprise in use upper and lower edges that extend at least partially around the circumference of the inner cup, and opposite ends that extend between the upper and lower edges. The bonded regions may be disposed at or proximate the opposite ends of the sleeve. The bonded regions may be in the form of bonded strips. In one embodiment the ends of the sleeve may overlap. The one or more bonded regions may be disposed at the overlapped ends of the sleeve. In this way, the bonding between the ends of the sleeve, and the bonding between the middle and outer layers, may align along a generally longitudinal band or strip of the cup assembly (e.g. extending between the upper and lower edges of the sleeve). It is not necessary that the band or strip be continuous, and instead may be formed of e.g. small bonded regions spaced along the band or strip.

In one embodiment the middle layer and the outer layer may only be bonded to one another at their overlapped ends (or overlapped portions that may or may not be at the ends of middle and/or outer layers). This may help to maximize the space available on the outer layer for an embossed and/or debossed design.

In one embodiment the cup assembly may comprise a single bonded region in the form of a bonded strip extending between the upper and lower edges of the sleeve. That is, the middle layer and outer layer may remain detached outside of the bonded strip. This may reduce the amount of bonding in the cup assembly and may, for example, limit heat transfer between the inner cup and the outer layer.

In one embodiment an inner surface of a first of the ends of the sleeve may be bonded to an outer surface of a second of the ends of the sleeve.

In one embodiment the sleeve may be bonded to the inner cup along a generally central circumferential portion intermediate in use upper and lower edges of the sleeve. This may secure the sleeve from sliding relative to the inner cup.

In one embodiment the outer layer may be a thermoformed stretchable paper.

In one embodiment the stretchability of the stretchable paper may be at least 5% in the machine direction (MD) and the cross direction (CD) when measured according to ISO 1924/3.

In one embodiment the stretchability of the stretchable paper may be at least 13% in the machine direction (MD) and 7% in the cross direction (CD) when measured according to ISO 1924/3. Such a stretchability may allow the outer layer to be embossed and/or debossed.

In one embodiment the inner cup may comprise a base portion connected to the sidewall, the base portion and sidewall defining a liquid containing recess. In one embodiment air pockets may be formed between the outer layer and the middle layer. The air pockets may provide further insulation (i.e. so as to isolate a user from hot or cold contents contained in the inner cup).

In one embodiment air pockets may be formed between the middle layer and the inner cup. Again, this may help to insulate e.g. a user from hot or cold contents stored within the inner cup.

In one embodiment the middle layer may be scored. The scoring may be such that raised portions are formed on the middle layer. The scoring may help to define the air pockets between the middle layer and the outer layer, or between the middle layer and the inner cup. In one embodiment the outer layer may comprise one or more embossed and/or debossed portions arranged to form one or more indicia. Such indicia may be in the form of text, images, branding, etc. Alternatively or additionally, the outer layer may comprise one or more raised embossed portions arranged in a nonrepeating manner. The one or more embossed and/or debossed portions may be disposed at a free region of the outer layer.

In one embodiment the cup assembly may be a disposable paper cup for hot or cold liquids such as e.g. coffee, tea, etc.

Also disclosed is a method of forming a cup assembly. The method comprises bonding an embossed and/or debossed outer layer formed of stretchable paper to a middle layer to form a sleeve, and arranging the sleeve around an inner cup to form the cup assembly. In one embodiment the method may comprise embossing and/or debossing the stretchable paper layer.

In one embodiment the bonding may be performed such that the outer and middle layers are bonded at one or more bonded regions, and remain detached from one another at one or more free regions. As set forth above, the term 'free region' is intended to define an area that is generally free of bonding, but not necessarily completely free of bonding (i.e. the free regions may comprise minimal or insignificant bonding).

In one embodiment the one or more bonded regions are disposed at a periphery of the outer layer, and the one or more free regions may be disposed at a central portion of the outer layer.

In one embodiment the sleeve may comprise in use upper and lower edges that extend at least partially around the circumference of the inner cup when the sleeve is arranged therearound, and opposite ends that extend between the upper and lower edges. The bonding may be performed such that the bonded regions are disposed at or proximate the opposite ends of the sleeve.

In one embodiment the method may comprise the step of overlapping the ends of the sleeve and bonding the ends to define a generally cylindrical (or frusto- conical) hollow interior for receipt of the inner cup. In one embodiment the steps of bonding the overlapped ends of the sleeve and bonding the outer layer to the middle layer may be performed concurrently. This may, for example, be performed by a machine that wraps the outer and middle layers around a template so that their ends overlap and then bonds the overlapped ends to one another. In one embodiment the method may further comprise the step of applying adhesive along an edge of the outer layer and a corresponding edge of the middle layer. The edges may define the outer overlapped ends of the sleeve when wrapped around the inner cup. In one embodiment the adhesive may be a hot melt adhesive and the bonding may be performed by way of ultrasonic welding applied to the hot melt adhesive.

In one embodiment the ultrasonic welding may be performed along a single bonding strip between the upper and lower edges of the sleeve. As set forth above, this may minimize the amount of adhesive used to form the cup assembly, and may also maximize the space on the outer layer that comprises an embossed and/or debossed design.

In one embodiment the step of arranging the sleeve around the inner cup may further comprise bonding the sleeve to the inner cup. For example, an adhesive may be applied to the inner cup and may bond the sleeve to the inner cup when it is received around the sidewall. Alternatively, the adhesive may require curing by way of the application of ultrasonic welding.

In one embodiment the outer layer may be a thermoformed stretchable paper.

In one embodiment the stretchability of the stretchable paper may be at least 5% in the machine direction (MD) and the cross direction (CD) when measured according to ISO 1924/3.

In one embodiment the stretchability of the stretchable paper may be at least 13% in the machine direction (MD) and 7% in the cross direction (CD) when measured according to ISO 1924/3. In one embodiment the step of embossing and/or debossing may comprise forming one or more raised portions that are arranged so as to define one or more indicia. The step of embossing and/or debossing may alternatively or additionally comprise forming one or more raised portions that are arranged in a non-repeating manner. The one or more embossed and/or debossed portions may be formed at a free region.

In one embodiment the method may further comprise scoring the middle layer. The scoring may enable air pockets to form between the middle layer and the inner cup. BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described by way of example only, with reference to the accompanying drawings, in which:

Figures 1A and IB are respective front and front-section (exploded) views of a cup assembly;

Figure 2A illustrates an exploded view of a sleeve of a cup assembly;

Figure 2B illustrates the sleeve of Figure 2A in an assembled form;

Figure 3A is a top-section view of a sleeve;

Figure 3B is a detail view of the sleeve of Figure 3A; and Figure 4 schematically depicts a process for producing a cup assembly.

DETAILED DESCRIPTION

In the following detailed description, reference is made to accompanying drawings which form a part of the detailed description. The illustrative embodiments described in the detailed description, depicted in the drawings and defined in the claims, are not intended to be limiting. Other embodiments may be utilised and other changes may be made without departing from the spirit or scope of the subject matter presented. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings can be arranged, substituted, combined, separated and designed in a wide variety of different configurations, all of which are contemplated in this disclosure.

Figure 1A illustrates a cup assembly 100, which comprises a paper inner cup 102 and a sleeve 104 wrapped around the inner cup 102. Figure IB shows a section through the same cup assembly 100 (in exploded form for clarity). The inner cup 102 comprises a generally frusto-conical sidewall 106 and a base portion 108 that, together, define a recess 110 for containing e.g. a liquid. The base portion 108 comprises a generally planar body and a circumferential projection or lip that protrudes downwardly (in use) from the planar body. An in use lower edge 112 of the sidewall 106 is folded over this lip, and then the lip and folded portion of sidewall 106 are rolled together to form a liquid tight seal at the base 108. The inner cup 102 may also comprise a barrier coating (at least on an interior surface thereof) to prevent liquid leaking from the recess.

An in use upper edge 114 of the sidewall 106, opposite the lower edge 112, is rolled so as to form a lip of the inner cup 102. Among other things, this provides structural rigidity to the inner cup 102 and also facilitates attachment of a lid to the inner cup 102.

The sleeve 104 is wrapped around the sidewall 106 of the inner cup 102 and comprises two layers: an outer layer 116 that forms an external layer of the cup assembly 100, and a middle layer 118 sandwiched between the sidewall 106 of the inner cup 102 and the outer layer 116. The outer layer 116 is formed of stretchable paper. The stretchable paper may have a stretchability of at least 5% in the machine direction (MD) and cross direction (CD) when measured according to ISO 1924/3. Alternatively, the stretchable paper may have a stretchability at least 13% in the machine direction (MD) and 7% in the cross direction (CD) when measured according to ISO 1924/3. In general the stretchability of the paper of the outer layer 116 may be outside of these ranges so long as it is sufficient to allow embossing and/or debossing.

The outer layer 116 is embossed and debossed so that it comprises a plurality of raised portions 120 (e.g. raised by approximately 2-3 mm). Unlike corrugation, embossing and debossing allows the raised portions 120 to be arranged in a nonrepeating manner. This allows the raised portions to be arranged in such a way that they form indicia (e.g. logos, branding, text, images, etc). This indicia may be functional in nature (e.g. it may depict a warning to a user) or may be aesthetic in nature so as to enhance the aesthetics of the cup assembly 100 and make the cup assembly 100 more attractive to e.g. a consumer.

Other than forming indicia, the raised portions 120 may be arranged so as to provide an ergonomic surface for a user of the cup assembly 100. For example, the raised portions 120 may be arranged to provide finger and/or thumb grips. Similarly, the raised portions 120 may provide a textured surface that improves the grip of the surface of the outer layer 116 and facilitates handling of the cup assembly 100.

The raised portions 120 also form air gaps or pockets 122 between the outer and middle layers. The air pockets 122 can increase the overall thermal conductance of the sleeve 104 so as to insulate a user's hand from cold or hot substances stored within the recess 110 of the inner cup 102, thereby increasing user comfort when handling the cup assembly 100.

The middle layer 118 is formed of a thicker paper than the outer layer 116. This thicker paper provides a stiffer backing to the outer layer 116 and offers further support to the sleeve 104. The middle layer 118 also separates the outer layer 116 from the inner cup 102 which, again, helps to thermally insulate a user's hand from substances stored within the recess 110 of the inner cup 102. Although not apparent from the figures, the middle layer can be scored so as to create ridges that form further air pockets between the middle layer 118 and the inner cup 102, and between the middle layer 118 and the outer layer 116.

The embossed outer layer 116 (i.e. including the indicia) of stretchable paper can improve the visual aesthetics of the cup assembly 100 (e.g. increasing the marketability of the cup assembly 100 and its contents). However, such stretchable paper can also present difficulties in manufacturing and is not necessarily suited to conventional manufacturing techniques (i.e. using known equipment in a known manner). This may especially be the case where the cup assembly 100 comprises a middle layer 118 intermediate the outer (stretchable) layer 116 and the inner cup 102. For example, passing an inner cup 102 through a wrapping process twice (i.e. to wrap two layers around the inner cup) can be expensive, complicated, time consuming and, in some cases, not possible.

One way of addressing such difficulties is by way of the bonding arrangement of the presently illustrated embodiment. As is more apparent from Figures 2A and 2B, the middle 218 and outer layers 216 are bonded together to form the sleeve 204. These figures show a sleeve 204 (similar to that shown in Figures 1A and IB) in an unwrapped condition. Figure 2A, in particular, shows the undersides or inner surfaces of the outer 216 and middle 218 layers of the sleeve 204 prior to being bonded to one another. To perform the bonding, a hot melt adhesive is applied to the outer 216 and middle 218 layers. The bonding of these layers 216, 218 is subsequently performed by way of ultrasonic welding (i.e. which cures the adhesive). The application of adhesive is limited to a small area (i.e. bonding region) of the middle 218 and outer 216 layers. In particular, the adhesive is applied in two bands or strips: a first strip 226 that extends along an end of the outer layer 216, and a second strip 228 that extends along an end of the middle layer 218 (i.e. running perpendicular to the circumference of the inner cup 202).

Minimising the quantity of adhesive 226, 228 that is used to bond the layers 216, 218 can provide a number of beneficial effects. For example, it can reduce the cost (e.g. of adhesive) and time to produce the cup assembly 200. It can also reduce heat transfer between the layers 216, 218, which may provide the cup assembly 200 with greater insulation properties. That the strips of adhesive 226, 228 are limited to the ends of the layers 216, 1 18 may also mean that damage to, or deterioration of, (e.g. by compression) the raised portions 120 (not shown) during manufacture is limited.

As is apparent from Figure 2B, after the adhesive is applied, the outer 216 and middle 218 layers are placed on top of one another and are aligned. The middle layer 218 is smaller than the outer layer 216 such that its edges are set back (i.e. offset) from the edges of the outer layer 218. At this point, the layers 216, 218 are not bonded to one another. In order for the bonding to occur they are wrapped so as to be formed into a cylindrical or frusto-conical shape (e.g. around a template) and so that the ends of the sleeve 204 overlap.

Figures 3A and 3B illustrate a sleeve 304 that is bonded in this way and is formed from wrapped outer 316 and middle 318 layers. These layers 316, 318 are wrapped so as to form a hollow interior that generally corresponds, in size and shape, to an inner cup (not shown). As suggested above, the layers 316, 318 may be wrapped around a template to form this shape, or may be wrapped around an inner cup. In this way the layers 316, 318 form the sleeve 304 that can then be arranged around the inner cup (i.e. by receipt of the inner cup within the hollow interior of the sleeve 304).

The sleeve 304 comprises upper 330 and lower edges 332 and opposite ends 334, 336 that extend between these edges 330, 332. The shape of the sleeve 304 is such that its ends 334, 336 overlap when wrapped in this manner. This is shown in detail in Figure 3B. This overlapping arrangement means that the ends 334, 336 of the sleeve 304 can be bonded to one another along a single strip, band or (bonded) region extending between the upper 330 and lower 332 edges.

As may be evident from Figure 3B, the positioning of the adhesive strips 326, 328 is such that there is no adhesive disposed between the middle 318 and outer 3 16 layers at one end 334 of the sleeve 304. In practice, the ultrasonic welding causes the adhesive 326, 328 to soften and spread between these layers 318, 316 (e.g. through the pores of the layers 316, 318) so that all of the layers 316, 318 (at both overlapped ends 334 336 of the sleeve 304) become bonded to one another along the single bonded strip or region. However, even if the middle 318 and outer 316 layers are not bonded at this end 334, the loose portion will remain held once an inner cup is received within the sleeve 304 (i.e. by way of it being sandwiched between the outer layer 316 and the inner cup).

In addition to being wrapped around an inner cup, the sleeve 304 can be bonded to an inner cup along a circumferential bonding region between the inner cup and the inner surface of the sleeve 304. Although the sleeve 304 is somewhat retained on the inner cup by its wrapping therearound, this further bonding ensure that the sleeve 304 does not slide off the inner cup.

Figure 4 illustrates a method 438 for producing a cup assembly that is the same or similar to that described above. The method comprises cutting 440 an outer layer blank 416 for the cup assembly 400 (e.g. from a roll of stretchable paper 442) and embossing and/or debossing the outer layer 416 according to a predetermined design (e.g. including indicia, finger grips, etc. as described above).

Concurrently, a middle layer blank 418 is cut from a roll of scored paper 444. Once cut, strips of adhesive 426, 428 are applied 446 to the inner-surfaces of the outer 416 and middle 418 layers. These layers 416, 418 are then turned over 448, placed on top of one another 450 and aligned 452. This set of actions does not cause the layers 416, 418 to be bonded to one another.

Rather the bonding 454 is performed by wrapping the layers 416, 418 around a e.g. template such that ends of the layers overlap. Ultrasonic welding is then performed on these overlapped ends so as to form a generally cylindrical or frusto-conical sleeve 404 with a bonded region in the form of a narrow strip at the overlapped ends.

The sleeve 404 is subsequently arranged 456 around an inner cup 402, which may be produced using known (automated or manual) cup-making processes. Prior to doing this, adhesive is applied circumferentially around the inner cup 402 such that the inner cup 402 becomes bonded to the sleeve 404 once arranged therearound.

As should be clear, the above described process may be performed by known cup- manufacturing equipment and/or known cup-manufacturing equipment that has been modified so as to be suitable for producing the described cup assembly.

Further, variations and modifications may be made to the parts previously described without departing from the spirit or ambit of the disclosure. For example the middle layer may not be in the form of a sheet material - it may instead be a spray on coating. Such a coating may be particularly chosen for low heat conductance. Similarly, the middle layer may be formed of materials other than paper (e.g. a polymer based material).

The bonding region may not be limited to the ends of the outer and middle layers, and may also incorporate further regions at the periphery of the outer layer (e.g. at upper and lower edges of the outer layer).

The middle layer may also be formed of stretchable paper and may have a form that is essentially a reflection of the outer layer. In this way air pocket may be formed between the "raised" (i.e. embossed or debossed) portions of the middle and outer layers, and these layers may meet at the non-raised portions.

Additionally, air pockets may be formed between the middle layer and the inner cup (when the sleeve is arranged therearound).

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or

"comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.