US20050178677A1 - Container assembly having an overcap with a storage compartment - Google Patents

Abstract

There is provided an overcap that includes a storage compartment for receiving a product to be mixed with a hot liquid. The overcap includes a top wall defining the storage compartment in an underside of the top wall surrounded by an annular portion. The overcap includes an aperture in the annular portion. The overcap also includes a skirt extending downward from a rim surrounding the annular portion. The skirt extends below a lowermost surface of the top wall and can define a grip surface which a consumer may use to hold the container assembly, such that the grip surface insulates against heat if a hot liquid is held in the container. The storage compartment is sealed with a membrane that is relatively impermeable to moisture. In addition, the skirt includes a plurality of spacers on the inside surface of the skirt that are circumferentially spaced apart and that extend downwardly from the rim of the overcap.

Description

BACKGROUND OF THE INVENTION
• 1. Field of the Invention
• The present invention is related to overcaps for container assemblies, and more particularly, overcaps having a recessed storage compartment for storing of a product.
• 2. Description of Related Art
• Convenience is a major factor in designing containers, such as cups, for holding consumable liquids, especially “travel” containers intended for easy transport without spillage of the liquid. To this end, such containers often have a lid, or overcap, affixed to the container so as to limit escape of the liquids due to changes in container orientation. Another problem with dispensing consumable liquids in containers is that the consumer often wishes to add various products to the liquid, such as sugar or powdered cream to coffee. However, such products are typically distributed in small, individual packages that are not easily located or opened to dispense their contents into the liquid.
• The container lid may be configured to store products that will be subsequently mixed with a liquid. U.S. Pat. No. 3,326,363 to Bennett et al. (“Bennett”) discloses a container lid with a plurality of integrally-formed, hollow pockets to hold products such as sugar, powdered cream, or soft-drink concentrate. A sealing member seals the product inside the pockets, and the sealing member may be easily torn or removed to provide access to the product. The Bennett patent, and similar lids with hollow pockets, do not provide an aperture for convenient access to the liquid or product within the container, thus requiring the consumer to remove the lid to gain access to the liquid.
• Containers for consumable liquids, particularly hot liquids, often include a sleeve to insulate against the heat from the hot liquid in the container. U.S. Pat. No. 5,765,716 to Cai et al. discloses a lid integrally formed with a sleeve that insulates the wall of the container. The sleeve is tethered to the lid and is configured to slidably receive the container. Connection of the lid to the container may be difficult for consumers because the container must first be inserted into the sleeve and then the tethered lid must be rotated to attach the lid to the open upper end.
• A need exists for a container lid or overcap that provides convenient access to liquids and includes a storage compartment for a product to be mixed with the liquid. A need also exists for a lid that is easily attached to a container and that provides a grip surface that insulates against heat from a hot liquid.
BRIEF SUMMARY OF THE INVENTION
• The invention addresses the above needs and achieves other advantages by providing an overcap for a container, wherein the overcap can store a product for mixing with a liquid held in the container. The overcap includes a rim configured to engage the container and a top wall that defines a storage compartment in an underside of the top wall. The top wall also includes a substantially horizontal annular portion radially inward of the rim and surrounding the storage compartment. The overcap also has a membrane removably attached to the underside of the top wall of the overcap covering the storage compartment for sealing a product in the storage compartment. The overcap may also be made of a multi-layer polymer material to provide oxygen and moisture protection. A drinking aperture is defined in the annular portion to provide convenient access to liquids that may be held in the container.
• The overcap of further embodiments includes a skirt extending downwardly from the rim and includes a grip surface defined on the skirt. The skirt may include a plurality of spacers along an inner surface of the skirt, and the spacers may be circumferentially spaced apart from each other and extend downwardly from the rim of the overcap. The grip surface can be held by the consumer to support the container assembly when a hot liquid is held in the container. In addition, the spacers of the skirt insulate against heat from the hot liquid by spacing the skirt from the container wall.
• Likewise, another embodiment of the present invention provides an overcap for a container, wherein the overcap includes a rim configured to engage the container and a top wall that defines a storage compartment in an underside of the top wall. The top wall also includes a substantially horizontal annular portion radially inward of the rim and surrounding the storage compartment. The overcap also has a membrane removably attached to the underside of the top wall of the overcap covering the storage compartment for sealing a product contained in the storage compartment. A skirt extends downwardly from the rim and includes a grip surface defined on the skirt. The grip surface can be held by the consumer to support the container assembly when a hot liquid is held in the container and may insulate against heat from the hot liquid.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
• Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
• FIG. 1 is a perspective view of a container assembly in accordance with one embodiment of the present invention, illustrating the membrane of the overcap being removed to expose the product within the storage compartment;
• FIG. 2 is a schematic, cross-sectional view of the container assembly ofFIG. 1, showing the product stored within the storage compartment;
• FIG. 3 is a perspective view of a container assembly in accordance with a second embodiment of the present invention, illustrating the membrane of the overcap being removed to expose the product within the storage compartment; and
• FIG. 4 is a schematic, cross-sectional view of the container assembly ofFIG. 3, showing the product stored within the storage compartment.
DETAILED DESCRIPTION OF THE INVENTION
• The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
• With reference toFIGS. 1 and 2, acontainer assembly10 in accordance with one embodiment of the invention is illustrated. Thecontainer assembly10 ofFIG. 1 includes a lid orovercap12 and acontainer14 that defines a cup. Further embodiments of the present invention may comprise alternative containers. Thecontainer14 is structured to hold a liquid, in particular a hot liquid, which can be inserted into the container and removed from the container, through atop opening16. Thecontainer14 ofFIG. 1 is a tapered cup of a paper, plastic, or expanded polystyrene material, to list three non-limiting examples. Thecontainer14 includes abottom wall18 and a generallytubular side wall20 that is integrally formed with and upstanding from the bottom wall and terminates at atop edge22. As shown, theside wall20 may taper such that the diameter is larger at theopening16 than at thebottom wall18. Thetop edge22 encircles and defines theopening16 of thecontainer14. Thetop edge22 can also include a bead that projects radially outward from the top edge of theside wall20 to provide an improved surface for securing theovercap12 to thecontainer14. The illustratedovercap12 andcontainer14 are generally circular, but the present invention may also includecontainer assemblies10 of any geometric shape or relative size. In addition, thecontainer14 may be a container for holding non-liquid products.
• Theovercap12 has atop wall24 that is configured to extend over theopening16 of thecontainer14 when the overcap is secured thereon. Thetop wall24 defines arecessed storage compartment26 in an underside of the top wall. Thestorage compartment26 is configured to receive aproduct28 that is kept in the storage compartment by a removably attachedmembrane30. Themembrane30 is removable, as indicated by the arrow inFIG. 1, to provide access to theproduct28, preferably when the product is to be mixed with a hot liquid in thecontainer14. Themembrane30 can be completely removed from theovercap12 by the consumer when the consumer removes theproduct28; however, the membrane can also remain attached to the overcap after removal of theproduct28. Themembrane30 is initially attached to the underside of thetop wall24 during the manufacture of thecontainer assembly10 after theproduct28 has been placed in thestorage compartment26.
• Themembrane30 of the illustrated embodiment is constructed of a membranous material that is relatively impermeable to moisture. Examples of such membranous material include, but are not limited to metal foil, polyethylene terephthalate, metallized polyethylene terephthalate, polyethylene naphthalate, metallized polypropylene, metal oxide and silicate coated polyester, metal oxide and silicate coated polypropylene, ethylene vinyl alcohol copolymer, and mixtures thereof. Themembrane30 preferably prevents the ingress of moisture and the egress of theproduct28 while the membrane is fully attached to the underside of thetop wall24.
• Thetop wall24 further includes anannular portion32 surrounding thestorage compartment26. Theannular portion32 ofFIG. 1 is a substantially horizontal surface that defines adrinking aperture34. Theaperture34 provides access to a liquid in thecontainer14, which may be a hot liquid into which the storedproduct28 is mixed, such that a consumer can drink the liquid without removing theovercap12. Theaperture34 ofFIG. 1 includes two parallel walls joined by two arcuate walls; however, apertures of further embodiments of the invention may have any geometric pattern or may be of any size relative to theannular portion32.
• Surrounding theannular portion32 is arim36, as illustrated inFIG. 2. Therim36 defines arecess38 that is sized to engage thetop edge22 of theside wall20 of thecontainer14. The engagement of therecess38 and thetop edge22 holds thetop wall24 of theovercap12 in position over theopening16. Therecess38 defines a channel within therim36 that preferably provides an interference fit with thetop edge22, by virtue of the width of the recess being less than the thickness of the top edge when theovercap12 is in an undeformed free state. Therecess38 preferably engages thetop edge22 along the entire circumference of the top edge to also provide a sealed interface to prevent the product, which is typically a liquid, from passing between theovercap12 and thetop edge22.
• Extending downwardly from therim36 is theskirt40, as shown inFIG. 2. Theskirt40 is attached to therim36 and encircles atop portion42 of thecontainer14. Thetop portion42 of thecontainer14 is the portion of theside wall20 opposite thebottom wall18 and includes thetop edge22. In other words, thetop portion42 is theside wall20 immediately below thetop edge22. Theskirt40 may extend perpendicular to the substantially horizontal annular portion, or the skirt may extend generally parallel to thetop portion42 of the container. In addition, theskirt40 can flare outwardly, as inFIG. 2. Theskirt40 preferably extends downwardly below a lowermost surface of thetop wall24. As illustrated inFIG. 2, the lowermost surface of thetop wall24 is the surface to which themembrane30 is attached.
• Theskirt40 defines agrip surface44, which a consumer may grasp to hold thecontainer assembly10 and which may insulate the consumer against heat if a hot liquid is held in thecontainer14. Thegrip surface44 may be of any axial length that is sufficient to allow a customer to hold thecontainer assembly10 with or without touching the remainder of theovercap12 orcontainer14. Theovercap12 ofFIG. 1 has agrip surface44 of at least approximately 0.5 inch in length, though the grip surface is preferably at least 1 inch in length and still more preferably is 2 inches in length, as illustrated inFIGS. 3 and 4.
• A second embodiment of thecontainer assembly110 is illustrated inFIGS. 3 and 4, wherein theovercap112 includes askirt140 that provides agrip surface144. Thegrip surface144 extends downwardly from therim136 of theovercap112 and is intended to be a surface a consumer can grasp to hold thecontainer assembly110 when the liquid in the container is hot. Thecontainer114 includes abottom wall118 and aside wall120 upstanding from the bottom wall and terminating at atop edge122. Thetop edge122 encircles and defines atop opening116 of thecontainer114, and the top edge can also include a bead that projects radially outward from the top edge.
• Theovercap112 ofFIGS. 3 and 4 has atop wall124 configured to extend over the opening116 of thecontainer114 when the overcap is secured thereon. Thetop wall124 defines a recessedstorage compartment126 on an underside of the top wall. Thestorage compartment126 is configured to receive aproduct128 that is sealed in the storage compartment by amembrane130. Themembrane130 is removable, as indicated by the arrow inFIG. 3, to provide access to theproduct128. Themembrane130 is removably attached to a surface on the underside of thetop wall124 during the manufacture of thecontainer assembly110. Themembrane130 is also relatively impermeable to moisture.
• Thetop wall124 further includes anannular portion132 surrounding thestorage compartment126. Theannular portion132 ofFIG. 3 is a substantially horizontal surface that defines adrinking aperture134. Theaperture134 provides access to a liquid in thecontainer114 and can have any geometric pattern or be of any size relative to theannular portion132. Surrounding theannular portion132 is arim136, as illustrated inFIG. 4. Therim136 defines arecess138 that is sized to engage thetop edge122 of theside wall120 of thecontainer114 to hold theovercap112 in position over theopening116. Therecess138 preferably provides an interference fit with thetop edge122 and preferably engages the top edge along the entire circumference of the top edge to provide a sealed interface.
• Extending downwardly from therim136 is theskirt140, as shown inFIG. 4. Theskirt140 is attached to therim136 and encircles atop portion142 of thecontainer114. Thetop portion142 of thecontainer114 is immediately below thetop edge122. Theskirt140 includes agrip surface144, which a consumer may grasp to hold thecontainer assembly110. Thegrip surface144 is preferably 2 inches in axial length in the embodiment illustrated inFIG. 4. Theskirt140 also extends downwardly below a lowermost surface of thetop wall124, which is the surface to which themembrane130 is attached, similar to the embodiment ofFIG. 2.
• Theskirt140 ofFIG. 3 also includes a plurality ofspacers146 on aninner surface148 of the skirt. Thespacers146 are circumferentially spaced apart from each other and extend downwardly from therim136 of theovercap112 to an end of theskirt140 opposite the rim. Thespacers146 can improve the engagement between theovercap112 and thecontainer114 if the spacers are sized to create an interference fit with theside wall120 of the container, as illustrated inFIG. 4. Thespacers146 project radially inwardly from theinner surface148 of theskirt140 and radially space the skirt from thecontainer side wall120 to insulate against the heat of a hot liquid in thecontainer114 by providing a continuous pocket, or individual pockets, of air between theside wall120 and theskirt140 that reduce the thermal transfer to the skirt. Therefore, theskirt140 ofFIGS. 3 and 4 provides agrip surface144 that a consumer can grasp to hold thecontainer assembly110 and to insulate the consumer's hand when the liquid in thecontainer114 is hot.
• Thestorage compartment26 and126 ofFIGS. 2 and 4, respectively, is a frustoconical chamber that includes a flat top surface. This domed portion of thetop wall24 and124 defines thestorage compartment26 and126, respectively. Further embodiments of the present invention include storage compartments of any shape, a non-limiting example being hemispherical. In addition, thestorage compartment26 and126 of additional embodiments also include a desiccant to absorb moisture so that the product, which is preferably a powder, is exposed to a minimal amount of moisture. The desiccant can be joined to the inside surface of thestorage compartment26 and126 or can be incorporated as a layer of themembrane30 and130. Non-limiting examples of desiccant material include sodium phosphate di-basic, calcium oxide, sucrose, gelatin, bentonite clay, and silica gel.
• Theannular portion32 and132 ofFIGS. 2 and 4, respectively, define a stacking surface upon which anothercontainer14 and114 can be stacked so that the top container is firmly supported by theovercap12 or112 of the bottom container. Thebottom wall18 and118 of thecontainer14 and114, respectively, defines a recess structured and arranged to receive thetop wall24 and124 of thecompartment26 and126 of theovercap12 and112. Advantageously, the recess of thebottom wall18 and118 prevents lateral sliding of the stacked container relative to the bottom container. Further embodiments of theovercap12 and112 may define an edge of therim36 and136 that engages the bottom of theside wall20 or120 to prevent lateral sliding of the stacked container relative to the bottom container. Still further embodiments of the present invention may comprise alternative stacking surfaces or features for secure stacking of a top container onto the overcap of a bottom container.
• To manufacture thecontainer assembly10 of the present invention, thecontainer14 and theovercap12 are individually formed. Preferably, theovercap12 is thermoformed, injected molded, or blow molded from a polymer material. Theovercap12 may be formed to include a multi-layer polymer structure to provide oxygen and moisture barrier should the packaged product require such a barrier. After theovercap12 hardens, theproduct28 can be inserted into thestorage compartment26 and themembrane30 attached to the underside of thetop wall24. Themembrane30 is attached to theovercap12 by any suitable process, which include conductive heat sealing, ultrasonic sealing, the applying of adhesives, or any other joining method. Once theproduct28 is securely stored in thestorage compartment26, theovercap12 can be paired with thecontainer14 to complete thecontainer assembly10.
• Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims (22)

1. An overcap for a container, wherein the overcap can store a product for mixing with a liquid held in the container, the overcap comprising:

a rim configured to engage the container;

a top wall defining a storage compartment in an underside of the top wall, the top wall having a substantially horizontal annular portion radially inward of the rim and surrounding the storage compartment, a drinking aperture being defined in the annular portion; and

a membrane removably attached to the underside of the top wall of the overcap covering the storage compartment for sealing a product contained in the storage compartment.

2. An overcap ofclaim 1, further comprising a skirt extending downwardly from the rim.

3. An overcap ofclaim 2, wherein the skirt defines a grip surface.

4. An overcap ofclaim 3, wherein the skirt extends below a lowermost surface of the top wall of the overcap.

5. An overcap ofclaim 3, wherein the skirt includes a plurality of spacers extending along an inner surface of the skirt.

6. An overcap ofclaim 5, wherein the plurality of spacers are circumferentially spaced apart from each other and extend downwardly from the rim of the overcap.

7. An overcap ofclaim 1, wherein the storage compartment defines a domed portion.

8. An overcap ofclaim 7, wherein the domed portion has incorporated therein a desiccant.

9. An overcap ofclaim 1, wherein the membrane is relatively impermeable to moisture.

10. An overcap for a container, wherein the overcap can store a product for mixing with a liquid held in the container, the overcap comprising:

a rim configured to engage the container;

a top wall defining a storage compartment in an underside of the top wall, the top wall having a substantially horizontal annular portion radially inward of the rim and surrounding the storage compartment;

a skirt extending downwardly from the rim, wherein the skirt defines a grip surface; and

a membrane removably attached to the underside of the top wall of the overcap covering the storage compartment for sealing a product contained in the storage compartment.

11. An overcap ofclaim 10, wherein the skirt extends below a lowermost surface of the top wall of the overcap.

12. An overcap ofclaim 11, wherein the skirt includes a plurality of spacers extending along an inner surface of the skirt.

13. An overcap ofclaim 12, wherein the plurality of spacers are circumferentially spaced apart from each other and extend downwardly from the rim of the overcap.

14. An overcap ofclaim 13, wherein the storage compartment defines a domed portion.

15. An overcap ofclaim 14, wherein the domed portion has incorporated therein a desiccant.

16. An overcap ofclaim 10, wherein the membrane is relatively impermeable to moisture.

17. An overcap ofclaim 10, further comprising a drinking aperture defined in the annular portion.

18. A container assembly comprising:

a container comprising a bottom wall and a tubular side wall upstanding from the bottom wall, the side wall having a top edge encircling a top opening of the container;

a cap having rim configured to engage the top edge of the container, the cap having a top wall defining a storage compartment in an underside of the top wall, the top wall having a substantially horizontal annular portion radially inward of the rim and surrounding the storage compartment, a drinking aperture being defined in the annular portion; and

a membrane removably attached to the underside of the top wall of the overcap covering the storage compartment for sealing a product contained in the storage compartment.

19. A container assembly ofclaim 18, further comprising a skirt extending downwardly from the rim.

20. A container assembly ofclaim 19, wherein the skirt extends below a lowermost surface of the top wall of the overcap and defines a grip surface.

21. A container assembly ofclaim 20, wherein the skirt includes a plurality of spacers extending along an inner surface of the skirt, wherein the plurality of spacers are circumferentially spaced apart from each other and extend downwardly from the rim of the overcap.

22. A container assembly ofclaim 18, wherein the membrane is relatively impermeable to moisture.

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