A disposable cup set and a method of assembling the same

Abstract

A disposable cup set is provided. Disposable cup set includes an outer cup including a top edge and a bottom edge opposite the top edge, such that the outer cup include an outer base at the bottom edge, an outer opening at the top edge, and an inner engaging portion surrounding the outer opening at the top edge; an inner cup comprising a top end and a bottom end opposite the top end, such that the inner cup include an inner base at the bottom end, an inner opening at the top end, and an outer engaging portion surrounding the inner opening at the top end, such that the outer engaging portion is adapted to engage the inner engaging portion and such that the inner cup is smaller than the outer cup; such that the disposable cup set is adapted to be assembled by inserting the inner cup into the outer cup and securing the outer engaging portion to the inner engaging portion. Further, a method of assembling the disposable cup set is provided.

Description

A Disposable Cup Set And A Method Of Assembling The SameTechnical Field

[0001] The present invention relates to a disposable cup set and a method of assembling the same. Specifically, the present invention relates to disassembled disposable cup set.Background

[0002] Disposable cups are generally used to contain beverages for take-away orders. For cold beverages, to keep the beverage cold, ice is added to the beverage. However, the ice when melted would dilute the beverage and result in the quality of the beverage to deteriorate.

[0003] In order to keep the beverage cold without ice, thermal insulating cups may be used. However, as such cups are typically made of metal or hard plastic. The cost of the beverage will be high due to the high cost of such cups. Furthermore, it is difficult to transport and store such cups as it has to be individually boxed and stored. Consequently, the cost for storing and transporting such cups will be high. Due to the high cost and material used, it is not practicable to use them as a disposable cup set.

[0004] Therefore, it would be beneficial to have a disposable cup that is able to keep beverage cold without ice. It would also be beneficial if the disposable cup does not take up storage space, especially during transportation.Summary

[0005] According to various embodiments, a disposable cup set is provided. Disposable cup set includes an outer cup including a top edge and a bottom edge opposite the top edge, such that the outer cup include an outer base at the bottom edge, an outer opening at the top edge, and an inner engaging portion surrounding the outer opening at the top edge; an inner cup comprising a top end and a bottom end opposite the top end, such that the inner cup include an inner base at the bottom end, an inner opening at the top end, and an outer engaging portion surrounding the inner opening at the top end, such that the outer engaging portion is adapted toengage the inner engaging portion and such that the inner cup is smaller than the outer cup; such that the disposable cup set is adapted to be assembled by inserting the inner cup into the outer cup and securing the outer engaging portion to the inner engaging portion.

[0006] According to various embodiments, the outer engaging portion may include a lip and the inner engaging portion may include a rim, such that the lip is snap-fitted onto the rim to engage it to secure the inner cup to the outer cup.

[0007] According to various embodiments, the lip may include a resilient channel having a J- shaped sectional profile, such that the rim is snap-fitted into the channel to allow the lip to engage the rim so as to secure the inner cup to the outer cup.

[0008] According to various embodiments, the outer cup may include an outer height from the top edge to the bottom edge and an outer perimeter of the outer cup, and the inner cup may include an inner height from the top end to the bottom end and an inner perimeter of the inner cup, such that the inner height is shorter than the outer height and the inner perimeter is smaller than the outer perimeter, such that when the inner cup is inserted into and secured to the outer cup, the outer engaging portion and the inner engaging portion forms a seal to form a liquid- tight space between the inner cup and the outer cup, and such that the space may be adapted to contain a liquid.

[0009] According to various embodiments, the liquid is filled into the outer cup before inserting the inner cup into the outer cup and securing the inner cup to the outer cup.

[0010] According to various embodiments, the amount of liquid filled may be at most 90% of the space.

[0011] According to various embodiments, the disposable cup set when assembled and filled with liquid is disposed in a freezer in an inverted position to freeze the liquid therein, such that in the inverted position, the outer base is above the outer opening.

[0012] According to various embodiments, the outer cup may be made of recyclable PET (polyethylene terephthalate) plastic or recyclable PP (polypropylene).

[0013] According to various embodiments, the inner cup may be made of recyclable PET (polyethylene terephthalate) or recyclable PP (polypropylene).

[0014] According to various embodiments, the inner cup may be made to be stiffer than the outer cup.

[0015] According to various embodiments, a method of assembling a disposable cup set is provided. The disposable cup set includes an outer cup comprising a top edge and a bottom edge opposite the top edge, such that the outer cup includes an outer base at the bottom edge, an outer opening at the top edge, and an outer engaging portion surrounding the outer opening at the top edge; an inner cup includes a top end and a bottom end opposite the top end, such that the inner cup include an inner base at the bottom end, an inner opening at the top end, and an inner engaging portion surrounding the inner opening at the top end, such that the outer engaging portion is adapted to engage the inner engaging portion and such that the inner cup is smaller than the outer cup; such that the disposable cup set is assembled by inserting the inner cup into the outer cup and securing the outer engaging portion to the inner engaging portion. The method includes positioning the outer cup in an upright position, such that the top edge is above the bottom edge; filling the outer cup with a liquid; inserting the inner cup in an upright position into the outer cup, such that the top end is above the bottom end; and engaging the outer engaging portion to the inner engaging portion to secure the inner cup to the outer cup to form a liquid tight space between the inner cup and outer cup.

[0016] According to various embodiments, the liquid may be filled up to 90% of the spaced formed between the inner cup and the outer cup.

[0017] According to various embodiments, the assembled disposable cup set is disposed in a freezer in an inverted position to freeze the liquid therein, such that in the inverted position, the outer base is above the outer opening.Brief Description of Drawings

[0018] Fig. 1 shows a sectional view of an exemplary embodiment of a disposable cup set.

[0019] Fig. 2 shows a sectional view of an exemplary embodiment of an assembled disposable cup set.

[0020] Fig. 3 shows a sectional view of another embodiment of the disposable cup set.

[0021] Fig, 4 shows a sectional view of the embodiment of the disposable cup set in Fig. 3 that has been assembled.

[0022] Fig. 5A and Fig. 5B show a sectional view of the outer cup filled with the liquid and with the inner cup inserted into the outer cup respectively.

[0023] Fig. 6 shows an exemplary method of assembling the disposable cup set.

[0024] Fig. 7 shows the assembled disposable cup set in an inverted position when being frozen.

[0025] Fig. 8 shows the assembled disposable cup with a cup cover.Detailed Description

[0026] In the following examples, reference will be made to the figures, in which identical features are designated with like numerals.

[0027] Fig. 1 shows a sectional view of an exemplary embodiment of a disposable cup set 100. Disposable cup set 100 includes an outer cup 110 comprising a top edge HOT and a bottom edge HOB opposite the top edge HOT, such that the outer cup 110 includes an outer base 112 at the bottom edge 110B, an outer opening 114 at the top edge HOT, and an outer engaging portion 116 surrounding the outer opening 114 at the top edge HOT. Disposable cup set 100 further includes an inner cup 120 comprising a top end 120T and a bottom end 120B opposite the top end 120T, such that the inner cup 120 includes an inner base 122 at the bottom end120B and an inner opening 124 at the top end 120T, and an inner engaging portion 126 surrounding the inner opening 124 at the top end 120T, such that the outer engaging portion 116 is adapted to engage the inner engaging portion 126. As shown in Fig. 1, the inner cup 120 is smaller than the outer cup 110. For example, inner cup 120 may be about 13.5oz and the outer cup 110 may be about 22oz. Inner cup 120 is adapted to contain beverage.

[0028] In order to allow the disposable cup set 100 to be disposable, the cost of the disposable cup set 100 has to be low. Hence, the costs of the material used for the disposable cup set 100 and its manufacturing costs has to be low. Preferably, the disposable cup set 100 is made from plastic material. For example, the outer cup 110 and / or the inner cup 120 may be made of recyclable PET (polyethylene terephthalate) plastic or recyclable PP (polypropylene). Inner cup 120 may be made to be stiffer than the outer cup 110 so that the inner cup 120 is rigid enough to secure the outer cup 110 to it. Inner cup 120 and outer cup 110 may have a tapered shape to allow stackability.

[0029] As the disposable cup set 100 is disassembled, it is possible to stack one outer cup 110 into another to form a tube of outer cups 110. Similarly, it is possible to form a tube of inner cups 120 with one inner cup 120 stacked into another. In this way, the amount of storage space required to store the inner cup 120 and outer cup 110 is significantly reduced. Consequently, it is possible to transport more cups 100 compared to conventional thermal insulating cups and the cost to transport the containers 110,120 is also reduced. At a beverage stall where space is limited, it is critical to make full use of any storage area so that the space is optimally utilized for other purposes.

[0030] Fig. 2 shows a sectional view of an exemplary embodiment of an assembled disposable cup set 100. Disposable cup set 100 is adapted to be assembled. Disposable cup set 100 may be assembled by inserting the inner cup 120 into the outer cup 110 and securing the outer engaging portion 116 to the inner engaging portion 126. When the inner cup 120 is inserted into and secured to the outer cup 110, the outer engaging portion 116 and the inner engaging portion 126 forms a seal to form an air-tight or liquid-tight space 100S between the inner cup 120 and the outer cup 110. As shown in Fig. 2, the disposable cup set 100 has a double wall construction. Space 100S is occupied with air and acts as an insulating barrier to prevent heat transfer between the beverage and the surrounding. Space 100S may be adapted to contain aliquid, e.g. water, freezing fluid. Beverage is filled into the assembled disposable cup set 100 by receiving the beverage via the inner opening 124.

[0031] As shown in Fig. 2, the outer cup 110 may include an outer height 110H from the top edge 110T to the bottom edge HOB and an outer perimeter 11 OP of the outer cup 110, and the inner cup 120 may include an inner height from the top end 120T to the bottom end 120B and an inner perimeter of the inner cup 120, such that the inner height 120H is shorter than the outer height 110H and the inner perimeter 120P is smaller than the outer perimeter HOP. Space 100S is enclosed by the inner cup 120 and the outer cup 110. For example, the outer cup 120 may have an outer perimeter of 308 mm (diameter of 98mm) and the inner cup 110 may have an inner perimeter of 289mm (diameter of 92mm). Outer perimeter HOP may be the average perimeter of the perimeters throughout the outer height 11 OH of the outer cup 110. Inner perimeter 120P may be the average perimeter of the perimeters throughout the inner height 120H of the inner cup 120. Outer height 110H may be shorter than the inner height 120H. As shown in Fig. 2, the inner base 122 is spaced from the outer base 112.

[0032] Outer engaging portion 116 may include a lip and the inner engaging portion 126 may include a rim. To engage the rim, the lip may be snap-fitted onto the rim to secure the inner cup 120 to the outer cup 110. Lip may include a resilient channel having a J-shaped sectional profile, such that the rim is snap-fitted into the channel to allow the lip to engage the rim so as to secure the inner cup 120 to the outer cup 110. As the lip is resilient, the channel expands outwardly when the rim is pushed into it and snaps back into position after the rim is in the channel.

[0033] Fig. 3 shows a sectional view of another embodiment of the disposable cup set 300. Outer engaging portion 316 may include a rim at the top edge 310T, an outer upper wall portion 316U extending downwardly from the rim 316R and an outer lower wall portion 316L extending from the outer upper wall portion 316U to the outer base 312 of the outer cup 310. Outer cup 310 may include a step 316S formed between the outer upper wall portion 316U and the outer lower wall portion 316L. Inner engaging portion 326 may include a border 326B at the top end 320T, an inner upper wall portion 326U extending downwardly from the border 326B and an inner lower wall portion 326L extending from the inner upper wall portion 326Uto the inner base 322. Inner cup 320 may include a shoulder 320S formed between the inner upper wall portion 326U and the inner lower wall portion 326L. The perimeter of the outer upper wall portion 316U may be slightly smaller than the perimeter of the inner upper wall portion 326U so that the inner cup 320 and the outer cup 310 may be secured to each other by an interference fit between the outer upper wall portion 316U and the inner upper wall portion 326U when the inner cup 320 is inserted into the outer cup 310. As shown in Fig. 3, the outer upper wall portion 316U and the inner upper wall portion 326U may be slanted. However, the outer upper wall portion 316U and the inner upper wall 326U may be vertical. In any case, the angle of the outer upper wall portion 316U and the inner upper wall portion 326U has to be the same so that they can fit tightly to each other to form a seal.

[0034] Fig, 4 shows a sectional view of the embodiment of the disposable cup set 300 in Fig. 3 that has been assembled. As shown in Fig. 4, the inner cup 320 is inserted into the outer cup 310 and the inner upper wall portion 326U is fitted into the outer upper wall portion 316U. Inner cup 320 is prevented from being displaced lower into the outer cup 310 by the border 326B abutting the rim 316R. Similarly, the inner cup 320 may be prevented from being displaced lower into the outer cup 310 when the step 316S rests on the shoulder 326S. When the inner cup 320 is engaged to the outer cup 310, the air-tight or liquid-tight space 300S is formed.

[0035] As the inner cup 120 and outer cup 110 are generally made from thin plastic, due to the strength of the material used for the inner cup 120 and outer cup 110, it would not be possible to incorporate thread to the inner cup 120 and the outer cup 110 to allow the outer cup 110 to be screwed onto the inner cup 120. Furthermore, due to the manufacturing process, e.g. injection moulding, it would be difficult to produce threads on the inner cup 120 and the outer cup 110. Even if it is produced, it would be difficult to manoeuvre the inner cup 120 to be screwed onto the outer cup 110.

[0036] Fig. 5A and Fig. 5B show a sectional view of the outer cup 110 filled with the liquid 20 and with the inner cup 120 inserted into the outer cup 110 respectively. Liquid 20 is filled into the outer cup 110 before inserting the inner cup 120 into the outer cup 110 and securingthe inner cup 120 to the outer cup 110. Preferably, the amount of liquid 20 filled may be at most 90% of the space 100S.

[0037] Fig. 6 shows an exemplary method 1000 of assembling the disposable cup set 100. Method 1000 includes positioning the outer cup 110 in an upright position as shown in Fig. 5 A in block 1100, such that the top edge 110T is above the bottom edge HOB, filling the outer cup 110 with a liquid in block 1200, inserting the inner cup 120 in an upright position into the outer cup 110 in block 1300, such that the top end 120T is above the bottom end 120B, and engaging the outer engaging portion 116 to the inner engaging portion 126 to secure the inner cup 120 to the outer cup 110 to form a liquid tight space between the inner cup 120 and outer cup 110 in block 1400.

[0038] Fig. 7 shows the assembled disposable cup set 100 in an inverted position when being frozen. As shown in Fig. 7, the assembled disposable cup set 100 may be disposed in a freezer in an inverted position to freeze the liquid 20 therein, such that in the inverted position, the outer base 112 is above the outer opening 114. As the material used for the disposable cup set 100 is not sufficient rigid, if the disposable cup set 100 is frozen in an upright position, the outer cup 110 may deform due to the expansion of the frozen water or ice. Hence, in the inverted position, the disposable cup set 100 will not be deformed due to the expansion of frozen water. In addition, it is possible to stack an assembled disposable cup set 100 into each other to save space in the freezer. An intermediate cup 30 may be disposed between two assembled disposable cup sets 100 to help retain the shape of the assembled disposable cup set 100 during freezing to maintain the shape of the disposable cup set 100.

[0039] Fig. 8 shows the assembled disposable cup 100 with a cup cover 140. Disposable cup set 100 may include a cup cover 140 adapted to cover the assembled disposable cup set 100. Cup cover 140 may be snap-fitted onto the inner engaging portion 126 of the inner cup 120. Cup cover 140 may include a cover opening for beverage to flow through or a straw to be inserted therethrough.

[0040] When the inner cups 120 and the outer cups 110 are delivered to the beverage stall, the stall operator would then be able to assemble the disposable cup set 100 on-site. If theassembled cup set 100 is filled with liquid 20, the stall operator would place the filled assembled disposable cup set 100 in the freezer. When an order for a cold beverage, e.g. cold brew coffee, is received, the stall operator may retrieve the frozen assembled disposable cup set 100 from the freezer to fill it with the beverage. In this way, the beverage is kept chilled for an extended period by the disposable cup set 100 without diluting the flavour of the beverage so that the consumer can enjoy the original taste of the beverage. Hence, the disposable cup set 100 may also be known as an insulating disposable cup set 100 which insulates heat from reaching the beverage. Also, as the cost of the disposable cup set 100 is low, the price of the beverage can be kept affordable with adequate profit margin for the stall operator.

[0041] A skilled person would appreciate that the features described in one example may not be restricted to that example and may be combined with any one of the other examples.

[0042] The present invention relates to a disposable cup set and a method of assembling the disposable cup set generally as herein described, with reference to and / or illustrated in the accompanying drawings.

Claims

Claim1. A disposable cup set comprising: an outer cup comprising a top edge and a bottom edge opposite the top edge, wherein the outer cup comprises an outer base at the bottom edge, an outer opening at the top edge, and an inner engaging portion surrounding the outer opening at the top edge; an inner cup comprising a top end and a bottom end opposite the top end, wherein the inner cup comprises an inner base at the bottom end, an inner opening at the top end, and an outer engaging portion surrounding the inner opening at the top end, wherein the outer engaging portion is adapted to engage the inner engaging portion and wherein the inner cup is smaller than the outer cup; wherein the disposable cup set is adapted to be assembled by inserting the inner cup into the outer cup and securing the outer engaging portion to the inner engaging portion.

2. The disposable cup set according to claim 1, wherein the outer engaging portion comprises a lip and the inner engaging portion comprises a rim, wherein the lip is snap-fitted onto the rim to engage it to secure the inner cup to the outer cup.

3. The disposable cup set according to claim 1 or 2, wherein the lip comprises a resilient channel having a J-shaped sectional profile, wherein the rim is snap-fitted into the channel to allow the lip to engage the rim so as to secure the inner cup to the outer cup.

4. The disposable cup set according to any one of claims 1 to 3, wherein the outer cup comprises an outer height from the top edge to the bottom edge and an outer perimeter of the outer cup, and the inner cup comprises an inner height from the top end to the bottom end and an inner perimeter of the inner cup, wherein the inner height is shorter than the outer height and the inner perimeter is smaller than the outer perimeter, wherein when the inner cup is inserted into and secured to the outer cup, the outer engaging portion and the inner engaging portion forms a seal to form a liquid-tight space between the inner cup and the outer cup, and wherein the space is adapted to contain a liquid.

5. The disposable cup set according to claim 4, wherein the liquid is filled into the outer cup before inserting the inner cup into the outer cup and securing the inner cup to the outer cup.

6. The disposable cup set according to claim 4 or 5, wherein the amount of liquid filled is at most 90% of the space.

7. The disposable cup set according to any one of claims 4 to 6, wherein the disposable cup set when assembled and filled with liquid is disposed in a freezer in an inverted position to freeze the liquid therein, wherein in the inverted position, the outer base is above the outer opening.

8. The disposable cup set according to any one of claims 1 to 7, wherein the outer cup is made of recyclable PET (polyethylene terephthalate) plastic or recyclable PP (polypropylene).

9. The disposable cup set according to any one of claims 1 to 8, wherein the inner cup is made of recyclable PET (polyethylene terephthalate) or recyclable PP (polypropylene).

10. The disposable cup set according to any one of claims 1 to 9, wherein the inner cup is made to be stiffer than the outer cup.

11. A method of assembling a disposable cup set comprising an outer cup comprising a top edge and a bottom edge opposite the top edge, wherein the outer cup comprises an outer base at the bottom edge, an outer opening at the top edge, and an outer engaging portion surrounding the outer opening at the top edge; an inner cup comprising a top end and a bottom end opposite the top end, wherein the inner cup comprises an inner base at the bottom end, an inner opening at the top end, and an inner engaging portion surrounding the inner opening at the top end, wherein the outer engaging portion is adapted to engage the inner engaging portion and wherein the inner cup is smaller than the outer cup; wherein the disposable cup set is assembled by inserting the inner cup into the outer cup and securing the outer engaging portion to the inner engaging portion; wherein the method comprising:positioning the outer cup in an upright position, wherein the top edge is above the bottom edge; filling the outer cup with a liquid; inserting the inner cup in an upright position into the outer cup, wherein the top end is above the bottom end; and engaging the outer engaging portion to the inner engaging portion to secure the inner cup to the outer cup to form a liquid tight space between the inner cup and outer cup.

12. The method according to claim 11, wherein the liquid is filled up to 90% of the spaced formed between the inner cup and the outer cup.

13. The method according to claim 11 or 12, wherein the assembled disposable cup set is disposed in a freezer in an inverted position to freeze the liquid therein, wherein in the inverted position, the outer base is above the outer opening.

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