Abstract: A thermally insulated cup is formed from a single-walled paper or plastic inner cup and an insulating outer wrapper. The insulating outer wrapper comprises a paper base sheet or outer sidewall blank, optionally printed on one side, and a corrugated paper or foamed plastic insulating insert. The insulating insert is similar in shape to the outer sidewall blank but smaller in size. The insert is glued in a centered position to the non-printed side of the sidewall blank to form a two-layered insulating wrapper. Less than 20% of the area of the insert is glued to the base sheet. Specifically, no glue is applied to the area adjacent to the cut side edges of the insert, and as such these edges are not attached to the base sheet. The wrapper is then wrapped around the single walled inner cup. The side edges of the base sheet of the wrapper overlap and are sealed directly together to form a side seam. The side seam is itself adhesively secured to the side wall of the inner cup.

Abstract: A flexible container cover with an elastic gathering band around its edge is formed from a rectangular sheet of plastic film with recessed cut corners to form four flaps. The sheet is placed atop a mandrel having a rectangular flat top with eaves or undercut surfaces and four corner slots. Four hooks are positioned outside the slots so they underlie the cut-off corners of the sheet. An elastic band is stretched around the hooks and the flaps of the sheet. The hooks are moved inwardly into the slots to allow the segments of the band to pull and fold a middle portion of each flap inward. A set of tucker blades is then moved inward to push the folded portions of the flaps against side surfaces of the mandrel under the eaves. Four heat-sealing bars are moved up against the eaves to seal the flaps around the segments of the band to form hems.

Abstract: A flexible, elastically gathered cover for food containers or the like, and a method of making such covers, uses a forming machine with a lower section having: a) a square shaped forming mandrel having a top, four substantially vertical sides, and a heating element extending longitudinally along each side, b) four elongated sealing bars having a tops with a guide and a front with an elongated strip of rubber attached, and c) a cover ejector with upwardly extending ejector pins. Each sealing bar is positioned opposite a respective side of the forming mandrel separated to create a forming groove around the mandrel. An upper section having a forming head assembly comprises: a) a forming die with sides that define a cavity sized to telescope over the forming mandrel, and b) a band ejector plate with plural downwardly extending ejector pins located along the perimeter. The forming die hangs below the band ejector plate.

Abstract: A flexible cover is formed from a rectangular sheet of plastic film material and a continuous elastic or rubber band. The sheet has a predetermined amount of material cut from each corner. The sheet is placed onto a table between four posts that extend from the table. The sheet is positioned so that a post lines up with each corner of the sheet. A rubber band is stretched across the four posts into a similar shaped rectangle and rests just above side edges of the sheet. The side edges of the sheet are folded inward and over the stretched band and heat sealed directly to the sheet. The band is now sealed within a pocket formed along the sides of the sheet. Each corner of the stretched band is released from its post, allowing the band to relax and pull the formed pockets toward the center.

Abstract: A flexible cover is formed from a rectangular sheet of plastic film material and a continuous elastic or rubber band. The sheet has a predetermined amount of material cut from each corner. The sheet is placed onto a table between four posts that extend from the table. The sheet is positioned so that a post lines up with each corner of the sheet. A rubber band is stretched across the four posts into a similar shaped rectangle and rests just above the sheet. The stretched rubber band now has four sides which correspond to the four sides of the sheet. The side edges of the sheet are folded inward and over the stretched band and heat sealed directly to the sheet. The band is now sealed within a pocket that is formed along the sides of the sheet. Each corner of the stretched band is released from its post, allowing the band to relax and pull the four pockets of the sheet toward the center.

Abstract: A method of producing an insulated container having a cup and an insulating wrapper is provided. In some embodiments, the insulating wrapper is formed by adhering an insert to a base sheet without attaching the edges of the insert to the base sheet. The insulating wrapper is then wrapped around the cup using automated cup forming machinery.

Abstract: A flexible, elastically gathered cover for food containers or the like, and a method of making such covers, uses a forming machine with a lower section having: a) a square shaped forming mandrel having a top, four substantially vertical sides, and a heating element extending longitudinally along each side, b) four elongated sealing bars having a tops with a guide and a front with an elongated strip of rubber attached, and c) a cover ejector with upwardly extending ejector pins. Each sealing bar is positioned opposite a respective side of the forming mandrel separated to create a forming groove around the mandrel. An upper section having a forming head assembly comprises: a) a forming die with sides that define a cavity sized to telescope over the forming mandrel, and b) a band ejector plate with plural downwardly extending ejector pins located along the perimeter. The forming die hangs below the band ejector plate.

Abstract: The present invention relates to insulated containers useful for serving, for example, hot beverages. Specifically, the present invention relates to multilayer containers comprising a corrugated sheet as an inner insulating liner wherein the liner comprises interruptions.

Abstract: A flexible cover is formed from a rectangular sheet of plastic film material and a continuous elastic or rubber band. The sheet has a predetermined amount of material cut from each corner. The sheet is placed onto a table between four posts that extend from the table. The sheet is positioned so that a post lines up with each corner of the sheet. A rubber band is stretched across the four posts into a similar shaped rectangle and rests just above the sheet. The stretched rubber band now has four sides which correspond to the four sides of the sheet. The side edges of the sheet are folded inward and over the stretched band and heat sealed directly to the sheet. The band is now sealed within a pocket that is formed along the sides of the sheet. Each corner of the stretched band is released from its post, allowing the band to relax and pull the four corners of the sheet toward the center.

Abstract: The present invention relates to insulated containers useful for serving, for example, hot beverages. Specifically, the present invention relates to multilayer containers comprising a corrugated sheet as an inner insulating liner wherein the liner comprises interruptions.

Abstract: A cup and lid holder has two parts: a bottom part holds two stacks of insulated paper cups and a top part holds two stacks of mating lids. The holder is folded from a flat blank. The blank is one piece and folds into a two-level structure with three horizontal parts: a bottom, a partition to separate the lids from the cups, and a top. The bottom has two fold-up tabs that fit into the bottoms of the bottom cup of each stack to hold them in place. The top comprises two rings that fit around the turrets of the top lid of each stack to hold them in place. The middle partition rests against the tops of the top cup in each stack to hold the stack in position. The middle partition is formed of two sets of two tabs each that interfit and extend from the tops of the front and bottom walls. Two stacks of lids are loaded into the top part and two stacks of cups are loaded into the bottom part. The holder with the loaded lids and cups is shrink-wrapped and printed.

Abstract: An insulating cup or container (50) and a method of manufacturing it comprises (first embodiment) a sidewall blank (12B) having two sections separated by a fold score (15), and a separate insulating sheet (18)(corrugated, ribbed, embossed, foamed, perforated, etc.) which is adhesively fastened to one of the sections. The blank is folded in half along the fold score, to form a three-layered assembly with the insulating sheet in the middle. To reduce the thickness of the seam, the blank is thinned in the area adjacent a fold score prior to folding. The assembly is wrapped around a mandrel to bring the outer edges together at a side seam (22S) to form a sidewall 12. The side seam is sealed, the bottom is added, and the rim is formed. In a second embodiment, the insulating layer can be a coating on one or both of the sections of the two-section starting blank. In a third embodiment, the insulating section (40) can be integral with, and extend from, one edge of the starting blank.

Abstract: An insulating cup or container (50) and a method of manufacturing it comprises (first embodiment) providing a sidewall blank (12B) having two sections separated by a fold score (15), and a separate insulating sheet (18)(corrugated, ribbed, embossed, foamed, perforated, etc.) which is adhesively fastened to one of the sections. The blank is folded in half along the fold score, to form a three-layered assembly with the insulating sheet in the middle. To reduce the thickness of the seam, the blank is thinned in the area adjacent a fold score prior to folding. The assembly is wrapped around a mandrel to bring the outer edges together at a side seam (22S) to form a sidewall 12. The side seam is sealed, the bottom is added, and the rim is formed. In a second embodiment, the insulating layer can be a coating on one or both of the sections of the two-section starting blank. In a third embodiment, the insulating section (40) can be integral with, and extend from, one edge of the starting blank.

Abstract: An insulating cup or container (50) and a method of manufacturing it comprises (first embodiment) providing a sidewall blank (12B) having two sections separated by a fold score (15), and a separate insulating sheet (18) (corrugated, ribbed, embossed, foamed, perforated, etc.) which is adhesively fastened to one of the sections. The blank is folded in half along the fold score, to form a three-layered assembly with the insulating sheet in the middle. To reduce the thickness of the seam, the blank is thinned in the area adjacent a fold score prior to folding. The assembly is wrapped around a mandrel to bring the outer edges together at a side seam (22S) to form a sidewall 12. The side seam is sealed, the bottom is added, and the rim is formed. In a second embodiment, the insulating layer can be a coating on one or both of the sections of the two-section starting blank. In a third embodiment, the insulating section (40) can be integral with, and extend from, one edge of the starting blank.

Abstract: An insulating cup or container (50) and a method of manufacturing it comprises (first embodiment) providing a sidewall blank (12B) having two sections separated by a fold score (15), and a separate insulating sheet (18) (corrugated, ribbed, embossed, foamed, perforated, etc.) which is adhesively fastened to one of the sections. The blank is folded in half along the fold score, to form a three-layered assembly with the insulating sheet in the middle. To reduce the thickness of the seam, the blank is thinned in the area adjacent a fold score prior to folding. The assembly is wrapped around a mandrel to bring the outer edges together at a side seam (22S) to form a sidewall 12. The side seam is sealed, the bottom is added, and the rim is formed. In a second embodiment, the insulating layer can be a coating on one or both of the sections of the two-section starting blank. In a third embodiment, the insulating section (40) is integral with, and extends from, one edge of the starting blank.

Abstract: An insulating cup or container (50) and a method of manufacturing it comprises (first embodiment) providing a sidewall blank (12B) having two sections separated by a fold score (15), and a separate insulating sheet (18)(corrugated, ribbed, embossed, foamed, perforated, etc.) which is adhesively fastened to one of the sections. The blank is folded in half along the fold score, to form a three-layered assembly with the insulating sheet in the middle. To reduce the thickness of the seam, the blank is thinned in the area adjacent a fold score prior to folding. The assembly is wrapped around a mandrel to bring the outer edges together at a side seam (22S) to form a sidewall 12. The side seam is sealed, the bottom is added, and the rim is formed. In a second embodiment, the insulating layer can be a coating on one or both of the sections of the two-section starting blank. In a third embodiment, the insulating section (40) can be integral with, and extend from, one edge of the starting blank.

Abstract: An insulating cup or container (50) and a method of manufacturing it comprises (first embodiment) providing a sidewall blank (12B) having two sections separated by a fold score (15), and a separate insulating sheet (18)(corrugated, ribbed, embossed, foamed, perforated, etc.) which is adhesively fastened to one of the sections. Adhesive is applied to an area (21) adjacent the fold score. The blank is folded in half along the fold score, to form a three-layered assembly with the insulating sheet in the middle. The adhesive that was applied adjacent the fold score bonds the two sections together at an area (21) adjacent a fold edge (22) on the inside surfaces of the folded blank. The assembly is wrapped around a mandrel to bring the outer edges together at a sideseam (22S) to form a sidewall 12. The side seam is sealed, the bottom is added, and the rim is formed.

Abstract: An elongated blank (10) is used to form a thermally insulated cup (30). The blank includes a pair of spaced apart smooth portions (12, 13) connected by a middle portion (11). The blanks may have chamfered or trimmed comers to reduce the amount of waste on the sheet from which they are cut. The smooth portions are folded on opposite sides of the middle portion. The middle portion is corrugated or otherwise distorted or deformed to create air space. The folded sheet is wound around a mandrel to form a cylinder or conoid. The ends of the smooth portions are joined together, and a bottom closure (14) is attached to form the cup. The finished cup includes a smooth outer shell (12S), a smooth inner shell (13S), and a middle layer (11L) sandwiched therebetween. The middle layer forms many air spaces between the shells to thermally insulate the contents of the cup, and also provide structural strength.

Abstract: A thermally insulated cup or container (30) includes a smooth outer shell (12S), a smooth inner shell (13S), a corrugated layer (11L) sandwiched therebetween, and a bottom closure (14). The inner shell, corrugated layer, and outer shell are formed by simply winding a continuous elongated paper sheet (10) in a three-layered spiral, then sealing them together. The corrugated layer forms many air pockets between the shells to thermally insulate the contents of the cup, and also provide structural strength. The paper construction of the cup makes it biodegradable and recyclable, and the simple construction method of the cup makes it easy and inexpensive to manufacture.