Recyclable coffee cup with integrated lid

Abstract

A disposable cup with an integrated hinged lid is provided. The disposable cup can be unitarily formed entirely of a wood, cellulosic, or other type of fiber pulp-based material that is readily recyclable using a single recycling process for the entire product. The entire product can be recycled using the same recycling process, as compared to conventional disposable cups which can require the separation of the product into its various components, each of which may require a different type of recycling process.

We claim: 
     
         1 . A disposable cup unitarily formed entirely of a cellulosic material, comprising:
 a body portion having an inner surface that defines a cavity fillable with liquid, the body portion having a tapered cylindrical shape with a rim at an upper end;   a hinged lid coupled to the body portion via a hinge, the hinged lid including a lower portion and an upper portion separated by a shoulder that surrounds the hinged lid, the hinged lid defining a spout, wherein the lower portion has a smaller diameter than the upper portion and is configured to be received into the body portion when the hinged lid is in a closed position; and   a hinged stopper coupled to the hinged lid via a stopper hinge, the hinged stopper including a spout stopper configured to selectively seal the spout when the hinged stopper is in a closed position.   
     
     
         2 . The disposable cup of  claim 1 , wherein the cellulosic material is a wood or fiber pulp-based material. 
     
     
         3 . The disposable cup of  claim 1 , wherein the hinge is a living hinge that is integrally molded with the body portion and the hinged lid. 
     
     
         4 . The disposable cup of  claim 1 , wherein the outer surface of the lower portion of the hinged lid is in frictional contact with the inner surface of the body portion when the hinged lid is in the closed position. 
     
     
         5 . The disposable cup of  claim 1 , wherein the shoulder sits on the rim of the body portion to create a liquid tight seal between the hinged lid and the body portion when the hinged lid is in a closed position. 
     
     
         6 . The disposable cup of  claim 1 , wherein the tapered cylindrical shape of the body portion allows multiple disposable cups to be nested into each other in a stacked configuration when the hinged lids are positioned in an open position. 
     
     
         7 . The disposable cup of  claim 1 , wherein the stopper hinge is frangible such that the hinged stopper can be selectably detached from the hinged lid. 
     
     
         8 . The disposable cup of  claim 1 , wherein the hinge comprises a flexible web of material formed during a molding manufacturing process. 
     
     
         9 . The disposable cup of  claim 1 , further comprising a stopper dock formed on the hinged lid, the stopper dock configured to receive and retain the hinged stopper when the hinged stopper is in an open position. 
     
     
         10 . The disposable cup of  claim 1 , wherein the hinged lid further defines an air vent, and wherein the stopper hinge extends outwardly from the hinged lid. 
     
     
         11 . A disposable cup unitarily formed entirely of a cellulosic material, comprising:
 a body portion having an inner surface that defines a cavity fillable with liquid, the body portion having a rim at an upper end;   a hinged lid coupled to the body portion via a hinge, the hinged lid including a lower portion and an upper portion separated by a shoulder that surrounds the hinged lid, the hinged lid defining a spout and an air vent, wherein the air vent is positioned to facilitate pressure equalization during liquid dispensing; and   a hinged stopper coupled directly to the hinged lid via a stopper hinge that extends outwardly from the hinged lid, the hinged stopper including a spout stopper configured to engage with the spout when the hinged stopper is in a closed position.   
     
     
         12 . The disposable cup of  claim 11 , wherein the cellulosic material is a wood or fiber pulp-based material. 
     
     
         13 . The disposable cup of  claim 11 , wherein the hinge is a living hinge that enables repeated pivoting movement of the hinged lid relative to the body portion. 
     
     
         14 . The disposable cup of  claim 11 , wherein the lower portion has a smaller diameter than the upper portion. 
     
     
         15 . The disposable cup of  claim 14 , wherein the shoulder has a width that corresponds to the rim of the body portion, providing a sealing interface when the hinged lid is positioned in a closed configuration. 
     
     
         16 . The disposable cup of  claim 11 , wherein the stopper hinge is configured as a frangible component that allows selective detachment of the hinged stopper from the hinged lid. 
     
     
         17 . The disposable cup of  claim 11 , wherein the spout stopper is dimensioned to create interference fit engagement with the spout, providing secure sealing that resists inadvertent opening during handling while allowing deliberate manipulation through applied force. 
     
     
         18 . A disposable cup unitarily formed entirely of a cellulosic material, comprising:
 a body portion having an inner surface that defines a cavity fillable with liquid, the body portion including a plurality of ribs formed on an external surface that create alternating thicker and thinner sections around the body portion while maintaining structural continuity of the cellulosic material construction; and   a hinged lid coupled to the body portion via a hinge, the hinged lid defining a spout.   
     
     
         19 . The disposable cup of  claim 18 , wherein the plurality of ribs are spiral flutes extending around the circumference of the body portion in a helical pattern. 
     
     
         20 . The disposable cup of  claim 18 , wherein the thicker sections of the body portion have a thickness that is about 2 to about 8 times greater than the thinner sections of the body portion.