Splash-resistant lids, container assemblies including such lids and related methods

Abstract

In some embodiments, a lid may include a valve chamber comprising a hollow chamber, a valve flap and a hinge. The hollow chamber may be defined by one or more sidewalls and have a first opening at a first longitudinal end and a second opening at an opposing, second longitudinal end. The valve flap may be positioned at least proximate to the second longitudinal end and have a shape and size substantially the same as a shape and size of the second opening. The hinge may couple the valve flap to a sidewall of the one or more sidewalls and may be sized and configured to enable the rotation of the valve flap from an open position to a substantially closed position. Container assemblies and methods of forming lids are also disclosed.

What is claimed is: 
     
         1 . A lid, comprising:
 a valve chamber, the valve chamber comprising:
 a hollow chamber defined by one or more sidewalls having a first opening at a first longitudinal end and a second opening at an opposing, second longitudinal end; 
 a valve flap positioned at least proximate to the second longitudinal end, the valve flap having a shape and size substantially the same as or smaller than a shape and size of the second opening; and 
 a hinge coupling the valve flap to the lid, the hinge sized and configured to enable rotation of the valve flap from an open position to a substantially closed position and to bias the valve flap to the substantially closed position; 
   wherein the lid is shaped and configured to nest with a substantially identical lid with the valve flap positioned fully within a valve chamber of the substantially identical lid and with the lid positioned at a parallel orientation to the substantially identical lid.   
     
     
         2 . The lid of  claim 1 , wherein the valve flap is configured to inhibit the flow of liquid through the second opening in the substantially closed position. 
     
     
         3 . The lid of  claim 1 , wherein the valve chamber further comprises a drain positioned at least proximate to the second longitudinal end, the drain configured to flow residual fluid therethrough when the valve flap is in the substantially closed position. 
     
     
         4 . The lid of  claim 3 , wherein the valve flap is angled from the hinge downward between about 1° and about 10° relative to a horizontal position when the valve flap is in the substantially closed position. 
     
     
         5 . The lid of  claim 4 , wherein the drain is positioned at a lowest side of the valve flap. 
     
     
         6 . The lid of  claim 3 , wherein the drain comprises at least one of: a notch formed in the valve flap and a corresponding notch formed in the one or more sidewalls of the valve chamber; and a slit-like opening between the valve flap and a portion of the hollow chamber defining the second opening. 
     
     
         7 . A lid for a container assembly, comprising:
 a channel configured to engage a rim of a container to form a seal between the lid and the rim of the container, and to cover a peripherally outermost surface of the rim of the container; and   a valve chamber, the valve chamber comprising:
 a hollow chamber defined by one or more sidewalls having a first opening at a first longitudinal end and a second opening at an opposing, second longitudinal end; 
 a valve flap positioned at least proximate to the second longitudinal end, the valve flap having a shape and size smaller than a shape and size of the second opening; and 
 a hinge coupling the valve flap to the lid, the hinge sized and configured to enable rotation of the valve flap from an open position to a substantially closed position and to bias the valve flap to the substantially closed position; 
   wherein the lid is a monolithic structure.   
     
     
         8 . The lid of  claim 7 , wherein the channel is configured to engage a rim of a container selected from the group consisting of an insulated disposable coffee cup, a non-insulated disposable coffee cup, and a disposable soft-drink cup. 
     
     
         9 . The lid of  claim 7 , wherein the one or more sidewalls comprise a first sidewall and an opposing second sidewall. 
     
     
         10 . The lid of  claim 7 , wherein the first sidewall has an angle between about 2° and about 20° relative to the opposing second sidewall. 
     
     
         11 . The lid of  claim 10 , wherein the first sidewall has an angle of about 10° relative to the opposing second sidewall. 
     
     
         12 . The lid of  claim 7 , wherein the valve chamber comprises a cross-sectional shape selected from the group consisting of circular, square, rectangular, and oval. 
     
     
         13 . The lid of  claim 7 , wherein the valve chamber has a height from the first opening to the second opening of between about 3/16 of an inch and about ⅜ of an inch. 
     
     
         14 . A method of forming a lid, comprising:
 forming a single, monolithic structure, comprising:
 forming a channel configured to engage and seal around a rim of a container; and 
 forming a valve chamber comprising:
 a hollow chamber defined by one or more sidewalls having a first opening at a first longitudinal end and a second opening at an opposing, second longitudinal end; 
 a valve flap positioned at least proximate to the second longitudinal end, the valve flap having a shape and size substantially the same as or smaller than a shape and size of the second opening; and 
 a hinge coupling the valve flap to the lid, the hinge sized and configured to enable rotation of the valve flap from an open position to a substantially closed position and to bias the valve flap to the substantially closed position, 
 
   wherein the lid is formed to nest with a substantially identical lid with the valve flap of the lid positioned fully within a valve chamber of the substantially identical lid and with the lid positioned at a parallel orientation to the substantially identical lid.   
     
     
         15 . The method of  claim 14 , further comprising forming the lid with a thermal vacuum forming process. 
     
     
         16 . The method of  claim 14 , further comprising forming the valve flap by cutting the formed valve chamber. 
     
     
         17 . The method of  claim 14 , wherein forming a single, monolithic structure comprises forming the lid from a plastic material. 
     
     
         18 . The method of  claim 14 , wherein the valve flap is formed at an angle relative to horizontal when the lid is oriented horizontally. 
     
     
         19 . The method of  claim 18 , wherein the valve flap is formed at an angle of between about 5° and about 7° relative to horizontal when the lid is oriented horizontally. 
     
     
         20 . The method of  claim 14 , further comprising removing material from the single, monolithic structure proximate the valve flap to form a drain for draining residual fluid from the valve chamber.