INSULATED CONTAINERS AND METHODS FOR FORMING THE SAME

FIELD

The present invention relates generally to the field of containers. More specifically, the invention relates to insulated metal containers and methods for forming the same.

BACKGROUND

Many insulated containers exist for keeping fluids, such as beverages, hot or cold longer. However, these containers are generally not intended for single use and are often formed of more than one material, such as a combination of metals and plastics. Being formed of more than one material makes recycling the insulated containers difficult, if possible at all.

Insulated single-use containers that exist generally are formed of paper or plastic, which have drawbacks. Paper containers may degrade over even short periods of use. Although made from a renewable resource, paper is generally considered not as recyclable as metal. Paper containers also generally require a sleeve or other protector when holding hot or cold beverages to prevent a user from experiencing uncomfortable temperatures while holding paper containers filled with such hot or cold beverages. Plastic containers too are generally considered not as recyclable as metal. Plastic is also becoming an increasingly larger problem as we better understand its true effect on the environment.

Accordingly, these and other issues are solved by the disclosed insulated metal containers and methods for forming the same.

SUMMARY

One exemplary embodiment of the invention relates to an insulated container. The container includes an outer shell formed of a thin wall of aluminum. The outer shell includes an outer wall and an outer base. The container further includes an inner shell formed of a thin wall of aluminum. The inner shell includes an inner wall and an inner base. The inner wall is coupled to the outer wall at a top of the container and is at least partially tapered. The container further includes a joint between the outer base and the inner base at a bottom of the container. The outer shell and the inner shell define a space between the outer wall and the inner wall along a height of the container and between the outer base and the inner base across the bottom of the container.

An aspect of the embodiment includes the space including a continuous cylindrical portion along the height of the container and a continuous circular portion around the joint across the bottom of the container. The continuous cylindrical portion can be open to the continuous circular portion. Alternatively, the continuous cylindrical portion can be closed to the continuous circular portion by an interference fit between the inner wall and the outer wall.

Another aspect of the embodiment includes the space being under vacuum relative to the atmosphere.

Another aspect of the embodiment includes the space being filled with at least one gas. The at least one gas can be air. The at least one gas can have a thermal conductivity lower than air.

Another aspect of the embodiment includes the inner shell being coupled to the outer shell by a curl in one or both of the inner shell and the outer shell. At least one of the outer shell and the inner shell can include a texture in the thin wall of aluminum where the inner shell is coupled to the outer shell at the curl.

Another aspect of the embodiment includes the inner shell being coupled to the outer shell by a weld between the inner wall and the outer wall. The weld can be an electromagnetically formed weld such that the transition between the outer wall and the inner wall is continuous. The inner shell, the outer shell, or both can be curled above the weld at the top of the container.

Another aspect of the embodiment includes a distance between the outer shell and the inner shell being substantially constant along the height of the container. The inner shell can include a radially outward step where the inner shell is coupled to the outer shell.

Another aspect of the embodiment includes the space being tapered such that a distance between the inner wall and the outer wall at the top of the container is smaller than at the bottom of the container.

Another aspect of the embodiment includes the outer shell being cylindrical.

Another aspect of the embodiment includes the outer shell being at least partially tapered. The amount of taper of the inner shell can be greater than an amount of taper of the outer shell.

Another aspect of the embodiment includes the container being formed of only one or more recyclable metals. The one or more recyclable metals can be aluminum.

Another aspect of the embodiment includes the thickness of the outer wall being 0.07 mm to 0.20 mm.

Another aspect of the embodiment includes the thickness of the inner wall being 0.07 mm to 0.20 mm.

Another aspect of the embodiment includes the thickness of the outer base being 0.15 mm to 0.36 mm.

Another aspect of the embodiment includes the thickness of the inner base being 0.15 mm to 0.36 mm.

Another aspect of the embodiment includes the joint being a protrusion in one of the inner base or the outer base that contacts the other of the inner base or the outer base. The protrusion can be a circular protrusion centered about the inner base and the outer base. Alternatively, the protrusion can be an annular ring centered about the inner base and the outer base.

Another aspect of the embodiment includes the joint being a circular protrusion in the inner base or the outer base that mates with an annular protrusion in the outer base or the inner base, respectively.

Another aspect of the embodiment includes the joint being a protrusion in the inner base that contacts a protrusion in the outer base.

Another aspect of the embodiment includes the joint being an interference fit between the outer wall and the inner wall at the base of the container.

Another aspect of the embodiment includes the joint being a post that extends from one of the outer base or the inner base and contacts the other of the outer base or the inner base.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.

FIG. 1 is a cross-sectional view of an outer shell of an insulated container, according to an embodiment of the present invention.

FIG. 2 is a cross-sectional view of an outer shell of an insulated container, according to another embodiment of the present invention.

FIG. 3 is a cross-sectional view of an outer shell of an insulated container, according to another embodiment of the present invention.

FIG. 4 is a cross-sectional view of an inner shell of an insulated container, according to an embodiment of the present invention.

FIG. 5 is a cross-sectional view of an insulated container, according to an embodiment of the present invention.

FIG. 6 is a cross-sectional view of an insulated container, according to another embodiment of the present invention.

FIG. 7A is a cross-sectional view of a step for forming a curl at the top of the insulated container of FIG. 6, according to an embodiment of the present invention.

FIG. 7B is a cross-sectional view of a step for forming an alternative curl at a top of the insulated container of FIG. 6, according to an embodiment of the present invention.

FIG. 8 is a cross-sectional view of a step for forming an alternative curl at a top of an insulated container, according to an embodiment of the present invention.

FIG. 9 is a cross-sectional view of one stage of a container preform used in forming an insulated container, according to an embodiment of the present invention.

FIG. 10 is a cross-sectional view of another stage of the container preform of FIG. 9, according to an embodiment of the present invention.

FIG. 11 is a cross-sectional view of an insulated container, according to another embodiment of the present invention.

FIG. 12 is a cross-sectional view of an insulated container, according to another embodiment of the present invention.

FIG. 13 is a cross-sectional view of an insulated container, according to another embodiment of the present invention.

FIG. 14 is a cross-sectional view of an insulated container, according to another embodiment of the present invention.

FIG. 15 is a side view of an insulated container, according to another embodiment of the present invention.

FIG. 16 is a cross-sectional view of an insulated can, according to another embodiment of the present invention.

FIG. 17 is a plot showing the hot temperature performance of a can preform formed according to aspects of the present disclosure compared to a standard can.

FIG. 18 is another plot showing the hot temperature performance of a can preform formed according to aspects of the present disclosure compared to a standard can.

FIG. 19 is another plot showing the hot temperature performance of a can preform formed according to aspects of the present disclosure compared to a standard can.

FIG. 20 is a plot showing the cold temperature performance of a can preform formed according to aspects of the present disclosure compared to a standard can.

While the invention is susceptible to various modifications and alternative forms, specific forms thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but, on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.

DETAILED DESCRIPTION

Objects of the present invention are directed to an insulated container and steps for forming the insulated container. More specifically, objects of the present invention are directed to a generally single-use or disposable insulated container. The container is formed only of one or more metals or metal alloys that are recyclable. For example, the container is formed only of aluminum, such as standard aluminum used in making beverage cans. By being formed only of one or more recyclable metals or metal alloys, the container can be recycled without having to be dismantled to have different component materials separated. It is contemplated that an optional thin polymer coating that is typically used on metal (e.g., aluminum) beverage containers to prevent chemical reaction between the beverage container and the beverage contained therein may be used on the inner surface of the container in certain embodiments.

The containers further are formed of an outer shell and an inner shell, with a space there between. The outer shell and the inner shell are made of a thin wall of metal or metal alloy, such as aluminum. The thickness of the thin wall generally makes the containers single use, as the thin wall is generally not suitable for multiple uses. Specifically, the thin wall can become damaged and unusable after repeated uses. The thickness of the metal wall further keeps costs down such that the containers can be used as single-use containers without being cost-prohibitive. It is contemplated that the inner shell and the outer shell can be made from the same stock material and production line used for forming standard beverage containers, with only a simple change in tooling. Thus, the inventive containers can be produced from the same materials and production lines with simple tooling modifications which, in turn, provides for manufacturing efficiencies.

A space between the outer shell and the inner shell acts as a thermal insulation barrier to reduce heat transfer. The reduction in heat transfer has several benefits beyond merely keeping cold beverages cold and warm beverages warm. The reduction in heat transfer also allows a user to hold a container filled with a warm or cold beverage without feeling as much discomfort as would occur with an otherwise un-insulated container. Further, a sleeve or some other type of protector is not needed for the user to hold a container filled with, for example, a warm liquid, unlike most conventional paper containers. In one or more embodiments, the space can include a continuous cylindrical space along the height of the container and a continuous circular space around the base of the container. The space can be filled with air. Alternatively, the space can be filled with one or more gases that have a thermal conductivity lower than air, which can further limit heat transfer between the outer shell and the inner shell. In one or more embodiments, the space can be at vacuum relative to the atmosphere, which can further limit heat transfer.

At the top of the container, the outer shell is coupled to the inner shell so that the outer shell and the inner shell cannot be separated without deforming or damaging one or both of the shells. The shells can be coupled together by, for example, one or more curls in the outer shell and/or the inner shell. Alternatively, the shells can be coupled together by, for example, a weld between the shells, such as an electromagnetically formed weld. Alternatively, the shells can be coupled together through both one or more curls and a weld, such as the one or more curls being above the weld.

At the bottom of the container, the inner shell is supported by a joint between the outer shell and the inner shell. In one or more embodiments, the joint can be a protrusion from the base(s) of one or both of the outer shell and the inner shell that contacts the opposite shell. The joint provides additional support and rigidity for the container. In one or more embodiments, the joint further aids in aligning, and keeping aligned, the outer shell with the inner shell. The contact area between the outer shell and the inner shell can be minimized at the joint to minimize the amount of thermal conductivity between the outer shell and the inner shell.

Referring to FIG. 1, illustrated is a cross-sectional view of an outer shell 102 that forms part of an insulated container, according to an embodiment of the present invention. The outer shell 102 can be formed of a thin wall of metal or a metal alloy, particularly a recyclable metal, and more particularly aluminum. In one or more embodiments, the thickness of the thin wall of metal of the outer shell 102 can be, for example, about 0.07 millimeters (mm) to about 0.20 mm, more preferably about 0.08 mm to about 0.15 mm, and most preferably about 0.10 mm to about 0.12 mm. The thickness can be consistent along the height and width of the outer shell 102. Alternatively, the thickness can vary, such as being thicker or thinner at the bottom versus the top, as disclosed further below.

The outer shell 102 includes an outer wall 104, an outer base 106, and an open end 108, which is also generally referred to the top of the outer shell 102 in the orientation shown in FIG. 1. Although not shown, the outer wall 104 is generally cylindrical. Alternatively, the outer wall 104 can have other shapes, such as a triangular, square, rectangular, etc. cross-section across the width of the outer shell 102. The outer wall 104 is generally tapered such that the distance across the outer wall 104 is smaller at the outer base 106 than at the open end 108. However, the outer wall 104 can at least initially not be tapered, such as where the outer wall 104 joins the outer base 106. In one or more embodiments, the taper can be up to about 10 degrees relative to vertical, preferably up to about 6 degrees, more preferably up to about 4 degrees. The thickness of the outer wall 104 can be about 0.07 mm to about 0.20 mm, more preferably about 0.08 mm to about 0.15 mm, and most preferably about 0.10 mm to about 0.12 mm. Where the thickness varies, the thickness of the outer wall 104 at the top can be about 0.07 mm to about 0.20 mm, more preferably about 0.08 mm to about 0.15 mm, and most preferably about 0.10 mm to about 0.12 mm, and the thickness of the outer wall 104 at the bottom can be about 0.09 mm to about 0.30 mm, more preferably about 0.12 mm to about 0.27 mm, and most preferably about 0.15 mm to about 0.25 mm.

The outer wall 104 includes one or more steps 110. Each step 110 is a change in the amount of taper of the outer wall 104, which forms an abrupt radially outward increase in the distance across the outer wall 104. As shown, the outer wall 104 can include four steps 110. Alternatively, the outer wall 104 can include any number of steps 110, such as one, two, three, five, six, seven, etc. steps 110. In one or more embodiments, the steps 110 can be formed by a tapered expander tool. Between adjacent steps 110, the outer wall 104 has a uniform or consistent taper. The thickness of the thin wall of metal of the outer wall 104 for each step 110 can be slightly thicker at the bottom versus the top because the thickness of the thin wall of metal of the outer wall 104 can be reduced as a result of the manufacturing process, such as by expansion of the thin wall.

The outer wall 104 includes a curl 112. The curl 112 is formed by curling the thin wall of metal or metal alloy that forms the outer shell 102. As shown in FIG. 1, the curl 112 is an outward curl in that it initially curls away from the center of the outer shell 102. However, in one or more embodiments, and as disclosed below with respect to FIG. 7B, alternatively the curl 112 can be an inward curl. In one or more embodiments, the outer wall 104 leading up to the curl 112 may be straight because a taper at this point may comprise the curl 112.

The outer base 106 is generally flat across the width of the outer shell 102. The thickness of the thin wall of metal of the outer base 106 can be about 0.15 mm to about 0.36 mm, more preferably about 0.20 mm to about 0.30 mm, and most preferably about 0.22 mm to about 0.28 mm.

FIG. 2 is a cross-sectional view of an outer shell 202 that forms an insulated container, according to another embodiment of the present invention. The outer shell 202 is similar to the outer shell 102 such that element numbers in FIG. 2 ending with the same ones and tens digits as the element numbers in FIG. 1 are the same features, unless otherwise described below. The outer shell 202 is similar to the outer shell 102 in FIG. 1 except that the outer shell 202 does not have any steps (i.e., steps 110). Instead, the outer wall 204 is generally uniformly tapered from the outer base 206 to the open end 208 of the outer shell 202.

FIG. 3 is a cross-sectional view of an outer shell 302 that forms an insulated container, according to another embodiment of the present invention. The outer shell 302 is similar to the outer shell 102 such that element numbers in FIG. 3 ending with the same ones and tens digits as the element numbers in FIG. 1 are the same features, unless otherwise described below. The outer shell 302 is similar to the outer shell 102 in FIG. 1 except that the outer shell 302 does not have any steps (i.e., steps 110) and is generally not tapered. Instead, the outer wall 304 has generally the same diameter along the height of the outer shell 302 from the outer base 306 to the open end 308 such that the outer wall 304 is vertically straight up and down.

Referring to FIG. 4, illustrated is a cross-sectional view of an inner shell 422 that forms an insulated container, according to an embodiment of the present invention. The inner shell 422 can be formed of a thin wall of metal or a metal alloy, particularly a recyclable metal, and more particularly aluminum. In one or more embodiments, the thickness of the thin wall of metal of the inner shell 422 can be, for example, about 0.07 mm to about 0.20 mm, more preferably about 0.08 mm to about 0.15 mm, and most preferably about 0.10 mm to about 0.12 mm. The thickness can be consistent along the height and width of the inner shell 422. Alternatively, the thickness can vary, such as being thicker or thinner at the bottom versus the top, as disclosed below.

It is contemplated that an optional thin polymer coating that is typically used on metal (e.g., aluminum) beverage containers to prevent metal oxidation may be used on the inner surface of the container (i.e., the inner shell 422) in certain embodiments. Where employed in the inventive beverage containers, the inside polymer coating is extremely thin and burns off during recycling. The optional thin polymer coating has the advantage of preventing chemical reaction between the beverage container and the beverage contained therein without impacting the recyclability of the beverage container.

The inner shell 422 includes an inner wall 424, an inner base 426, and an open end 428, which is also generally referred to the top of the inner shell 422 in the orientation shown in FIG. 4. Although not shown, the inner wall 424 can be generally cylindrical. Alternatively, the inner wall 424 can have other shapes, such as a triangular, square, rectangular, etc. cross-section across the width of the inner shell 422. The inner wall 424 is generally tapered such that the distance across the inner wall 424 is smaller at the inner base 426 than at the open end 428. In one or more embodiments, the taper can be up to about 10 degrees relative to vertical, preferably up to about 6 degrees, more preferably up to about 4 degrees. The taper can be the same as or less than the taper of the outer shell 110. However, the inner wall 424 can at least initially not be tapered, such as where the inner wall 424 joins the inner base 426. The thickness of the inner wall 424 can be about 0.07 mm to about 0.20 mm, more preferably about 0.08 mm to about 0.15 mm, and most preferably about 0.10 mm to about 0.12 mm. Where the thickness varies, the thickness of the inner wall 424 at the top can be about 0.07 mm to about 0.20 mm, more preferably about 0.08 mm to about 0.15 mm, and most preferably about 0.10 mm to about 0.12 mm, and the thickness of the inner wall 424 at the bottom can be about 0.09 mm to about 0.30 mm, more preferably about 0.12 mm to about 0.27 mm, and most preferably about 0.15 mm to about 0.25 mm.

The inner wall 424 includes one or more steps 430. Each step 430 is a change in the amount of taper of the inner wall 424 that forms an abrupt radially outward increase in the distance across the inner wall 424. As shown, the inner wall 424 can include four steps 430. Alternatively, the inner wall 424 can include one or more steps 430, such as one, two, three, five, six, seven, etc. steps 430.

The inner wall 424 includes a curl 432. The curl 432 is formed by curling the thin wall of metal or metal alloy that forms the inner shell 422. As shown in FIG. 4, the curl 432 is an outward curl in that it initially curls away from the center of the inner shell 422. However, in one or more embodiments, and as disclosed below with respect to FIG. 7B, alternatively the curl 432 can be an inward curl.

The inner base 426 is generally flat across the width of the inner shell 422, except that the inner base 426 includes a protrusion 434 that extends downward in the orientation of FIG. 4. The thickness of the thin wall of metal of the inner base 426 can be about 0.15 mm to about 0.36 mm, more preferably about 0.20 mm to about 0.30 mm, and most preferably about 0.22 mm to about 0.28 mm. The protrusion 434 is generally in the shape of a frustum, although it can have various other shapes, such as a cylinder, square column, etc. As disclosed further below, the protrusion 434 can provide support for the inner shell 422 when combined with an outer shell, such as the outer shell 102. The protrusion 434 can also assist in aligning the inner shell 422 relative to the outer shell 102.

FIG. 5 is a cross-sectional view of an insulated container 500, according to an embodiment of the present invention. The insulated container 500 is formed by coupling together the outer shell 102 of FIG. 1 with the inner shell 422 of FIG. 4. The outer shell 102 is coupled to the inner shell 422 at the curls 112 and 432, respectively. For example, the curl 432 of the inner shell 422 wraps around the curl 112 of the outer shell 102 and forms an interference fit with the curl 112. This couples the outer shell 102 to the inner shell 422. Thus, although generally disclosed as a container, the container 500 is generally a cup because it has the open end 428 based on the open end 428 of the inner shell 422 disclosed above. More specifically, the container 500 generally is a single-use cup based on the thin walls of the outer shell 102 and the inner shell 422, as disclosed above.

At the outer base 106 and the inner base 426, the protrusion 434 contacts the outer base 106 to form a joint 568 between the outer shell 102 and the inner shell 422. The protrusion 434 at the joint 568 supports the inner shell 422 within the outer shell 102. To limit heat transfer between the inner shell 422 and the outer shell 102, the contact area between the protrusion 434 and the outer base 106 at the joint 568 can be minimal. For example, the area of contact can be about 20 mm²to about 200 mm², more preferably about 40 mm²to about 150 mm², and most preferably about 60 mm²to about 120 mm².

The shape of the outer shell 102 can be generally consistent with the shape of the inner shell 422. For example, steps 110 in the outer shell 102 can generally be aligned with steps 430 in the inner shell 422. This aids in stacking multiple containers 500 on top of each other. This also provides for a consistent width of the space between the outer shell 102 and the inner shell 422, as disclosed further below. The outer shell 102 can also have generally the same amount of taper as the inner shell 422. Keeping the difference between taper angle of the inner shell 422 and the outer shell 102 aids with stacking during storage and transportation.

The outer shell 102 coupled to the inner shell 422 forms a space 562 there between. As shown in the detailed view in FIG. 5, the space 562 can have a width or distance D1, which can be about 0.5 mm to about 8.0 mm, more preferably about 1.5 mm to about 5.0 mm, and most preferably about 2.5 mm to about 4.0 mm. This distance D1 can be substantially constant along the height of the container 500. Alternatively, the distance D1 can vary along the height of the container 500, such as being wider or narrower toward the outer base 106. The space 562 generally has a continuous cylindrical portion 564 along and around the height of the insulated container 500. The space 562 further generally has a continuous circular portion 566 around the joint 568 across the bottom of the container 500. Because the outer shell 102 and the inner shell 422 contact each other only at the curls 112 and 432 and the joint 568, the continuous cylindrical portion 564 is open to the continuous circular portion 566.

The space 562 provides insulation between the inner shell 422 and the outer shell 102 by having a lower thermal conductivity than the inner shell 422 or the outer shell 102. The space 562 allows for the container 500 to maintain beverages colder or warmer for longer than a container that does not include the space. The space 562 also allows for the container to hold beverages at cold or warm temperatures without a user experiencing the cold or warm temperatures while holding the container 500. Thus, the space 562 acts as a barrier so that the container 500 can hold cold or warm beverages without the user experiencing uncomfortable cold or warm temperatures, and also without the need for an additional sleeve or protector around the container 500.

The space 562 can be filled with air, which has a lower thermal conductivity than the thin metal, such as aluminum, used to form the inner shell 422 and the outer shell 102. However, the space 562 can be filled with another material, such as one or more gases other than air, such as nitrogen. For example, the one or more other gases can have a thermal conductivity lower than air to limit further the heat transfer between the inner shell 422 and the outer shell 102. In one or more embodiments, the space 562 can be under vacuum relative to the atmosphere. For example, the vacuum within the space 562 can be about 12,000 Pascals (Pa) to about 55,000 Pa, more preferably about 20,000 Pa to about 40,000 Pa, and most preferably about 28,000 Pa to about 35,000 Pa, depending on the thickness of the outer wall 104 and the inner wall 424 for maintaining structural integrity of the container 500.

FIG. 6 is a cross-sectional view of an insulated container 600, according to another embodiment of the present invention. The insulated container 600 is similar to the insulated container 500 such that element numbers in FIG. 6 ending with the same ones and tens digits as the element numbers in FIG. 5 are the same features, to the extent the element numbers differ and unless otherwise described below. Specifically, the container 600 includes a different joint 668 than the container 500. More specifically, the outer shell 602 of the container 600 includes a protrusion 614. The protrusion 614 is in the shape of an annular ring that is sized and shaped so as to fit the protrusion 434 of the inner shell 422. The protrusion 614 provides additional contact area between the inner shell 422 and the outer shell 602 for additional support. The shape of the protrusion 614 also assists in aligning the outer shell 602 with the inner shell 422 by keeping the protrusion 434 centered relative to the outer shell 602.

FIG. 7A is a cross-sectional view of a step for forming the curls 432 and 612 at the top of the insulated container 600 of FIG. 6, according to an embodiment of the present invention. Although disclosed below and shown in FIG. 7A as being applied to the container 600, the step of FIG. 7A can be applied to any insulated container disclosed herein. As shown on the left side of FIG. 7A, the curl 432 of the inner shell 422 may not be fully curled. The inner shell 422 is placed within the outer shell 602. The curl 432 may partially surround the curl 612. Thereafter, and as shown on the right side of FIG. 7A, the curl 432 is fully formed by wrapping around the curl 612. This step can be performed by one or more curling steps. The fully formed curl 432 couples the inner shell 422 to the outer shell 602. The fully formed curl 432 also presents a single, continuous surface that defines the lip of the open end 428 of the container 600.

In one or more embodiments, one or both of the outer wall 104 and the inner wall 424 can be textured where the outer wall 104 and the inner wall 424 touch, such as at the curls 612 and 432. The textured can be, for example, embossed into the thin metal that forms the outer wall 104 and/or the inner wall 424. The texture can assist with coupling the outer shell 102 to the inner shell 422 by increasing friction between the outer wall 104 and the inner wall 424 to facilitate curling.

According to one or more embodiments, the curls 112 and 432 can be formed together such that the outer shell 102 and the inner shell 422 are brought together and then the curls 112 and 432 are formed together according to a single curling process. This is in contrast to one or both of the outer shell 102 and the inner shell 422 having separate curls 112 and 432, respectively, prior to the final coupling of the outer shell 102 to the inner shell 422.

FIG. 7B is a cross-sectional view of a step for forming an alternative curls 432′ and 612′ at the top of the insulated container 600′ of FIG. 6, according to another embodiment of the present invention. The step shown in FIG. 7B is similar to the step shown in FIG. 7A, except that the curls 432′ and 612′ are inward curls rather than outward curls. Therefore, the process is flipped in terms of which curl is curled over the other. Specifically, and as shown on the left side of FIG. 7B, the curl 612′ of the outer shell 602′ is not yet fully curled. The inner shell 422′ is placed within the outer shell 602′. The curl 612′ may partially surround the curl 432′. Thereafter, and as shown on the right side of FIG. 7B, the curl 612′ is fully formed by wrapping around the curl 432′. This step can be performed by one or more curling steps. The fully formed curl 612′ couples the inner shell 422′ to the outer shell 602′. The fully formed curl 612′ also presents a single, continuous surface that defines the lip of the open end 428′ of the container 600′.

FIG. 8 is a cross-sectional view of a step for forming an alternative curl at a top of an insulated container 600″, according to an embodiment of the present invention. As shown on the left side of FIG. 8, the inner shell 422′ can initially have a flange 433 rather than a curl (e.g., curl 432). Similarly, the outer shell 602″ can initially have a flange 613 rather than a curl (e.g., curl 612). The flange 433 can rest on the flange 613 to support the inner shell 422″ within the outer shell 602″. Thereafter, as shown on the right side of FIG. 8, the flanges 433 and 613 can be curled together to form a curled lip 638. The curled lip 638 presents a single, continuous surface that defines the lip of the open end 428″ of the container 600″.

FIG. 9 is a cross-sectional view of one stage of a container preform 980 used in forming an insulated container, according to an embodiment of the present invention. Element numbers in FIG. 9 ending with the same ones and tens digits as the element numbers in FIG. 6 are the same features, except as otherwise described below. The preform 980 includes an outer shell preform 901 and an inner shell preform 921. These shell preforms 901 and 921 are similar to the outer shells and inner shells described above, except that they are not fully formed yet. Moreover, the process of coupling the outer shell preform 901 and the inner shell preform 921 varies from the processes described above with respect to the curls. As a result, a resulting insulated container also differs, as disclosed below.

The outer shell preform 901 includes a straight portion 982 at the open end 928 of the preform 980. Similarly, the inner shell preform 921 includes a straight portion 984 also at the open end 928 of the preform 980. However, alternatively, the straight portion 984 can include a slight taper. As shown in the detailed views, because of the steps 910 and 930 in the outer wall 904 and the inner wall 924 respectively (and/or the taper of the portion 984 relative to the straight portion 982), a width or distance D2 of the space 962 between the straight portion 982 and the straight portion 984 is less than the distance D1. For example, the distance D2 can be about 0.5 mm to about 1.0 mm. In one or more embodiments, the straight portion 982 may be at least partially touching the straight portion 984, such as at the open end 928. The narrower thickness of the space 962 at the straight portion 982 and the straight portion 984 promotes the coupling of the outer shell preform 901 and the inner shell preform 921 as disclosed below in FIG. 10.

More specifically, FIG. 10 is a cross-sectional view of another stage of the container preform 980 of FIG. 9, according to embodiment of the present invention. As shown in the detailed portion, the straight portion 982 and the portion 984 from FIG. 9 are welded together to form the welded portion 1086. The welded portion 1086 couples the outer shell preform 901 to the inner shell preform 921 at the open end 928. Welding can be used instead of, for example, chemical bonding (e.g., adhesive), which may deteriorate over time with temperature changes, even without use of the container. Moreover, welding may be particularly beneficial for containers made of the thin wall of metal at the higher end of the thickness ranges. As the wall thickness increases, sealing via curling can become more difficult.

The straight portion 982 and the portion 984 can be welded together according to various welding techniques. In one or more embodiments, the welded portion 1086 can be electromagnetically formed such that the transition between the outer wall 904 and the inner wall 924 is continuous. In one or more embodiments, the welded portion 1086 subsequently can be curled to form a curl (not shown). However, because the welded portion 1086 is one integral piece after joining the straight portion 982 and the portion 984, the resulting curl is a single curl. Alternatively, the welded portion 1086 can be left as is to act as the lip of a resulting insulated container, or can be smoothed so as to remove any sharp edges or burrs.

Although shown as being welded together prior to having curls, in one or more embodiments, the outer shell preform 901 and the inner shell preform 921 initially can have curls. The curls can be the portions of the outer shell preform 901 and the inner shell preform 921 that are welded together, such as through electromagnetic welding.

FIG. 11 is a cross-sectional view of an insulated container 1100, according to another embodiment of the present invention. The insulated container 1100 is similar to the insulated containers disclosed above such that element numbers in FIG. 11 ending with the same ones and tens digits as the element numbers in FIG. 5, for example, are the same features, unless otherwise described below. Specifically, and referring to the top detailed portion in FIG. 11, the inner wall 1124 of the inner shell 1122 includes a step 1130 that does not have a complimentary step in the outer wall 1104 of the outer shell 1102. Thus, at the step 1130 illustrated in the top detailed portion, the inner wall 1124 of the inner shell 1122 becomes closer to the outer wall 1104 of the outer shell 1102. This allows for the outer wall 1104 and the inner wall 1124 to be joined together, such as by welding, to form the welded portion 1186. Above the welded portion 1186, the outer wall 1104 and the inner wall 1124 may be separated (i.e., not welded together). In which case, the outer wall 1104 and the inner wall 1124 can include the curl 1112 and the curl 1132, respectively. The curls 1112 and 1132 can further couple the outer shell 1102 and the inner shell 1122. Alternatively, the curls 1112 and 1132 can simply be present to provide for a rounded lip of the container 1100 from which a user can drink fluids held by the container 1100. Alternatively, only the curl 1132 can be present to provide for a continuous curled lip for the container 1100.

Referring to the bottom detailed view in FIG. 11, the outer base 1106 can include a protrusion 1116. The protrusion 1116 can generally be the inverse of the protrusion 1134 such that it extends up from the outer base 1106. The protrusion 1116 and the protrusion 1134 together form the joint 1168. The joint 1168 provides support for the inner shell 1122 contacting the outer shell 1102. The contact area between the protrusion 1116 and the protrusion 1134 can be minimal so as to limit the heat transfer between the outer base 1106 and the inner base 1126. For example, the contact area between the protrusion 1116 and the protrusion 1134 can be about 20 mm²to about 100 mm².

Still referring to the bottom detailed view in FIG. 11, the inner base 1126 can include another protrusion 1192. The protrusion 1192 can be an annular ring that protrudes down generally around the perimeter of the inner base 1126. The protrusion 1192 can extend down about the same distance as the protrusion 1134. Alternatively, the protrusion 1192 can extend down less than or more than the distance of the protrusion 1134. The protrusion 1192 forms an interference fit with the bottom portion 1190 of the outer wall 1104. The interference fit between the protrusion 1192 and the bottom portion 1190 of the outer wall 1104 further supports the inner shell 1122 retained by the outer shell 1102. Because of the contact between the outer wall 1104 and the inner wall 1124 at the protrusion 1192, the cylindrical space 1164 is generally closed off from the circular space 1166.

In one or more embodiments, the joint 1168 can be considered only the contact between the protrusions 1116 and 1134. Alternatively, the joint 1168 can be considered the combination of the contact between (a) the protrusions 1116 and 1134 and (b) the protrusion 1192 and the bottom portion 1190 of the outer wall 1104. In one or more embodiments, the protrusions 1116 and 1134 can be omitted. Instead, the container 1100 may have only the protrusion 1192 contacting the bottom portion 1190 of the outer wall 1104.

FIG. 12 is a cross-sectional view of an insulated container 1200, according to another embodiment of the present invention. The insulated container 1200 is similar to the insulated containers disclosed above such that element numbers in FIG. 12 ending with the same ones and tens digits as the element numbers in FIG. 5, for example, are the same features, unless otherwise described below. Referring to the detailed portion, the inner base 1226 of the inner shell 1222 includes a protrusion 1292 similar to the protrusion 1192 of container 1100 in FIG. 11. The protrusion 1292 similarly forms an interference fit with the bottom portion 1290 of the outer wall 1204 of the outer shell 1202. Further, the outer wall 1204 includes a step 1210 below the protrusion 1292 and upon which at least part of the protrusion 1292 sits. The contact area between the protrusion 1292 and the bottom portion 1290 of the outer wall 1204, and the contact area between the step 1210 and the protrusion 1292, forms the joint 1268 for the container 1200.

Still referring to the detailed view in FIG. 12, the outer base 1206 can further include a protrusion 1294. The addition of the protrusion 1294 can provide additional strength and rigidity to the outer base 1206 of the container 1200. The protrusion 1294 can also form a space between the outer shell 1202 and the inner shell 1222 to minimize contact between the two shells.

FIG. 13 is a cross-sectional view of an insulated container 1300, according to another embodiment of the present invention. The insulated container 1300 is similar to the insulated containers disclosed above such that element numbers in FIG. 13 ending with the same ones and tens digits as the element numbers in FIG. 5, for example, are the same features, to the extent different and unless otherwise described below. Specifically, instead of, for example, the protrusion 434, the joint 1368 of the container 1300 is a solid post 1336 that is between and contacts the outer base 106 of the outer shell 102 and the inner base 426 of the inner shell 422. The post 1336 provides support for the inner shell 422 on the outer base 106 of the outer shell 102. The contact area of the post 1336 with the inner base 426 and the outer base 106 can be minimal so as to minimize heat transfer between the outer shell 102 and the inner shell 422. For example, the post 1336 can be generally cylindrical with a diameter of about 2 mm to about 6 mm.

FIG. 14 is a cross-sectional view of an insulated container 1400, according to another embodiment of the present invention. The insulated container 1400 is similar to the insulated container 600 such that element numbers in FIG. 14 ending with the same ones and tens digits as the element numbers in FIG. 6 are the same features, to the extent the element numbers differ and unless otherwise described below. Specifically, the container 1400 includes steps 1430 in the inner wall 1424 of the inner shell 1422. The container 1400 further includes steps 1410 in the outer wall 1404 of the outer shell 1402. However, the steps 1410 and steps 1430 are positioned relative to each other so that there are contact points 1490 where the inner wall 1424 contacts the outer wall 1404. The contact points 1490 provide extra support between the outer shell 1402 and the inner shell 1422. The extra support can, for example, reduce buckling. Specifically, air in the space 1462 between the outer shell 1402 and the inner shell 1422 can expand or contract when heated or chilled, respectively. For example, when the container 1400 holds a cold fluid, the cold fluid may cause the temperature of the inner shell 1422 to drop, which will also cause the temperature of the air in the space 1462 to drop. A drop in the temperature of the air causes a drop in the pressure in the space 1462. As result, the outer shell 1402 can buckle inward if the outer shell 1402 alone does not have enough strength to withstand the drop in pressure. However, the contact points 1490 reduce the likelihood of the outer shell 1402 buckling inward as a result of the drop in pressure. Yet, the contact points 1490 are still minimal such that the contact points 1490 result in minimal heat transfer between the inner shell 1422 and the outer shell 1402.

FIG. 15 is a side view of an insulated container 1500, according to another embodiment of the present invention. The insulated container 1500 is similar to the insulated container 600 such that element numbers in FIG. 15 ending with the same ones and tens digits as the element numbers in FIG. 6 are the same features, to the extent the element numbers differ and unless otherwise described below. Specifically, the outer wall 1504 of the outer shell 1502 includes one or more holes 1592. The holes 1592 allow air to equilibrate between the outer shell 1502 and the inner shell (not shown) in response to the container 1500 containing hot or cold fluid. For example, when a cold fluid fills the container 1500, the holes 1592 allow air to be drawn into the gap (not shown) between the inner shell and the outer shell 1502, reducing the chance of the outer shell 1502 buckling. When a hot fluid fills the container 1500, these holes 1592 allow some air between inner shell (not shown) and outer shell 1502 to escape, reducing the chance of the inner shell buckling. Although the holes 1592 may allow for increased heat transfer, the holes 1592 have the benefit of not requiring the contact points 1490 of the container 1400 in FIG. 14.

Although FIG. 15 shows five holes 1592, there may be one, two, three, four, six, seven, or more holes 1592 located generally in the same spot on the outer shell 1502 or at different locations around the outer shell 1502. Although the holes 1592 are circular, the holes 1592 can have other geometries, including slots, slits, etc. The holes 1592 can also be placed in other locations on the outer shell 1502, including on the bottom of the outer shell 1502.

Although the foregoing disclosure primarily focuses on containers in the form of cups, the aspects of the present disclosure can also be applied to containers generally in the form of cans. For example, FIG. 16 shows a cross-sectional view of an insulated can preform 1600, according to another embodiment of the present invention. The can preform 1600 includes an outer shell 1602 formed of a thin wall of metal or a metal alloy, particularly a recyclable metal, and more particularly aluminum. The outer shell 1602 includes an outer wall 1604, an outer base 1606, and an open end 1608, which is also generally referred to as the top of the can preform 1600 in the orientation shown in FIG. 16. The outer wall 1604 generally has the profile of a standard can, although the outer wall 1604 can have various other profiles.

The can preform 1600 further includes an inner shell 1622. The inner shell 1622 can be formed of a thin wall of metal or a metal alloy, particularly a recyclable metal, and more particularly aluminum. The inner shell 1622 includes an inner wall 1624, an inner base 1626, and an open end 1628, which is also generally referred to as the top of the can preform 1600 in the orientation shown in FIG. 16. The open end 1628 is essentially the same as the open end 1608 based on the inner diameters of the outer shell 1602 and the inner shell 1622 the open ends substantially matching. Although not shown, the inner wall 1624 is generally cylindrical. However, the inner wall 1624 can have various other profiles, such as a profile that generally corresponds to the profile of the outer shell 1602.

The inner base 1626 can have generally a standard profile of a can, and the outer base 1606 also can have generally a standard profile of a can. A contact point 1696 forms where the inner base 1626 contacts the outer base 1606. Where the inner base 1626 and the outer base 1606 are cylindrical, the contact point 1696 is generally annular. The contact point 1696 provides support for, and aligns, the inner shell 1622 with the outer shell 1602. The surface area of the contact point 1696 can be minimal to reduce heat transfer between the inner shell 1622 and the outer shell 1602.

The outer shell 1602 coupled to the inner shell 1622 forms a space 1662 therebetween. The space 1662 generally has a continuous cylindrical portion 1664 along and around the can preform 1600. The space 1662 further generally has a circular portion 1666 at the bottom of the can preform 1600 separated from the portion 1664 by the contact point 1696. Like the space 562 disclosed above, the space 1662 provides insulation between the inner shell 1622 and the outer shell 1602 by having a lower thermal conductivity than the inner shell 1622 or the outer shell 1602. The space 1662 allows for a resulting can formed from the can preform 1600 to maintain beverages colder or warmer for longer than a standard can. The space 1662 also allows for the resulting can to hold beverages at cold or warm temperatures without a user experiencing the cold or warm temperatures while holding the can preform 1600. Thus, the space 1662 acts as a barrier so that the resulting container formed from the can preform 1600 can hold cold or warm beverages without the user experiencing uncomfortable cold or warm temperatures, and also without the need for an additional sleeve or protector.

Further like the space 562 disclosed above, the space 1662 can be filled with air, which has a lower thermal conductivity than the thin metal, such as aluminum, used to form the inner shell 1622 and the outer shell 1602. However, the space 1662 can be filled with another material, such as one or more gases other than air, such as nitrogen. For example, the one or more other gases can have a thermal conductivity lower than air to limit further the heat transfer between the inner shell 1622 and the outer shell 1602. In one or more embodiments, the space 1662 can be under vacuum relative to the atmosphere. For example, the vacuum within the space 1662 can be about 12,000 Pascals (Pa) to about 55,000 Pa, more preferably about 20,000 Pa to about 40,000 Pa, and most preferably about 28,000 Pa to about 35,000 Pa, depending on the thickness of the outer wall 1604 and the inner wall 1624 for maintaining structural integrity of the can preform 1600.

The can preform 1600 was used in tests to validate its temperature performance versus a standard can (outer shell only; no insulation). Specifically, the can preform 1600 was filled with six ounces of hot liquids and a cold liquid. One thermocouple was attached to the exterior of the outer wall 1604 to measure wall temperature, and a second thermocouple was inserted in the can preform 1600 to monitor the liquid temperature. The same arrangement was provided for with the standard can. Specifically, one thermocouple was attached to the exterior of the standard can to measure wall temperature, and a second thermocouple was inserted in the standard can to monitor the liquid temperature. During testing, the can preform 1600 and the standard can were sitting at room temperature without lids.

The can preform 1600 and the standard can were filled with hot liquids at 160° F. (71.1° C.), 175° F. (79.4° C.), and 195° F. 195 (90.6)° C. The temperature performance of the can preform 1600 and the standard can are both shown in FIGS. 17-19 for the hot liquids at 160° F. (71.1° C.), 175° F. (79.4° C.), and 195° F. 195 (90.6° C.), respectively. As shown in FIGS. 17-19, the can preform 1600 had superior temperature performance compared to the standard can. Specifically, the can preform 1600 kept the liquids at higher temperatures for longer periods of time. For example, after 30 minutes, the hot liquids in the can preform 1600 were 5° F. (2.78° C.) higher than in the standard can. For the liquid at 160° F. (71.1° C.), 175° F. (79.4° C.), and 195° F. 195 (90.6)° C., it took the can preform 1600 more than 5 minutes to drop below 120° F. (48.9° C.), 125° F. (51.7° C.), and 140° F. (60° C.), respectively, as compared to the standard soda can. Further, when the liquids were at 160° F. (71.1° C.) and 175° F. (79.4° C.), the can preform 1600 kept the outside wall temperature below 120° F. (48.9° C.). Even for the liquid at 195° F. (90.6)° C., the outside wall temperature for the can preform 1600 was just over 120° F. (48.9)° C. However, for the standard can with the liquid at 195° F. (90.6° C.), the outside wall temperature was so hot that the standard can could not be handled with bare hands.

The can preform 1600 experienced similar superior temperature performance over the standard can for a cold liquid, the result of which is shown in FIG. 20. In tests using the same configuration as described above, a liquid at 35° F. (1.67° C.) reached 45° F. (7.22° C.) in 16 minutes in the standard can. In contrast, for the can preform 1600, the liquid at 35° F. (1.67° C.) reached 45° F. (7.22° C.) after 31 minutes, almost double the time as the standard can.

The exterior of the can preform 1600 also stayed warmer as compared to the exterior of the standard can. For example, the exterior of the standard can was 10° F. (5.56° C.) lower than the exterior of the can preform 1600. While these actual temperatures may not cause discomfort to a consumer per se, the can preform 1600 also is unlikely to sweat in a hot and humid environment, which provides better handling and performance than the standard can.

The containers of the present disclosure provide a single-use container with improved insulation properties verses other single-use containers made of metal. The containers of the present disclosure further provide better temperature resistance as compared to containers made of other materials, such as plastic. For example, the containers of the present disclosure are more resistant to warping from high temperatures and cracking from low temperatures. As stated above, the containers of the present disclosure also have improved recyclability over paper and plastic containers. As a result, the containers of the present disclosure have a reduced impact on waste streams as compared to plastic and paper containers by being more easily recycled. The containers of the present disclosure also can be manufactured with less material than plastic or paper containers because of the greater rigidity of the material used in the containers. Using less material further adds to the reduction in waste streams regardless of recyclability.

Each of the above embodiments and obvious variations thereof are contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. Moreover, the present concepts expressly include any and all combinations and sub-combinations of the preceding elements and aspects.

As utilized herein, the terms “approximately,” “about,” “substantially”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.

It should be noted that the terms “exemplary” and “example” as used herein to describe various embodiments are intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).

Any references herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the Figures. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.

Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions, and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

INSULATED CONTAINERS AND METHODS FOR FORMING THE SAME

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