U.S. patent application number 12/910951 was filed with the patent office on 2012-04-26 for insulated beverage container.
Invention is credited to Sven Samuel Arenander, Vladislav Babinsky, Dobridge Celeste Newman.
Application Number | 20120097685 12/910951 |
Document ID | / |
Family ID | 44736055 |
Filed Date | 2012-04-26 |
United States Patent
Application |
20120097685 |
Kind Code |
A1 |
Babinsky; Vladislav ; et
al. |
April 26, 2012 |
Insulated Beverage Container
Abstract
A container including a wall that defines an internal volume and
an opening into the internal volume, the wall including an internal
surface and an external surface, and being formed as a layered
structure that includes a first layer positioned proximate the
internal surface and a second layer positioned proximate the
external surface, the second layer including major bosses extending
into engagement with the first layer to space the second layer from
the first layer.
Inventors: |
Babinsky; Vladislav; (Fuquay
Varina, NC) ; Arenander; Sven Samuel; (Raleigh,
NC) ; Newman; Dobridge Celeste; (Glen Allen,
VA) |
Family ID: |
44736055 |
Appl. No.: |
12/910951 |
Filed: |
October 25, 2010 |
Current U.S.
Class: |
220/592.2 ;
220/660; 220/703; 220/739 |
Current CPC
Class: |
B65D 81/3869
20130101 |
Class at
Publication: |
220/592.2 ;
220/660; 220/703; 220/739 |
International
Class: |
B65D 81/38 20060101
B65D081/38; A47G 19/22 20060101 A47G019/22; B65D 25/00 20060101
B65D025/00; B65D 90/02 20060101 B65D090/02 |
Claims
1. A container comprising at least one wall that defines an
internal volume and comprises an internal surface and an external
surface, said wall being formed as a layered structure comprising:
a first layer positioned proximate said internal surface; and a
second layer positioned proximate said external surface, said
second layer comprising a plurality of major bosses protruding into
engagement with said first layer to space said second layer from
said first layer.
2. The container of claim 1 wherein said second layer is embossed
to define said plurality of major bosses.
3. The container of claim 1 wherein each major boss of said
plurality of major bosses has a surface area ranging from about 25
to about 100 mm.sup.2.
4. The container of claim 1 wherein each major boss of said
plurality of major bosses is spaced about 15 to about 50 mm from
adjacent major bosses of said plurality of major bosses.
5. The container of claim 1 wherein said second layer has a surface
area, and wherein said plurality of major bosses comprises about 2
to about 20 percent of said surface area.
6. The container of claim 1 wherein said second layer comprises
about 0.5 to about 2 major bosses of said plurality of major bosses
per square inch of said second layer.
7. The container of claim 1 wherein each major boss of said
plurality of major bosses has a protruding depth of at least 5
points.
8. The container of claim 1 wherein each major boss of said
plurality of major bosses comprises a rounded distal end.
9. The container of claim 1 wherein said second layer further
comprises a plurality of minor bosses, each minor boss of said
plurality of minor bosses having an average minor boss surface
area, each major boss of said plurality of major bosses having an
average major boss surface area, said average minor boss surface
area being less than said average major boss surface area.
10. The container of claim 9 wherein said plurality of minor bosses
protrude away from said first layer.
11. The container of claim 9 wherein said plurality of minor bosses
protrude toward said first layer.
12. The container of claim 9 wherein each minor boss of said
plurality of minor bosses has a surface area ranging from about 1
to about 25 mm.sup.2.
13. The container of claim 9 wherein each minor boss of said
plurality of minor bosses is spaced about 1 to about 15 mm from
adjacent minor bosses of said plurality of minor bosses.
14. The container of claim 9 wherein each minor boss of said
plurality of minor bosses has a protruding depth ranging from about
2 to about 10 points.
15. The container of claim 1 wherein said layered structure further
comprises an adhesive connecting said second layer to said first
layer.
16. The container of claim 15 wherein said adhesive forms a string
pattern in said layered structure.
17. The container of claim 15 wherein said adhesive is a foam
adhesive.
18. The container of claim 17 wherein said foam adhesive comprises
an organic binder and at least one of an organic filler and an
inorganic filler.
19. A container comprising at least one wall that defines an
internal volume and comprises an internal surface and an external
surface, said wall being formed as a layered structure comprising:
a first layer positioned proximate said internal surface; a second
layer positioned proximate said external surface, said second layer
comprising a plurality of major bosses protruding into engagement
with said first layer to space said second layer from said first
layer and a plurality of minor bosses protruding away from said
first layer; and an adhesive positioned between said second layer
and said first layer.
20. A container comprising: a side wall that defines a longitudinal
axis and an internal volume; a sleeve coaxially received over said
side wall, said sleeve defining a plurality of major bosses and a
plurality of minor bosses, said major bosses of said plurality of
major bosses having a larger surface area than said minor bosses of
said plurality of minor bosses, wherein said major bosses protrude
radially inward into engagement with said side wall to space said
sleeve from said side wall; and an adhesive positioned between said
sleeve and said side wall.
Description
FIELD
[0001] This application relates to containers and, more
particularly, to insulated beverage containers.
BACKGROUND
[0002] Beverage containers, such as beverage cups, are used to hold
both hot and cold beverages. Cold beverages, such as soda and iced
tea, are typically served with ice and, over time, result in the
formation of water droplets (i.e., condensation) on the external
surface of the beverage container due to humidity in the ambient
air.
[0003] Condensation on the external surface of a beverage container
inhibits the user's ability to securely grip the beverage
container, which may result in accidental spillage, particularly
when the beverage is being consumed on the go. Furthermore, the
formation of condensation on the external surface of beverage
containers often results in the undesirable pooling of condensate
on the surface supporting the beverage container.
[0004] Condensate formation may be inhibited by insulating the cold
beverage in the beverage container from the external-most surface
of the beverage container (i.e., the surface that is in contact
with the humid ambient air). As one example, vacuum bottle-type
beverage containers use the insulating properties of a vacuum to
insulate the external-most surface of the beverage container from
the contents of the beverage container, thereby inhibiting, if not
eliminating, condensate formation. Unfortunately, vacuum
bottle-type beverage containers can be quite expensive and,
therefore, are not practical for disposable applications. As
another example, polystyrene foam beverage containers are available
at a relatively low cost and offer improved insulation and, hence,
reduced condensate formation. However, polystyrene foam beverage
containers tend to be fragile and are not biodegradable.
[0005] Accordingly, those skilled in the art continue with research
and development efforts in the field of insulated beverage
containers.
SUMMARY
[0006] In one aspect, the disclosed insulated beverage container
may include a wall that defines an internal volume and an opening
into the internal volume. The wall includes an internal surface and
an external surface, and is formed as a layered structure that
includes a first layer positioned proximate the internal surface
and a second layer positioned proximate the external surface. The
second layer includes major bosses extending into engagement with
the first layer to space the second layer from the first layer.
[0007] In another aspect, the disclosed insulated beverage
container may include a wall that defines an internal volume and
includes an internal surface and an external surface. The wall is
formed as a layered structure that includes a first layer
positioned proximate the internal surface and a second layer
positioned proximate the external surface. The second layer
includes a plurality of major bosses extending into engagement with
the first layer to space the second layer from the first layer and
a plurality of minor bosses extending away from the first layer. An
adhesive connects the second layer to the first layer.
[0008] In yet another aspect, the disclosed insulated beverage
container may include a side wall that defines a longitudinal axis
and an internal volume, a sleeve defining a plurality of major
bosses and a plurality of minor bosses, the major bosses having a
larger surface area than the minor bosses, wherein the major bosses
protrude radially inward into engagement with the side wall to
space the sleeve from the side wall, and an adhesive positioned
between the sleeve and the side wall.
[0009] Other aspects of the disclosed insulated beverage container
will become apparent from the following description, the
accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a front elevational view of one aspect of the
disclosed insulated beverage container;
[0011] FIG. 2 is a front elevational view, in section, of the
insulated beverage container of FIG. 1;
[0012] FIG. 3 is a cross-sectional view of a portion of the side
wall of the insulated beverage container of FIG. 2;
[0013] FIG. 4A is a front elevational view of the insulated
beverage container of FIG. 2, shown with the outer layer of the
side wall removed to show the underlying structure;
[0014] FIG. 4B is a front elevational view of the insulated
beverage container of FIG. 4B in accordance with an alternative
construction; and
[0015] FIG. 5 is a cross-sectional view of a portion of the side
wall of an insulated beverage container in accordance with another
aspect of the disclosure.
DETAILED DESCRIPTION
[0016] Referring to FIGS. 1 and 2, one aspect of the disclosed
insulated beverage container, generally designated 10, may be
formed as a beverage cup, such as a 12-ounce, 16-ounce, 21-ounce or
24-ounce disposable take-out beverage cup. While a generally
frustoconical beverage container is shown in FIGS. 1 and 2, those
skilled in the art will appreciate that beverage containers of
various shapes and sizes may be constructed without departing from
the scope of the present disclosure.
[0017] The insulated beverage container 10 may include a side wall
12 and a bottom wall 14 (FIG. 2). The side wall 12 may include an
upper end portion 16 and a lower end portion 18, and may extend
circumferentially about a longitudinal axis A to define an internal
volume 20 (FIG. 2) of the insulated beverage container 10. The
bottom wall 14 may be connected to the lower end portion 18 of the
side wall 12 to partially enclose the internal volume 20. The upper
end portion 16 of the side wall 12 may define an opening 22 (FIG.
2) into the internal volume 20. Optionally, the upper end portion
16 of the side wall 12 may additionally include a circumferential
lip 24 for securing a lid (not shown) or the like to the upper end
portion 16 of the side wall 12, thereby further enclosing the
internal volume 20.
[0018] As shown in FIG. 3, the side wall 12 may be formed as a
layered structure that includes a first, inner layer 26 and a
second, outer layer 28. The outer layer 28 may be spaced apart from
the inner layer 26, as will be described in greater detail below.
An adhesive 30 may connect the outer layer 28 to the inner layer
26.
[0019] The inner layer 26 may include an inner surface 32 and an
outer surface 34. The inner surface 32 of the inner layer 26 may
define (or may be proximate) the interior surface 36 (FIG. 2) of
the side wall 12.
[0020] In one optional implementation, the inner surface 32 of the
inner layer 26 may be coated with a moisture barrier layer 38,
thereby rendering the interior surface 36 of the side wall 12 of
the insulated beverage container 10 resistant to moisture
penetration when the internal volume 20 of the insulated beverage
container 10 is filled with a beverage (not shown). The moisture
barrier layer 38 may have a cross-sectional thickness ranging from
about 0.5 to about 3.5 points, wherein 1 point equals 0.001 inches.
For example, the moisture barrier layer 38 may be (or may include)
a layer of polyethylene that has been laminated, extrusion coated
or otherwise connected (e.g., with adhesives) to the inner surface
32 of the inner layer 26. Other moisture barrier materials useful
in the moisture barrier layer 44 are commercially available and
known to the skilled artisan.
[0021] The inner layer 26 may be formed from a sheet of material
capable of being shaped into the side wall 12. The inner layer 26
may have a cross-sectional thickness T.sub.1 and a rigidity
sufficient to impart the side wall 12 of the insulated beverage
container 10 with sufficient structural integrity to maintain the
desired shape of the insulated beverage container 10 when a
beverage is placed in the internal volume 20. In one construction,
the inner layer 26 may be formed from a recyclable material, such
as paperboard. The paperboard may have a cross-sectional thickness
T.sub.1 of at least about 6 points, such as about 8 to about 24
points. In another construction, the inner layer 26 may be formed
from a polymeric material, such as polycarbonate or polyethylene
terephthalate.
[0022] The outer layer 28 may include an inner surface 40 and an
outer surface 42. The outer surface 42 of the outer layer 28 may
define (or may be proximate) the external surface 44 (FIG. 2) of
the side wall 12.
[0023] The outer layer 28 may be a sleeve or wrap positioned over
the inner layer 26. As such, the overall surface area of the outer
layer 28 may be less than the overall surface area of the inner
layer 26, as shown in FIGS. 1 and 2. Therefore, the outer layer 28
may cover only a portion of the inner layer 26. As one example, the
outer layer 28 may cover at least 60 percent of the inner layer 26.
As another example, the outer layer 28 may cover at least 80
percent of the inner layer 26. As yet another example, the outer
layer 28 may cover at least 90 percent of the inner layer 26.
[0024] The outer layer 28 may be formed from a sheet of paperboard,
which may be bleached or unbleached, and which may have a basis
weight of at least about 85 pounds per 3000 square feet and a
thickness T.sub.2 of at least about 6 points. For example, the
outer layer 28 may be formed from paperboard, such as linerboard or
solid bleached sulfate (SBS), having a basis weight ranging from
about 180 to about 270 pounds per 3000 square feet and a thickness
T.sub.2 ranging from about 8 to 36 points.
[0025] As shown in FIGS. 1-3, the outer layer 28 may include a
plurality of major bosses 46 and a plurality of minor bosses 48. In
one particular implementation, the major and minor bosses 46, 48
may be formed by embossing the outer layer 28 prior to forming the
side wall 12. For example, a sheet of paperboard may be passed
through an embossing press prior to forming the outer layer 28 of
the side wall 12.
[0026] The major bosses 46 may have a surface area (in plan view)
ranging from about 25 to about 100 mm.sup.2. For example, the major
bosses 46 shown in FIG. 1 are hemispherical (circular in plan view)
and may have a diameter of about 8 mm. Therefore, the major bosses
46 shown in FIG. 1 may have a surface area of about 50 mm.sup.2.
While the major bosses 46 are shown as being circular (in plan
view) in the drawings, those skilled in the art will appreciate
that major bosses 46 of various shapes (in plan view), such as
diamond, square, oblong, star or irregular, may be used without
departing from the scope of the present disclosure.
[0027] The major bosses 46 may be spaced across the outer layer 28
of the side wall 12. In one particular expression, the center of
each major boss 46 may be spaced about 15 to 50 mm from the center
of each adjacent major boss 46. As a first example, the major
bosses 46 may be equidistantly spaced across the outer layer 28 of
the side wall 12. As a second example, the major bosses 46 may be
arranged in a uniform pattern across the outer layer 28 of the side
wall 12. As a third example, the major bosses 46 may be randomly
arranged across the outer layer 28 of the side wall 12.
[0028] In one embodiment, the total surface area of the major
bosses 46 (i.e., the total number of major bosses on the outer
layer 28 multiplied by the average surface area of the major
bosses) may account for about 2 to about 20 percent of the total
surface area of the outer layer 28 of the side wall 12. As a
specific example, the major bosses 46 may account for about 8
percent of the total surface area of the outer layer 28 of the side
wall 12.
[0029] In another embodiment, the outer layer 28 of the side wall
12 may include about 0.5 to about 2 major bosses 46 per square inch
of the outer layer 28. As a specific example, the outer layer 28 of
the side wall 12 may include about 1.25 major bosses 46 per square
inch of the outer layer 28.
[0030] At this point, those skilled in the art will appreciate that
the number of major bosses 46 present on the outer layer 28 of the
side wall 12 may be dictated by the overall surface area of the
outer layer 28.
[0031] Referring to FIG. 3, the major bosses 46 may protrude
radially inward from the plane P (a wrapped plane) defined by the
outer layer 28 of the side wall 12 (i.e., toward the inner layer
26) such that each major boss 46 has a depth D.sub.1 and extends
into engagement with the inner layer 26. In one general example,
the depth D.sub.1 of each major boss 46 may be at least 5 points.
In another general example, the depth D.sub.1 of each major boss 46
may range from about 10 to about 25 points.
[0032] Thus, the major bosses 46 may function as spacers that space
the outer layer 28 from the inner layer 26 by a distance
corresponding to the depth D.sub.1 of the major bosses 46. As such,
an annular region 50 may be defined between the inner and outer
layers 26, 28.
[0033] As best shown in FIG. 3, the valley 52 (i.e., the distal
end) of each major boss 46 may be rounded (or pointed) to minimize
contact between the inner layer 26 and the outer layer 28. The
rounded valley 52 of each major boss 46 may have a radius of at
most 20 mm. Those skilled in the art will appreciate that
minimizing the total surface area of the outer layer 28 that is in
contact with the inner layer 26 may inhibit heat transfer between
the inner layer 26 and the outer layer 28.
[0034] The minor bosses 48 may have a surface area that is less
than the surface area of the major bosses 46. In one realization,
the minor bosses 48 may have a surface area (in plan view) ranging
from about 1 to about 25 mm.sup.2. For example, the minor bosses 48
shown in FIG. 1 are hemispherical (circular in plan view) and may
have a diameter of about 3 mm. Therefore, the minor bosses 48 shown
in FIG. 1 may have a surface area of about 7 mm.sup.2. In another
realization, the minor bosses 48 may have a surface area (in plan
view) that is at most 25 percent of the surface area of the major
bosses 46. While the minor bosses 48 are shown as being circular
(in plan view) in the drawings, those skilled in the art will
appreciate that minor bosses 48 of various shapes (in plan view),
such as diamond, square, oblong, star or irregular, may be used
without departing from the scope of the present disclosure.
[0035] The minor bosses 48 may be spaced across the outer layer 28
of the side wall 12. In one particular expression, the center of
each minor boss 48 may be spaced about 1 to 15 mm from the center
of each adjacent minor boss 48. As a first example, the minor
bosses 48 may be equidistantly spaced across the outer layer 28 of
the side wall 12. As a second example, the minor bosses 48 may be
arranged in a uniform pattern across the outer layer 28 of the side
wall 12. As a third example, the minor bosses 48 may be randomly
arranged across the outer layer 28 of the side wall 12.
[0036] In one embodiment, the number of minor bosses 48 present on
the outer layer 28 of the side wall 12 may be dictated by the
number of major bosses 46 present. As one general example, the
outer layer 28 of the side wall 12 may include at least 4 minor
bosses 48 for each major boss 46. As another general example, the
outer layer 28 of the side wall 12 may include about 6 to about 20
minor bosses 48 for each major boss 46. As a specific example, the
outer layer 28 of the side wall 12 may include 12 minor bosses 48
for each major boss 46.
[0037] In another embodiment, the number of minor bosses 48 present
on the outer layer 28 of the side wall 12 may be dictated by the
overall surface area of the outer layer 28 of the side wall 12. As
one general example, the outer layer 28 of the side wall 12 may
include at least 10 minor bosses 48 per square inch of the outer
layer 28. As another general example, the outer layer 28 of the
side wall 12 may include about 15 to about 25 minor bosses 48 per
square inch of the outer layer 28. As a specific example, the outer
layer 28 of the side wall 12 may include 20 minor bosses 48 per
square inch of the outer layer 28.
[0038] As shown in FIG. 3, the minor bosses 48 may protrude
radially outward from the plane P defined by the outer layer 28 of
the side wall 12 (i.e., away from the inner layer 26) and may have
a protruding depth D.sub.2. The protruding depth D.sub.2 of each
minor boss 48 may be less than the protruding depth D.sub.1 of the
major bosses 46. In one general example, the depth D.sub.2 of each
minor boss 48 may be at least 2 points. In another general example,
the depth D.sub.2 of each minor boss 48 may range from about 4 to
about 10 points.
[0039] Thus, the minor bosses 48 may further space the outer layer
28 from the inner layer 26, thereby further increasing the volume
of the annular region 50 between the inner and outer layers 26, 28.
Furthermore, the minor bosses 48 may texture the external surface
44 of the side wall 12 to enhance the ability to grip the insulated
beverage container 10.
[0040] As shown in FIG. 5, in an alternative aspect, the minor
bosses 48' may protrude radially inward from the plane P defined by
the outer layer 28' of the side wall 12' (i.e., toward the inner
layer 26). Such inwardly protruding minor bosses 48' may also
provide the external surface 44 of the side wall 12 with sufficient
texture to enhance the ability to grip the insulated beverage
container 10.
[0041] Optionally, the paperboard used to form the outer layer 28
may include various components and optional additives in addition
to cellulosic fibers. For example, the outer layer 28 may
optionally include one or more of the following: binders, fillers,
organic pigments, inorganic pigments, hollow plastic pigments,
expandable microspheres and bulking agents, such as chemical
bulking agents.
[0042] In a first optional aspect, the paperboard used to form the
outer layer 28 may include ground wood particles dispersed therein.
Without being limited to any particular theory, it is believed that
the presence of ground wood particles in the outer layer 28 may
encourage the absorption of condensation that is formed on the
external surface 44 of the side wall 12 into the outer layer
28.
[0043] In a second optional aspect, the outer layer 28 may be
engineered to maximize the transfer of moisture (i.e.,
condensation) forming on the external surface 44 of the side wall
12 into the outer layer 28. For example, the surface sizing and the
porosity of both the inner and outer surfaces 40, 42 of the outer
layer 28 may be engineered to maximize moisture (i.e.,
condensation) absorption and minimize the negative effects of
condensate formation.
[0044] In one implementation of the second optional aspect, the
surface sizing of the inner and outer surfaces 40, 42 of the outer
layer 28 may be controlled such that the inner surface 40 has a
Hercules sizing that is less than the Hercules sizing of the outer
surface 42. For example, the surface sizing of the inner and outer
surfaces 40, 42 of the outer layer 28 may be controlled such that
the inner surface 40 has a sizing in the range from about 30 to
about 80 Hercules units, while the outer surface 42 has a sizing in
the range from about 100 to about 150 Hercules units.
[0045] In another implementation of the second optional aspect, the
porosities of the inner and outer surfaces 40, 42 of the outer
layer 28 may be controlled such that the inner surface 40 has a
Gurley porosity that is less than the Gurley porosity of the outer
surface 42 (i.e., greater pore volume on the inner surface 40 than
on the outer surface 42). For example, the porosities of the inner
and outer surfaces 40, 42 of the outer layer 28 may be controlled
such that the inner surface 40 has a porosity of about 20 Gurley
units (400 cc test), while the outer surface 42 has a porosity of
about 40 Gurley units (400 cc test).
[0046] Those skilled in the art will appreciate that surface sizing
may be controlled using various sizing agents, such as alkyl ketene
dimer. Furthermore, those skilled in the art will appreciate that
other properties pertaining to moisture absorption, such as
porosity, can be achieved by modifying the paperboard making
process, such as modifying the selection of the forming, pressing
and drying fabrics.
[0047] Accordingly, by modifying the surface sizing and porosity of
both the inner and outer surfaces 40, 42 of the outer layer 28, the
rate of moisture absorption can be controlled. For example,
moisture absorption rates of 0.02 to 0.1 g/cm.sup.2/min at the
outer surface 42 and 0.03 to 0.2 g/cm.sup.2/min at the inner
surface 40 may be achieved.
[0048] As noted above, the outer layer 28 of the side wall 12 may
be connected to the inner layer 26 with an adhesive 30 (FIG. 3).
Other techniques for securing the outer layer 28 relative to the
inner layer 26 are also contemplated. For example, mechanical
fasteners or an interference fit may provide the necessary
connection between the inner and outer layers 26, 28.
[0049] Those skilled in the art will appreciate that various
adhesives may be used to connect the outer layer 28 to the inner
layer 26. However, in one particular implementation, the adhesive
30 may be a thermally insulating adhesive. An adhesive may be
deemed thermally insulating if it has an insulating R value per
unit of thickness that is greater than the insulating R value per
unit of thickness of the outer layer 28. For example, the ratio of
the insulating R value per unit of thickness of the adhesive 30 to
the insulating R value per unit thickness of the outer layer 28 may
be at least about 1.25:1, such as 1.5:1, 2:1 or even 3:1.
[0050] A suitable thermally insulating adhesive 30 may be formed as
a composite material that includes an organic binder and a filler.
The organic binder may comprise 15 to 70 percent by weight of the
adhesive 30 and the filler may comprise 2 to 70 percent by weight
of the adhesive 30.
[0051] The organic binder component of the thermally insulating
adhesive 30 may be any material, mixture or dispersion capable of
bonding the outer layer 28 to the inner layer 26. The organic
binder may also have insulating properties. Examples of suitable
organic binders include latexes, such as styrene-butadiene latex
and acrylic latex, starch, such as ungelatinized starch, polyvinyl
alcohol, polyvinyl acetate, and mixtures and combinations
thereof.
[0052] The filler component of the thermally insulating adhesive 30
may include an organic filler, an inorganic filler, or a
combination of organic and inorganic fillers. Organic fillers
include hard organic fillers and soft organic fillers. Examples of
suitable hard organic fillers include sawdust and ground wood.
Examples of suitable soft organic fillers include cellulose pulp,
pearl starch, synthetic fiber (e.g., rayon fiber), gluten feed,
corn seed skin and kenaf core (a plant material). Examples of
suitable inorganic fillers include calcium carbonate, clay,
perlite, ceramic particles, gypsum and plaster. For example,
organic filler may comprise 2 to 70 percent by weight of the
thermally insulating adhesive 30 and inorganic filler may comprise
0 to 30 percent by weight of the thermally insulating adhesive
30.
[0053] All or a portion of the filler may have a relatively high
particle size (e.g., 500 microns or more). The use of high particle
size filler material may provide the thermally insulating adhesive
30 with structure such that the thermally insulating adhesive 30
functions to further space the outer layer 28 of the side wall 12
from the inner layer 26. For example, the thermally insulating
adhesive 30 may be formed as a composite material that includes an
organic binder and a hard organic filler, such as sawdust, that has
an average particle size of at least 500 microns, such as about
1000 to about 2000 microns.
[0054] In one particular expression, the thermally insulating
adhesive 30 may be a foam. The foam may be formed by mechanically
whipping the components of the thermally insulating adhesive 30
prior to application. Optionally, a foam forming agent may be
included in the adhesive layer formulation to promote foam
formation. As one example, 10 to 60 percent of the foam of the
thermally insulating adhesive 30 may be open voids, thereby
facilitating the absorption of moisture from the external surface
44 of the insulated beverage container 10. As another example, 10
to 30 percent of the foam of the thermally insulating adhesive 30
may be open voids.
[0055] In another particular expression, the thermally insulating
adhesive 30 may be formed from a binder-filler formulation having a
pseudoplasticity index in the range of 0.3 to 0.5. Such a
pseudoplasticity index may provide the thermally insulating
adhesive 30 with a sufficient minimum thickness, while preserving
the ability to apply the formulation at a low viscosity. For
example, the formulation may have a low shear viscosity in the
range of 2,000 to 50,000 centipoises and a high shear viscosity in
the range of 100 to 5,000 centipoises.
[0056] As one option, the thermally insulating adhesive 30 may
additionally include a plasticizer. The plasticizer may comprise
0.5 to 10 percent by weight of the thermally insulating adhesive
30. Examples of suitable plasticizers include sorbitol, Emtal
emulsified fatty acids and glycerine.
[0057] As another option, the thermally insulating adhesive 30 may
additionally include sodium silicate, which may act as a filler,
but is believed to aid in binding and curing of the binder by
rapidly increasing viscosity of the binder during the drying
process. The sodium silicate may comprise 0 to 15 percent by weight
of the thermally insulating adhesive 30, such as about 1 to about 5
percent by weight of the thermally insulating adhesive 30.
[0058] As yet another option, the thermally insulating adhesive 30
may be formulated to be biodegradable.
[0059] As a specific example, the thermally insulating adhesive 30
may include styrene-butadiene or acrylic SRB latex (binder), wood
flour (organic filler), Aero Whip.RTM. (foam stabilizer available
from Ashland Aqualon Functional Ingredients of Wilmington, Del.),
corn fibers (organic filler), calcium carbonate (inorganic filler)
and starch (binder), wherein the components of the thermally
insulating adhesive have been mechanically whipped together to form
a foam. Other examples of suitable thermally insulating adhesives
are described in greater detail in U.S. Ser. No. 61/287,990 filed
on Dec. 18, 2009, the entire contents of which are incorporated
herein by reference.
[0060] The adhesive 30 may be positioned between the inner and
outer layers 26, 28 in various ways to connect the inner layer 26
to the outer layer 28. When the adhesive 30 is a thermally
insulating adhesive, such as a foam adhesive, a portion (if not
all) of the annual region 50 between the inner and outer layers 26,
28 may be filled with the thermally insulating adhesive.
[0061] In one construction, the adhesive 30 may be deposited at the
points where the major bosses 46 contact the inner layer 26.
Therefore, the adhesive 30 may be concentrated around the major
bosses 46 and may only slightly fill the annular region 50.
[0062] In another construction, the adhesive 30 may be applied to
the inner and/or outer layers 26, 28 as a plurality of strings 31,
as shown in FIG. 4A. The strings 31 may extend longitudinally (FIG.
4A), laterally (not shown) or otherwise along the side wall 12, and
may be applied at a coating thickness that is equal to or greater
than the protrusion depth D.sub.1 of the major bosses 46. In the
assembled container 10, the strings 31 of adhesive 30 may be
sandwiched between the inner and outer layers 26, 28 and may fill
(at least partially) the annular region 50.
[0063] In another construction, the adhesive 30 may be applied to
the inner and/or outer layers 26, 28 in a swirl pattern, as shown
in FIG. 4B. The swirl pattern may extend longitudinally (FIG. 4B),
laterally (not shown) or otherwise along the side wall 12. In the
assembled container 10, the swirl pattern of adhesive 30 may be
sandwiched between the inner and outer layers 26, 28 and may fill
(at least partially) the annular region 50.
[0064] In yet another construction, the adhesive 30 may cover all,
or only a portion, of the inner surface 40 of the outer layer 28.
As one example, the adhesive 30 may cover about 20 to about 100
percent of the surface area of the inner surface 40 of the outer
layer 28. As another example, the adhesive 30 may cover about 20 to
about 80 percent of the surface area of the inner surface 40 of the
outer layer 28. As yet another example, the adhesive 30 may cover
about 40 to about 60 percent of the surface area of the inner
surface 40 of the outer layer 28. As yet another example, the
adhesive 30 may cover about 50 percent of the surface area of the
inner surface 40 of the outer layer 28.
[0065] Accordingly, the disclosed insulated beverage container 10
comprises inwardly-extending major bosses 46 that space the outer
layer 28 of the side wall 12 from the inner layer 26, thereby
defining an annular region 50 that insulates the outer layer 28
from the inner layer 26. Furthermore, the disclosed insulated
beverage container 10 comprises minor bosses 48 that provide
surface texture that promotes gripping of the container 10 and,
when the minor bosses extend radially outward, increase the volume
of the annular region 50 to increase the insulating effect of the
annular region 50.
[0066] Although various aspects of the disclosed insulated beverage
container have been shown and described, modifications may occur to
those skilled in the art upon reading the specification. The
present application includes such modifications and is limited only
by the scope of the claims.
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