Abstract:
An improved disposable storage and dispensing carafe which allows the easy transport and dispensing of a bulk volume of a hot or cold liquid in a throw-away container. The carafe comprises a rigid frame having a dispensing outlet, a pliable or plastic bag for holding a hot or cold liquid having a rigid spout affixed thereto, means for detachably connecting the rigid spout to the dispensing outlet, and an insulating jacket detachably connected to the frame and enveloping the pliable or plastic bag.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is based upon and gains priority from U.S. Provisional Patent Application Ser. No. 60/237,517, filed Oct. 4, 2000 by the inventors herein and entitled “Disposable Storage and Dispensing Caraffe.” 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention disclosed herein relates generally to beverage carafes, and more particularly to an improved disposable storage and dispensing carafe which allows the easy storage, transport and dispensing of a bulk volume of a hot or cold beverage in a throw-away container. 
     2. Description of the Background 
     Many food product retailers and food service providers offer their customers carry-out hot or cold beverages. The incremental sales of such hot or cold beverages provide a significant profit margin for such product and service suppliers. However, for the consumer purchasing such hot or cold beverages, a significant safety and product quality challenge exists in transporting volumes in excess of what would be consumed by a single consumer. From a safety perspective, while cardboard trays have been provided in the past to help a consumer transport up to four cups containing a hot or cold beverage, the transport of more than four cups is impractical and presents a safety risk of spilling the beverage and even possibly causing bums to the person carrying the beverages. Moreover, from a product quality perspective, the transport of a tray of multiple hot beverage containers is inclined to cool the beverages much more quickly than would a large volume insulated thermos or carafe. Unfortunately, however, the costs of traditional thermoses or carafes makes their sale as a container for a hot or cold beverage sold in a traditional carry-out or catering business setting highly impractical. 
     Still further, providing large volume containers for carry-out beverages creates a significant packaging and storage challenge, in that large volume carafes and thermoses take up large amounts of physical space both in shipping vehicles and in storage facilities at retail locations, making their widespread use even more impractical. While nock-down, folded cardboard containers have been used in the past, the use of such a non-rigid material precludes its use for carrying large volumes of a hot or cold beverage (e.g., up to 108 ounces/6 pounds) at one time). 
     Thus, there is a need in the art for a disposable storage and dispensing carafe which can safely transport and dispense a bulk volume (preferably at least 108 ounces) of a hot or cold beverage and which may be manufactured at sufficiently low cost to enable the carafe to be disposed of after use, and which is collapsible so as to allow easy transport to and storage at a retail establishment or the like. 
     SUMMARY OF THE INVENTION 
     It is, therefore, an object of the present invention to provide a cost efficient, disposable storage and dispensing carafe which avoids the disadvantages of the prior art. 
     It is another object of the present invention to provide a disposable storage and dispensing carafe which enables easy, safe dispensing of the contents of the carafe. 
     It is yet another object of the present invention to provide a disposable storage and dispensing carafe having an insulated exterior to maintain the temperature of the carafe contents and to protect persons and objects from inadvertent bums from contacting a stored hot beverage. 
     It is still yet another object of the present invention to provide a disposable storage and dispensing carafe having a rigid first means for manually transporting the carafe, and a rigid second means for dispensing the carafe contents. 
     It is still even yet another object of the present invention to provide a disposable storage and dispensing carafe having a rigid frame with a readily replaceable fluid content carrier. 
     In accordance with the above objects, a disposable storage and dispensing carafe is disclosed which enables the easy transport and dispensing of a large volume (preferably at least 96 to 128 fluid ounces) of a liquid without risk of bum or spillage of the carafe contents. The carafe comprises a rigid, generally rectangular frame having a dispensing outlet at its upper end, an insulated, waterproof, generally pliable or plastic bag for holding the fluid to be dispensed at up to 250° F. and having an opening at its upper end, a rigid spout affixed to the plastic bag at its opening, and means on the rigid spout for attaching the spout to the dispensing outlet of the frame. The frame is also provided a handle having a carrying portion and a dispensing portion. Insulating material preferably in the form of a corrugated paperboard jacket is connected to the frame about the pliable or plastic bag after it is positioned within the frame. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Other objects, features, and advantages of the present invention will become more apparent from the following detailed description of the preferred embodiment and certain modifications thereof when taken together with the accompanying drawings in which: 
     FIG. 1 is a side view of a beverage carafe of the instant invention. 
     FIGS. 2 a ,  2   b , and  2   c  are top, side, and rear views, respectively, of frame member  11 . 
     FIG. 2 d  is a top down, section view of a portion of frame member  11 . 
     FIG. 3 is a side perspective view of spout  15 . 
     FIGS. 4 a ,  4   b , and  4   c  are top, side, and sectional views, respectively, of spout  15 . 
     FIG. 5 is a side view of pliable bag  19 . 
     FIGS. 6 a  and  6   b  are side views of a right and left side panel of insulating jacket  20 , respectively. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     As shown in the side view of FIG. 1, the beverage carafe of the instant invention comprises a rigid frame (shown generally at  11 ) having a support member  12 , a spout holder  13  positioned at the top of support member  12 , and a handle  14 . While handle  14  is denoted in FIG. 1 as a single elongate member, it should be noted that handle  14  particularly comprises a pouring handle member  14   a  and a carrying handle member  14   b , and that such handle members may be provided as distinct rigid members without departing from the spirit and scope of the instant invention. An elongated, generally annular spout  15  having an inlet opening  16  and a dispensing outlet  17  is configured for insertion into spout holder  13 . An insulated, waterproof, generally pliable or plastic bag  19  for holding the fluid to be dispensed is connected at its upper end to a heat seal connecting section  18  on spout  15  to form an integral unit therewith. Pliable bag  19  and annular spout  15  are so connected into the supporting assembly  12  of the frame  11  and the spout holder  13  that the dispensing outlet  17  of annular spout  15  will be disposed exterior of frame  11  to enable a cover  20 , such as an internally threaded closure cap, to be detachably connected to annular spout  15  about dispensing outlet  17 . Insulating material in the form of a jacket  20  is connected to the support assembly  12  about pliable bag  19  and spout holder  13  after the integral spout/bag unit is connected in assembled position on support assembly  12  of frame  11 . 
     Referring next to the detailed top view, side view, and rear view of the frame of FIGS. 2 a ,  2   b , and  2   c , respectively, rigid frame  11  comprises support member  12 , spout holder  13  positioned at the top of support member  12 , and handle  14 . Support member  12  more particularly comprises an internal, rigid, generally rectangular support member  12   b  circumscribed by an external, rigid, generally rectangular support member  12   a . Support members  12   a  and  12   b  are interconnected via a planar web  12   c  extending between outer support member  12   a  and inner support member  12   b , and at their bases via ribs  21 . The uppermost section of support members  12   a  and  12   b  (as shown in FIG. 2 b ) may optionally be formed as a concave well extending into the area of the otherwise rectangular forms defined by support members  12   a  and  12   b , but may likewise be formed as a generally horizontal surface, or a convex hump, without departing from the spirit and scope of the instant invention. 
     Internal support member  12   b  is preferably provided with a series of clamping means  25  for holding insulating sleeve  20  on frame  11 , as will be discussed in greater detail below. As shown more particularly in the section view of the frame assembly of FIG. 2 d , each clamping means  25  preferably comprises a ramp extending outward from the face of support member  12   b  towards the interior face of support member  12   a , and defining a gap  25   a  between the top of clamping means  25  and the interior face of support member  12   a . Likewise, t-shaped tabs  24  are rigidly affixed to the interior of support member  12   b  and are configured to receive flexible storage bag  19  and hold the same within frame  11 , as explained in greater detail below. 
     As shown more particularly in FIGS. 2 a  and  2   c , frame  11  is also provided a rigid, ovular, planar base member  12   d  integrally formed with the other portions of frame  11  and providing a broad, flat base on which the carafe assembly may rest when not in use. 
     Rigidly affixed to an upper corner of both support members  12   a  and  12   b  is spout holder  13 . Spout holder  13  defines a generally annular passage extending from the interior of frame  11  to the exterior of frame  11 . The wall of spout holder  13  is preferably segmented at is bottom in order to provide a tab (shown generally at  30 ) which, due to the inherent flexibility of spout holder  13  (which is preferably formed of polypropylene), may move slightly into and away from the annular passage defined by spout holder  13 . The bottom portion of tab  30  is preferably provided a hook  30  for engaging a lip on annular spout  15  to hold annular spout  15  in place within spout holder  13 , as will be described in greater detail below. 
     Spout holder  13  is also provided a guide flange  31   a  (FIG. 2 a ) running parallel to the major axes of spout holder  13  and attached to an interior wall thereof. Guide flange  31   a  is configured to mate with a guide channel  36  (FIGS. 4 a  and  4   c ) on spout  15  so as to ensure proper alignment of spout  15  when it is placed in spout holder  13 . 
     Handle  14  extends outward from the upper edge of spout holder  13  towards an opposing upper corner of support member  12   a  where it intersects support member  12   a , and down to a location below the midpoint of the rear portion of support member  12   a . While the figures depict handle  14  as a generally rounded bar, it should be noted that any similarly configured elongate, rigid structure that intersects spout holder  13  and the top member of support member  12  to provide a handle for vertically transporting the beverage carafe would suffice and not depart from the spirit and scope of the instant invention. Likewise, any similarly configured elongate, rigid handle structure that provides a gripping means along the upper extent of the side member of support member  12  with a lower end attached below the midpoint of the rear portion of support member  12   a  so as to provide a handle for pouring the contents from the carafe while maintaining balanced control of the its contents would likewise suffice and not depart from the spirit and scope of the instant invention. 
     Rigid frame  11  is preferably formed of polypropylene, providing a light-weight structure of sufficient strength and rigidity to be able to support the weight of at least 108 fluid ounces of a beverage (i.e., at least 6 pounds). 
     As shown in the perspective view of FIG.  3  and the detailed top, side, and sectional views of FIGS. 4 a ,  4   b , and  4   c , respectively, spout  15  comprises an elongated, generally annular shaft having an inlet opening  16  and a dispensing outlet  17 , and is configured for insertion into spout holder  13  such that the uppermost portion of spout  15  extends above spout holder  13  when installed. The upper portion of spout  15  is provided with fastening means  32  preferably in the form of external threads circumscribing the outer circumference of the top portion of spout  15 , the fastening means being configured to receive and fasten to spout  15  a closure  20  (FIG. 1) on the dispensing outlet  17  of spout  15  to prevent inadvertent spillage during transport. Spout  15  is preferably provided a guide flange  33  running parallel to the major axis of spout  15  along an outer wall thereof rising in height away from the external surface of spout  15  as it extends down the length of spout  15 , and terminating in an abutment  34  formed as a ring circumscribing the exterior of spout  15  near its bottom end. Spout  15  is further preferably provided a guide channel  36  running parallel to the major axis of spout  15  along an outer wall thereof, such guide channel  36  being sized and configured to receive guide flange  31   a  (FIG. 2 a ) on spout holder  13  so as to align spout  15  as it is inserted into spout holder  13 . When installing spout  15  in spout holder  13 , spout  15  is inserted from the bottom portion of spout  15  and is pushed upwards (while being guided and aligned by guide channel  36  and guide flange  31   a ) until a top abutment  35  comes into contact with an interior ledge on spout holder  13  (not shown). As spout  15  is so inserted, hook  30  on tab  31  of spout holder  13  is guided by guide flange  33  and is thereby flexed outwardly from the center of spout holder  13 , until hook  30  overpasses abutment  34  at which point tab  31  snaps back into its original, at-rest position, in turn locking spout  15  in spout holder  13  so as to prevent rearward movement of spout  15  back into the volume of the carafe. Spout  15  is also provided at its bottom with connecting section  18  for heat sealing, adhesively connecting, or otherwise attaching an empty plastic bag  19  thereto, as discussed in greater detail below. 
     As shown more particularly in FIG. 5, an insulated, waterproof, generally pliable or plastic bag  19  for holding the fluid to be dispensed is provided which defines an open volume  40  configured to receive a minimum of 108 fluid ounces. Pliable bag  19  comprises two sections of pliable plastic which are heat sealed along two vertical edges, a top edge, and a bottom preferably concave edge which defines a curved bottom to open volume  40 , and is preferably comprised of pliable plastic which may withstand temperatures of up to 250° F. without degradation of the bag&#39;s integrity. Located between a vertical edge and the top edge of pliable bag  19  is weld spout area  19   a  which attaches to connecting section  18  on spout  15  to form an integral unit therewith, spout  15  in turn forming a dispensing outlet for the contents of pliable bag  19 . As mentioned briefly above, pliable bag  19  and annular spout  15  are so connected into the supporting assembly  12  of the frame  11  and the spout holder  13  that the dispensing outlet  17  of annular spout  15  will be disposed exterior of frame  11  to enable a cover means  20  to be detachably connected to annular spout  15  about dispensing outlet  17 . Openings  19   b  are provided within the heat-sealed region of bag  19 , openings  19   b  being sized to allow the insertion of tabs  24  on support member  12   b . When bag  19  is so attached to tabs  24 , inadvertent movement of the bag with respect to the interior of frame  11  is largely diminished. 
     As shown in the right side and left side views of FIGS. 6 a  and  6   b , respectively, jacket  20  comprises two planar sheets of insulating material configured to be attached to support assembly  12  about pliable bag  19  and spout holder  13  after the integral spout/bag unit is connected in assembled position on support assembly  12  of frame  11 . FIGS. 6 a  and  6   b  are mirror images of one another, FIG. 6 a  depicting a side panel for the right side of the carafe, and FIG. 6 b  depicting a side panel for the left side of the carafe. Each side panel of jacket  20  has generally flat bottom, front, and rear edges. Both the front and rear edges of each side panel are provided with fold lines  51  to facilitate insertion of the front and rear edges of each side panel into clamping means  25  on frame  11 . Although not particularly shown in FIGS. 6 a  and  6   b , additional fold or score lines may be provided between the front and rear edges of each side panel in order to more easily enable side panels of jacket  20  to form curved exterior side walls for the carafe body. 
     Each of the side panels is also provide a series of perforated tabs  52  positioned adjacent the front and rear edges of each side panel. Perforated tabs  52  are spaced apart from one another the same distance as their corresponding ramps  25  on frame support member  12   b , such that when each side panel edge is inserted into the gap  25   a  between ramps  25  and outer support member  12   a  and pushed towards frame support member  12   b , ramps  25  break the perforations on each perforated tab  52 . After the perforations are broken, the interior edge of each ramp  25  will engage the leading edge of the opening in the side panels formed from the separated tab  52  so as to prevent the front and rear edges of the side panels from being inadvertently withdrawn from the frame. 
     Further, the top edge of each side panel is provided with a curved score line  53  which, when folded, forms a curved plane  60  defining a top edge of jacket  20  and abutting the top edge of frame  11 . The upper, front comer of curved plane  60  is provided a cutout  54  enabling the front comer to lie flush against a side portion of spout holder  13 . Likewise, the upper, front comer of each side panel is provided a cutout  55  enabling such front corner to lie flush against the bottom portion of spout holder  13 . 
     Each side panel of jacket  20  is preferably formed of a pliable corrugated material such as single-faced corrugate, 130 lb. cover, enabling the side panels to provide an insulating surface protecting against inadvertent bums that might be caused by contacting pliable bag  19  directly. Moreover, the general planar form of each of the side panels of jacket  20 , as well as the minimal thickness profile of rigid frame  11  other than the base, enables multiple, unassembled carafe units of the instant invention to be shipped and stored in a flat, stacked package, while enabling the same to take on a rounded, full-volume, original carafe appearance when assembled. 
     Having now fully set forth the preferred embodiments and certain modifications of the concept underlying the present invention, various other embodiments as well as certain variations and modifications of the embodiments herein shown and described will obviously occur to those skilled in the art upon becoming familiar with said underlying concept. It should be understood, therefore, that the invention may be practiced otherwise than as specifically set forth herein.