Abstract:
A beverage container having a double-walled construction is provided. The container includes an inner wall with an inner bottom wall for containing a beverage, an outer wall which extends about the inner wall, and an outer bottom wall which extends under the inner bottom wall. A thermal break extends uninterrupted between the outer surface of the inner wall and the inner surface of the outer wall and the inner bottom and outer bottom walls. The container includes a top having an upper rim which joins the periphery of the top, the inner wall, and the outer wall.

Description:
BACKGROUND OF THE INVENTION 
     RELATED APPLICATIONS 
       [0001]    This application is a divisional application of, and claims priority to, U.S. patent application Ser. No. 12/395,393 filed Feb. 27, 2009, the entire disclosure of which is expressly incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to beverage containers. More specifically, the present invention relates to a double-walled beverage container having inner and outer walls joined at an upper rim and having a thermal break formed between the walls. 
       RELATED ART 
       [0003]    Beverage containers exist in various shapes and sizes. One common type of beverage container is an aluminum can having a partially-removable tab and a finger lever for opening the tab. Once opened, a beverage can be consumed or poured through the opened tab. Various types of beverages, such as sodas, beer, etc., are contained in cans of this type. 
         [0004]    Unfortunately, common aluminum beverage cans do not adequately insulate the contents of the can from heat outside of the can, due to the fact that the can is formed with a single wall which is thermally conductive. As a result, heat from the environment can heat the contents, and even more so, as one holds a cold beverage can, heat is transferred from one&#39;s hand to the contents of the can, adding sufficient heat to raise the temperature of the contents of the can to an undesirable level. One solution to this problem in the past is an insulating sleeve that fits over the can. Such sleeves are often made from foam or other similar insulating material. However such sleeves only partially fit over beverage containers, have poor insulating properties and are cumbersome to use. Other solutions relate to double-walled containers, however, these solutions do not provide a thermal break which extends, uninterrupted, along the entire side and bottom of the container. 
       SUMMARY OF THE INVENTION 
       [0005]    The present invention relates to a beverage container having a double-walled construction with a thermal break. The container includes an inner wall with an inner bottom wall for containing a beverage, an outer wall which extends about the inner wall, and an outer bottom wall which extends under the inner bottom wall. A thermal break extends, uninterrupted, between the inner wall and the outer wall and the inner bottom and outer bottom walls. The container includes a top having an upper rim which joins the periphery of the top, the inner wall, and the outer wall. The upper rim could be formed using a crimping process, wherein the peripheral edges of the top, the inner wall, and the outer wall are crimped together. 
         [0006]    The outer wall and the thermal break are co-extensive in height with the inner wall, so as to completely surround the inner wall, and the thermal break extends, uninterrupted, between the inner and outer walls and between the inner and outer bottom walls. The thermal break inhibits heat from the environment from being transmitted into the contents of the can, and even more so, heat from a person&#39;s hand when holding the container, to keep a beverage within the container cool. The thermal break could comprise air and/or a material which occupies all or part of the space between inner and outer walls (e.g., in the form of vertical strips of material, or annular rings of material), or the thermal break could be entirely comprised of a thermally non-conductive material. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The foregoing features of the invention will be apparent from the following Detailed Description of the Invention, taken in connection with the accompanying drawings, in which: 
           [0008]      FIGS. 1A-1B  are side and top views, respectively, showing the beverage container of the present invention; 
           [0009]      FIG. 2  is a cross-sectional view of the beverage container of the present invention, taken along line  2 - 2  of  FIG. 1B ; 
           [0010]      FIGS. 3-5  are cross-sectional views of the beverage container of the present invention, showing various configurations of the thermal break; 
           [0011]      FIGS. 6A-8  are close-up, cross-sectional views showing steps for fabricating the beverage container of the present invention; and 
           [0012]      FIGS. 9-10  are partial perspective views showing various configurations of the spacers of the beverage container of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0013]    The present invention relates to a beverage container, described in detail below in connection with  FIGS. 1A-10 . 
         [0014]      FIGS. 1A-1B  are side and top views, respectively, of the beverage container  10  of the present invention. The container  10  includes an outer wall  12  having an outer bottom wall  12   b , and an inner wall  14  having an inner bottom wall  14   b  positioned within the outer wall  12  and the outer bottom wall  12   b  for containing a liquid (e.g., a beverage). A thermal break  16  extends uninterrupted between the inner surface of the outer wall  12  and the outer surface of the inner wall  14 , and between the inner surface of the outer bottom wall  12   b  and the outer surface of the inner bottom wall  14   b.  The inner surface of the outer wall  12  and the thermal break  16  are co-extensive in height with the outer surface of the inner wall  14 , so as to completely surround the outer surface of the inner wall  14  to provide a thermal break along the entire height of the container. The thermal break  16  inhibits thermal energy outside of the outer wall  12  and the outer bottom wall  12   b  (e.g., heat in the ambient air, or heat from a person&#39;s hand when the container  10  is held) from being transmitted into a liquid contained within the inner wall  14  and the inner bottom wall  14   b,  to assist in keeping a beverage cool. The thermal break  16  could comprise air and/or a material which occupies all or part of the space between inner and outer walls  12 ,  14  and inner and outer bottom walls  12   b,    14   b  (e.g., in the form of vertical strips of material, or annular rings of material, discussed below), or the thermal break could be entirely comprised of thermally non-conductive material. 
         [0015]    As shown in  FIGS. 1A-1B , the container  10  is in the shape of a conventional beverage container (e.g., the shape of a beverage can). Of course, this shape could be varied as desired. The container  10  includes a tapered upper region  18 , an upper rim  20 , a tapered lower region  22 , and a recessed bottom region  24 . A tab  26  and an associated finger lever  28  could be provided, as in conventional beverage cans. The finger lever  28  can be raised by a person&#39;s finger to apply force to the tab  26  to partially separate the tab  26  from a top  30  of the can and to force the tab  26  below the top  30 , so as to open the container  10  to provide access to a liquid contained within the inner wall  14  and the bottom inner wall  14   b.  Advantageously, the thermal break  16  extends along the entire height of the container  10 , up to the upper rim  20 , and along the entire width of the bottom of the container  10  (i.e., extending continuously between the outer bottom wall  12   b  and the inner bottom wall  14   b ) so as to maximize insulation of the outer wall  12  from the inner wall  14 . Indeed, physical contact between the outer wall  12  and the inner wall  14  only occurs only at the upper rim  20 , thereby minimizing conduction of thermal energy between the outer wall  12  and the inner wall  14 . It is noted that the outer wall  12  and the outer bottom wall  12   b , the inner wall  14  and the inner bottom wall  14   b,  and the top  30 , as well as the tab  26  and the finger lever  28 , could be formed from any suitable, lightweight material, such as aluminum (as is used to form conventional beverage cans). 
         [0016]      FIG. 2  is a cross-sectional view of the container  10  of the present invention, taken along the line  2 - 2  of  FIG. 1B . The thermal break  16  could include annular strips of material  32  positioned between the outer wall  12  and the inner wall  14 . The strips  32  could be attached to the inner surface of the outer wall  12  and the outer surface of the inner wall  14  to provide a degree of structural rigidity for the container  10  and to resist compression of the outer wall  12  against the inner wall  14  (e.g., when force is applied by a person&#39;s hand while handling the container  10 ). Also, the strips  32  could be formed (e.g., by coating) on either the inner surface of the outer wall  12  or the outer surface of the inner wall  14  prior to assembly of the container  10 , or prior to the formation of the walls. The strips  32  also function as a thermal break. The strips  32  could be formed of any suitable, lightweight material, such as plastic or foam. 
         [0017]      FIGS. 3-4  are cross-sectional views of the container  10  of the present invention, wherein the thermal break  16  includes a plurality of vertical strips  34  are positioned between the inner surface of the outer wall  12  and the outer surface of the inner wall  14 . Similar to the annular strips  32  shown in  FIG. 2 , the vertical strips  34  could be attached between the inner surface of the outer wall  12  and the outer surface of the inner wall  14  to provide a degree of structural rigidity for the container  10 , and to resist compression of the outer wall  12  against the inner wall  14 . Additionally, similar to the annular strips  32 , the vertical strips  34  also function as a thermal break, and could be formed (e.g., by dipping, coating, spraying, etc.) on the inner surface of the outer wall  12  or the outer surface of the inner wall  14  prior to assembly of the container  10 , or prior to the formation of the walls. The strips  34  could be formed from any suitable, lightweight material, such as plastic or foam. 
         [0018]      FIG. 5  is a cross-sectional view of the container  10  of the present invention, wherein a continuous, uninterrupted layer of thermally non-conductive material  36  forms the thermal break between the outer wall  12  and the inner wall  14 , and between the outer bottom wall  12   b  and the inner bottom wall  14   b,  of the container  10 . The layer  36  could be formed from any suitable, thermally non-conductive material, such as plastic, foam, etc., and provides added structural rigidity for the container  10 . The layer  36  could be formed on the outer surfaces of the inner wall  14  and the inner bottom wall  14   b,  or on the inner surfaces of the outer wall  12  and the outer bottom wall  12   b,  using an suitable process, such as dipping, coating, spraying, etc. 
         [0019]      FIGS. 6A-8  are close-up, cross-sectional views showing fabrication of the container of the present invention. One way of fabricating the container is shown in  FIGS. 6A-6B . First, the inner wall  14 , the outer wall  12 , and the top  30  are formed using conventional fabrication processes for forming components of aluminum cans. Then, as shown in  FIG. 6A , the inner wall  14  is positioned within the outer wall  12 , and a flange  40  created on the inner wall  14  extends over the upper end  38  of the outer wall  12  and serves to support and locate the inner wall  14  with respect to the outer wall  12  and the inner bottom wall  14   b  with respect to the outer bottom wall  12   b,  so that a thermal break extending along the sides and bottom of the container is provided. Also, the top  30  is positioned on the flange  40 , such that a flange  42  of the top  30  is nested on top of the flange  40  of the inner wall  14 . Then, as shown in  FIG. 6B , the flanges  40 ,  42  and end  38  are crimped inwardly or seamed to form the upper rim  20 . It is noted that other methods of attaching the top  30  and the inner and outer walls  12 ,  14  as may be known in the art are within the scope of the present invention. It is noted that if the strips of the present invention are used, or if the thermal break will be filled with material, the strips of material could be positioned between the outer surface of the inner wall  14  and inner surface of the outer wall  12 , or formed on either the outer surface of the inner wall  14  or the inner surface of the outer wall  12  (e.g., by coating, spraying, adhering, or otherwise applying) prior to formation of the inner and outer walls, or after formation of the walls prior to positioning the inner wall within the outer wall. 
         [0020]    Another way of fabricating the beverage container of the present invention is shown in  FIGS. 7A-7D . First, as shown in  FIG. 7A , the layer  36  could be formed on the outer surface of the inner wall  14  (e.g., by coating, dipping, spraying, etc.). Optionally, a gap  37  could be provided to facilitate joining (e.g., crimping or seaming) of the inner wall  14 , the outer wall  12 , and the top  30 . Of course, the layer  36  could extend entirely along the inner wall  14  with no gap. Also, the layer  36  could be formed on the inner surface of the outer wall  12 , if desired. Once the layer  36  is formed, the inner wall  14  is inserted into position within the outer wall  12 , in the general direction indicated by arrow A, such that the inner wall  14  rests within the outer wall  12 , as shown in  FIG. 7B . In such circumstances, the layer  36  serves to support and position the inner wall  14  with respect to the outer wall  12 . Then, as shown in  FIG. 7C , the taper  18  is formed by bending both the inner wall  12  and the outer wall  14 , using conventional techniques utilized to form the taper of existing beverage containers. Finally, as shown in  FIG. 7D , the top  7 D is positioned on the inner wall  14  and the outer wall  12 , and the flanges  40 ,  42  and the end  38  are joined together (e.g., crimped, seamed, etc.) to form the complete container. As can be seen, the layer  36  extends up to the top  30 . 
         [0021]    Yet another way of fabricating the beverage container of the present invention is shown in  FIG. 8 . First, a taper  18 A is formed in the inner wall  14 , using conventional techniques. Then, the layer  36  is formed on the outer surface of the inner wall  14  (e.g., by dipping, coating, spraying, etc.), and the inner wall  14  is inserted into position within the outer wall  12 . As mentioned above, the layer  36  could also be formed on the inner surface of the outer wall  12 . Once the inner wall  14  is in position within the outer wall  12 , a taper could then be formed in the outer wall  12  to match the taper  18   a  of the inner wall  14 , so that both walls  12 ,  14  are tapered (as shown in  FIG. 7C ). Then, as shown in  FIG. 7D , the top  30  and walls  12 ,  14  could be joined, to form the complete container. 
         [0022]    It is noted that any desired number of strips, in any desired spatial arrangement, could form part of the thermal break  16  of the container  10 . For example, as shown in  FIG. 9 , three vertical strips  34  could be included in the thermal break  16  between the inner surface of the outer wall  12  and the outer surface of the inner wall  14 . Also, as shown in  FIG. 10 , three annular strips  32  could be included in the thermal break  16  between the inner surface of the outer wall  12  and the outer surface of the inner wall  14 . 
         [0023]    Having thus described the invention in detail, it is to be understood that the foregoing description is not intended to limit the spirit or scope thereof. What is desired to be protected is set forth in the following claims.