Patent Description:
Vacuum insulated beverage and food containers generally have a vacuum space defined by inner and outer shells of the container. The vacuum space provides thermal insulation to the container. Existing methods of forming such containers typically use a solder material to seal the vacuum space between the inner shell and the outer shell. The solder material may include a glass material that will melt and adhere to the outer shell.

During production of vacuum insulated beverage and food containers using such existing methods, a dimple or other depression is usually formed in a bottom surface of the outer shell or a bottom shell of the container. An opening through the outer shell is then formed in the dimple. The solder material is placed over the opening. The container (with the solder material over the opening) is then placed in a vacuum oven, where ambient pressure around the container is lowered and a temperature in the vacuum oven is raised. The vacuum oven creates a vacuum state in and around the unfinished container. When the temperature in the oven rises to or above a melting point of the solder material, the solder material melts and flows about the opening in the dimple to close the opening. The melted solder seals the opening and the vacuum within the space between the inner shell and the outer shell - namely, the intershell space. The temperature in the oven is reduced, and the melted solder cools and hardens over the opening. As the intershell space is now sealed within the container by the solder material, the container may now be removed from the vacuum oven for further finishing.

The existing methods use much energy to provide the heat needed to melt the solder material. Further, the existing method is slow - as much time is needed for the oven to heat and for the oven to cool. Further, the existing methods generally require a flat surface on the container that is held parallel to a horizontal plane during the vacuum forming process in order for the melted solder material to fill the opening in the dimple. It is difficult to seal an opening in a vertically oriented surface of the container, since the solder material is likely to fall or drip off of the container. In addition, in existing methods, it is difficult to seal a curved or otherwise non-linear surface. Further, in the existing methods, additional cap structures are often used for aesthetic purposes to cover or hide the dimple and the hardened solder material. Further, in the existing methods, the physical structure of the dimple passing inward from the outer shell toward the inner shell requires extra space between the outer shell and the inner shell in order to maintain integrity of the vacuum space - this extra space for the vacuum space may limit or decrease an overall size of the container.

<CIT> (describing the preamble of claim <NUM>) and <CIT> disclose a vacuum cup welding method in which the lower end port opening of a vacuum interlayer of the cup is welded within a vacuum environment using an external laser.

A method for forming vacuum insulated containers are shown and described. The method uses a laser to seal or weld closed an opening to an intershell space of the container while the container is maintained in a vacuum environment. The vacuum environment may be formed in a container holding element, which is sized and shaped to enclose part of the container or all of the container. The container holding element may be made from a material sufficient to maintain a vacuum within its interior. Examples of a container holding element include a vacuum chamber, vacuum fixture, or any other unit configured for this purpose.

In a first aspect of the present invention a method of forming a vacuum insulated container is defined in claim <NUM>, which includes joining an inner shell and an outer shell together to form an unfinished container. The method includes creating one or more openings in the outer shell of the unfinished container. The method includes placing the unfinished container in a container holding element and drawing a vacuum throughout the inside of the container holding element and around or about the unfinished container. The method includes lowering pressure around the unfinished container. The method includes passing a laser through a window of the container holding element and welding closed the one or more openings to seal the vacuum in a vacuum space between the inner shell and the outer shell of the container.

The vacuum space has a low pressure and is formed in between the inner and outer shells. The vacuum space provides insulation for the container. During the process, the whole unfinished container may be placed inside of the container holding element. The unfinished container may be completely enclosed or partially enclosed by the container holding element.

After attaining the desired vacuum level, a laser from outside the container holding element shoots through the transparent window and welds up the slit. After the shell is removed from the container holding element, the shell may optionally be put in an oven (at atmospheric pressure) to activate a getter inside of the shell. The transparent window in the container holding element may be made from glass or any other material having properties sufficient to permit the laser to pass therethrough to reach the container that also permit the desired vacuum level to be maintained in the container holding element.

The method may be used to form a variety of insulated containers. For example, the containers may be a two-piece design, four piece design, or other designs. A two piece design generally includes an inner shell and an outer shell. The four piece design general includes an inner shell, an inner bottom shell, an outer shell, and an outer bottom shell. The containers may be used to store hot or cold beverages, food products, or other consumer products. The containers may be beverage containers, beverage tumblers, jugs, food jars, carafes, pump pots, sippy cups, can insulators, etc..

Optionally, the methods include removing the containers from the vacuum space and heating the container in an oven, at atmospheric pressure, to activate a getter container within the vacuum space. The getter may remove any oxygen or other residual molecules from any air left in the vacuum space.

The method may form and close the one or more openings on any location of the container that is accessible by the laser beam. For the example, the one more opening may be on the sides, bottom surfaces, interior or exterior edges, or interior surfaces of the container. The methods and system utilize laser welding techniques or other laser implemented methods that do not require a solder material that is placed over the region of the container that is to be sealed.

The method forms vacuum insulated containers faster and more efficiently than prior methods. As no heating is required, the methods and systems of the present disclosure utilize much less energy than prior methods. Further, the one or more openings may be formed anywhere on or in the container that the laser can reach, which permits strategic placement of the opening. There may be some strategies to hide the opening, for example, along an edge of the container. Other strategies include placing the opening to correspond with a design of the container. Further, the one or more openings that have been sealed by the present method may be painted over. In addition, the one or more openings that have been sealed using the present method are often stronger and less likely to sustain breakage than a traditional solder-type closing. This reduces the need for a further cap or structure to cover the soldered opening formed in the prior methods. Also, since the current method does not require solder, this reduces materials needed as well.

For purposes of this application, any terms that describe relative position (e.g., "upper", "middle", "lower", "outer", "inner", "above", "below", "bottom", "top", etc.) refer to an embodiment of the invention as illustrated, but those terms do not limit the orientation in which the embodiments can be used.

A system <NUM> will now be described with reference to <FIG>. The system <NUM> directs a laser beam from a laser source <NUM> through a container holding element <NUM> to weld up an opening <NUM> in a container <NUM> that is within the container holding element <NUM>.

The system <NUM> includes a housing <NUM>. The housing <NUM> comprises a visual detection and laser welding assembly <NUM> that positions the laser source <NUM> proximate to the container holding element <NUM>. The visual detection and laser welding assembly <NUM> may be mounted to the housing <NUM> as shown in <FIG>. In others aspects, the visual detection and laser welding assembly <NUM> may be positioned over or supported proximate to the housing <NUM>.

The housing <NUM> may define a space in which a vacuum source <NUM> is positioned. The vacuum source <NUM> is connected to the container holding element <NUM> by bellows or other conduit, and is configured to draw the vacuum inside of the container holding element <NUM>. An example of a vacuum source <NUM> is a vacuum pump. The vacuum source <NUM> creates the vacuum for the container holding element <NUM> that lowers the pressure in the container holding element <NUM>. In other aspects, the vacuum source <NUM> may be positioned proximate the housing <NUM> and connected to the container holding element <NUM> by additional bellows or other conduits.

The visual detection and laser welding assembly <NUM> includes the laser source <NUM> to emit laser pulses to weld the one or more openings <NUM>. The visual detection and laser welding assembly <NUM> further includes a detector <NUM> to register the pulses from the laser source <NUM> with the openings <NUM> of the containers <NUM>. The system <NUM> includes a controller <NUM> to operate at least certain elements of the system <NUM>. The controller <NUM> may include a programmable logic controller. For example, the controller <NUM> may cause turning on, turning off, moving, calibrating or otherwise directing any or all of the laser source <NUM>, the detector <NUM>, or the vacuum source <NUM>.

The container holding element <NUM> receives the container <NUM> into an open interior <NUM> of the container holding element <NUM>. A lower portion <NUM> of the container holding element <NUM> includes a positioner <NUM> to hold the container <NUM>. In other embodiments not illustrated, a positioner <NUM> could be present in any orientation configured to properly position the container <NUM> for access by the laser source <NUM>. For example, in another embodiment, the positioner <NUM> may include a hook from which the container <NUM> may hang for a laser source <NUM> positioned below the container holding element <NUM>.

The container holding element <NUM> includes a window <NUM> made from, for example, an optical glass. The window <NUM> may be made from any optical glass that allows sufficient light energy from the laser source <NUM> to pass into the interior <NUM>. The window <NUM> may be made from other materials that allow for transmission or passage of the light energy and permit the vacuum to be drawn within the container holding element <NUM>. The window <NUM> separates the interior <NUM> from the ambient environment of the system <NUM>. In the aspect shown, the laser source <NUM> is external to the container holding element <NUM>. The laser beam from the laser source <NUM> passes through the window <NUM> and to the container <NUM> in the interior <NUM> of the container holding element <NUM>. In aspects in which the laser source <NUM> is positioned inside the container holding element <NUM>, a window <NUM> would not be necessary. In the illustrated aspect, the window <NUM> forms the cover of the container holding element <NUM>, but such window could be positioned anywhere on the container holding element <NUM>.

During production, the vacuum is formed within the interior <NUM> of the container holding element <NUM> by the vacuum source <NUM>. In the aspect shown, the container holding element <NUM> includes an upper portion <NUM> and the lower portion <NUM> that are removably connected. For example, the upper portion <NUM> may be removed from the lower portion <NUM> for inserting the container <NUM> into the container holding element <NUM>. For example, the upper portion <NUM> may seal to the lower portion <NUM> via a threaded, frictional, press-fit, or other mechanical connection that holds the upper portion <NUM> and the lower portion <NUM> together and to provide for the vacuum to form in the interior <NUM> of the container holding element <NUM>. Gaskets or other pliable seals may be used between the upper portion <NUM> and the lower portion <NUM> to seal the interior <NUM> such that the vacuum may be formed in the interior <NUM>. In other aspects, the cover <NUM> provides access to the interior <NUM> of the fixture <NUM>. For example, the cover <NUM> may be temporarily removed from the container holding element <NUM> in order to place the container <NUM> in the interior <NUM> of the container holding element <NUM>.

The lower portions <NUM> of the container holding elements <NUM> may be securely fastened to the frame <NUM> and/or the housing <NUM>. The lower portions <NUM> generally remain fastened to the frame <NUM> and/or the housing <NUM> during operation of the system <NUM> and/or during the loading and unloading of the containers <NUM> into the lower portions <NUM>. The lower portions <NUM> may pass through openings <NUM> in an upper surface <NUM> of the housing <NUM> and into an interior <NUM> of the housing <NUM>.

In the aspect shown in <FIG>, the window <NUM> is positioned at an upper end <NUM> of the container holding element <NUM>. In the aspects shown, the container <NUM> is held by the positioner <NUM> in an inverted position. This provides for the system <NUM> to form the openings <NUM> in a bottom <NUM> of the container <NUM>. The openings <NUM> are shown in <FIG>. In the aspect shown in <FIG>, the window <NUM> is positioned in a side wall <NUM> of the container holding element <NUM>. As shown in <FIG>, this provides for the system <NUM> to form the openings <NUM> in a side <NUM> of the container <NUM>, i.e., the laser source <NUM> is welding the openings <NUM> that are in a non-horizontal portion of the container <NUM>. The laser source <NUM> may weld the opening <NUM> that are in nearly any orientation - since no solder is needed to be used on the opening <NUM>. For example, <FIG> illustrate the opening <NUM> along an edge between the bottom <NUM> and the side <NUM> of the container <NUM>. Of course, the opening <NUM> may formed along any other edge of the container <NUM>.

The positioner <NUM> may include an extension <NUM> that fits into an interior of the container <NUM>. In other aspects, the positioner <NUM> may include threads to threadably engage with complementary threads of a mouth of a container <NUM>. The positioner <NUM> holds the container <NUM> steady during the laser welding process.

During the forming process, the unfinished containers <NUM> are placed completely inside of the container holding element <NUM>. The unfinished containers <NUM> are completely enclosed by the container holding element <NUM>. For example, a container <NUM> may have a two piece design with an inner shell and an outer shell. During the forming process, both the inner shell and the outer shell may be completely contained inside of the container holding element <NUM>. For example, a four piece design may have an inner shell, an inner bottom shell, an outer shell, and an outer bottom shell. During the forming process, all of the inner shell, the inner bottom shell, the outer shell, and the outer bottom shell may be completely contained inside of the container holding element <NUM>.

The container holding element <NUM> includes a conduit <NUM> leading to a bellows <NUM>, which are in communication with the vacuum source <NUM>. The container holding element <NUM> may include pressure sensors to monitor the pressure of the interior <NUM> of the container holding element <NUM>. In the aspect shown, the conduit <NUM> joins the bellows <NUM> with a conduit opening <NUM> in the lower portion <NUM> of the container holding element <NUM>. The conduit opening <NUM> provides passage into the interior <NUM> of the container holding element <NUM>. Opposite of the conduit <NUM>, the bellows <NUM> lead to the vacuum source <NUM>. The vacuum source <NUM> creates the vacuum for the container holding element <NUM> that lowers the pressure in the container holding element <NUM> and around or about the openings <NUM> of the containers <NUM>.

The housing <NUM> supports a mounting element <NUM> configured to position the visual detection and laser welding assembly <NUM>. The mounting element <NUM> may move the visual detection and laser welding assembly <NUM> in the X (generally horizontal) and the Y (generally vertical) directions to weld the openings <NUM> of the containers <NUM>. The illustrated aspect of the mounting element <NUM> includes a horizontal track <NUM> and a vertical track <NUM>. The visual detection and laser welding assembly <NUM> moves up and down on the vertical track <NUM>. The vertical track <NUM> moves left and right on the horizontal track <NUM>. The mounting element <NUM> may be mounted to the upper surface <NUM> of the housing <NUM>. After initial set up, the visual detection and laser welding assembly <NUM> may only need to move in the horizontal plane in order to laser weld the containers <NUM>. Non-illustrated aspects of a mounting element <NUM> may include a pivotable section, a mechanical arm, or any other configuration sufficient to properly support and position the visual detection and laser welding assembly <NUM>. Other aspects may include a separate mounting element <NUM> for each of the laser source <NUM> and the detector <NUM>.

The controller <NUM> operates the function and movement of the mounting element <NUM>. The controller <NUM> may further include a display and user input controls. The illustrated housing <NUM> further includes a door <NUM> leading to the interior <NUM> of the housing <NUM>. The vacuum source <NUM> may be positioned in the interior <NUM> underneath the container holding elements <NUM>.

In the aspect shown, the system <NUM> includes two visual detection and laser welding assemblies <NUM> on separate vertical tracks <NUM>. The separate vertical tracks <NUM> move independently on the horizontal track <NUM>. In other aspects, the system <NUM> may include a single visual detection and laser welding assembly <NUM> or any number of additional visual detection and laser welding assemblies <NUM>.

The housing <NUM> further includes the frame <NUM> to hold and/or position the container holding elements <NUM>. The frame <NUM> may be mounted to the upper surface <NUM> of the housing <NUM> adjacent to or supporting the mounting element <NUM>.

The vacuum source <NUM>, such as a pump, is positioned in or proximate the housing <NUM>. The vacuum source <NUM> draws the vacuum used to form the vacuum spaces within the containers <NUM>. One or more containers <NUM> are placed in the container holding elements <NUM>. The vacuum source <NUM> begins drawing a vacuum. The detector <NUM> determines the position of the openings <NUM> in order to direct the pulses from the laser source <NUM> to the openings <NUM>. When a sufficient or desired pressure is reached in the container holding element <NUM>, the laser source <NUM> welds the one or more openings <NUM> closed. The visual detection and laser welding assembly <NUM> moves to the next container <NUM> in a container holding element <NUM>.

The vacuum source <NUM> draws the vacuum in the container holding element <NUM> and in the vacuum space of the container <NUM>. The air pressure may be reduced from ambient pressure conditions to approximately <NUM>-<NUM> tor to approximately <NUM>-<NUM> tor depending on the materials used for the container <NUM> or other variables as needed. During the forming process, the whole unfinished container <NUM> is placed inside of the container holding element <NUM>. The unfinished container <NUM> is completely enclosed by the container holding element <NUM>.

The controller <NUM> may direct the movement of the visual detection and laser welding assembly <NUM> to the respective container holding elements <NUM>. The detector <NUM> is in communication with the controller <NUM> to determine the positioning of the openings <NUM>. The controller <NUM> may modulate the positioning of the laser welding assembly <NUM> based on input from the detector <NUM>. The controller <NUM> also monitors pressure of the container holding elements <NUM> via sensors internal to the container holding elements <NUM> or by readings obtained from the vacuum source <NUM>. The controller <NUM> may modulate the operation of the vacuum source <NUM> to obtain the desired vacuum pressures in the container holding elements <NUM>. When the desired position of the laser source <NUM> relative to the container <NUM> and the desired vacuum pressure in the container holding element <NUM> are achieved, the controller <NUM> will activate the laser source <NUM> to weld the opening <NUM>.

The controller <NUM> may move or change the orientation of the laser source <NUM> to direct the laser energy at a full length of the opening <NUM>. For example, the mounting element <NUM> may move the laser source <NUM>, while the laser source <NUM> is emitting laser energy, over the full length of the opening <NUM>. In some aspects, after one opening <NUM> is sealed, the mounting element <NUM> may move the laser source <NUM> to seal another opening <NUM> on the same container <NUM>. After one container <NUM> is sealed, the mounting element <NUM> may move the laser source <NUM> to successive containers <NUM> for sealing their openings <NUM>. As such, the system <NUM> may serially seal the openings <NUM> of a batch of the containers <NUM>.

The methods and systems <NUM> may include an optional pre-heating step or stage that vaporizes any surface moisture on or in the container <NUM>. Such surface moisture may lead to discoloring or interfere with further processing. In dry conditions, the pre-heating may not be needed. If the pre-heating is employed, the unfinished container <NUM> is placed in oven and the temperature is raised to approximately <NUM>° C to approximately <NUM>° C for a suitable time period to remove the moisture.

The laser source <NUM> may form one or more openings <NUM> anywhere on the container <NUM>, for example: on the edges, outer shell, inner shell, and/or the bottom outer shell of the container <NUM>. The one or more openings <NUM> may include slits, geometrically shaped openings, and/or amorphously shaped openings. The one or more openings <NUM> may vary in length, width, size, etc. depending on the container <NUM>, the laser source <NUM> used to close the one or more openings <NUM>, the material of the container <NUM>, the size of the container <NUM>, etc. In one aspect, the openings <NUM> include two slits of that are approximately <NUM> in length and having a width of approximately <NUM> to approximately <NUM> on the bottom outer shell of the container <NUM>. Although the two slits <NUM> are shown in a parallel configuration, the two slits <NUM> may be in other angular or spaced relationships with respect to each other.

Any type of laser with a proper wavelength may be used for the laser source <NUM>. The laser source <NUM> may be pulse or continuous. The laser source <NUM> may also simultaneously emit two laser beams to simultaneously seal two openings <NUM> on the container <NUM>. The laser source <NUM> may also emit an array of laser beams to seal a matching pattern of openings <NUM> on the container <NUM>.

The controller <NUM> operates the function of the system <NUM>. The controller <NUM> may be programmed via computer numerical control program in order to move the laser source <NUM> to successive container holding elements <NUM> A position of each container holding elements <NUM> is programmed into the controller <NUM>. The laser source <NUM> moves from position to position in order to weld the openings <NUM>. The detector <NUM> may include a photo-eye, orientation sensor, or other sensor to ensure that the laser source <NUM> is in proper position to weld the openings <NUM>. The controller <NUM> may modulate the positioning of the laser welding assembly <NUM> based on input from the detector <NUM>. The controller <NUM> also may monitor pressure of the container holding elements <NUM>. The controller <NUM> may be programmed to confirm that the pressure levels within the container holding elements <NUM> are acceptable before activating the laser source <NUM>.

The methods and system <NUM> may be used with, for example, containers made from stainless steels, PE, TX2001, or other metals and metal alloys.

The system <NUM> may include one or more container holding elements <NUM>. For example, the system <NUM> illustrated includes <NUM> individual container holding elements <NUM>. During operation, the vacuum source <NUM> may form a vacuum in all of the container holding elements <NUM> at the same time. Thus, the laser source <NUM> may immediately move on to the next container holding element <NUM> as soon as the openings <NUM> of a container <NUM> in a prior container holding element <NUM> are welded closed. In other aspects, the vacuum source <NUM> may form a vacuum in some of the container holding elements <NUM> simultaneously.

In other aspects, the system <NUM> may employ fewer or additional container holding elements <NUM>. For example, the system <NUM> may include a single container holding element <NUM>, <NUM> container holding elements <NUM>, or any other number of container holding elements <NUM>.

In other aspects, the system <NUM> may include a laser that is fixed in position. The containers <NUM> may be serially sealed by the laser.

In other aspects, a single container holding element <NUM> may have a larger volume capable of holding several containers <NUM>. The laser source <NUM> may move around or proximate to the single container holding element <NUM> to weld the containers <NUM> therein.

In others aspects, the welding gun or the laser may be incorporated inside of the vacuum space of the container holding element.

<FIG> show a container holding element <NUM> for holding a plurality of containers <NUM> for processing. The container holding element <NUM> may be incorporated onto the system <NUM> of <FIG> or other suitable systems. The plurality of containers <NUM> may be completely placed inside of the container holding element <NUM>.

The container holding element <NUM> allows the user to simultaneously apply a vacuum to the plurality of the containers <NUM>. A batch of the containers <NUM> may be loaded into the container holding element <NUM>, and the pressure inside of the container holding element <NUM> may be lowered - thus lowering the ambient pressure around each of the containers <NUM> in the batch of the containers <NUM>. This provides for the ambient pressure around multiple containers <NUM> to be lowered in a single step or process. This increases efficiency by reducing wait time between laser welding steps of the containers <NUM>, as the laser source <NUM> may move to successive containers <NUM> without waiting for a further vacuum to be formed.

The laser source <NUM> or other laser may be used to weld the one or more openings in the containers <NUM>. The container holding element <NUM> allows for the user to lower the pressure around the batch of the containers <NUM>, maintain the lowered pressure around the batch of the containers <NUM>, and then serially weld each of the containers <NUM> in the batch of the containers <NUM>. The laser source <NUM> or other laser may move on to the next container <NUM> in the container holding element <NUM> after the one or more openings in a first container <NUM> are welded. The laser source <NUM> or other laser may move on to successive containers <NUM> after the one or more openings in a prior container <NUM> are welded. There is generally no need to reduce pressure and/or open the container holding element <NUM> between the welding of the individual containers <NUM> in the plurality of the containers <NUM>.

The container holding element <NUM> includes a base <NUM> and a cover <NUM>. The cover <NUM> seals the base <NUM> to a closed and generally air-tight position. In certain aspects, the cover <NUM> also is the window, while in other aspects, the cover <NUM> may be opaque and a window is formed in another portion of the container holding element <NUM>. The base <NUM> defines a generally open interior <NUM> that receives the containers <NUM>. A rack <NUM> or other suitable transport device may be loaded with a plurality of the containers <NUM> and then lowered into the interior <NUM> of the base <NUM> of the container holding element <NUM>.

The rack <NUM> may include one or more openings <NUM> that receive one or more positioners <NUM> to align the rack <NUM> in the interior <NUM> of the base <NUM>. The positioners <NUM> may pass through the one or more openings <NUM> in the rack <NUM>. The positioners <NUM> may extend upwardly from a bottom <NUM> of the base <NUM> of the container holding element <NUM>. In the aspect shown, the base <NUM> includes four positioners <NUM>, although fewer or additional positioners <NUM> may be employed. The rack <NUM> may also include two oppositely disposed handles <NUM> to assist in the placement and withdrawal of the rack <NUM> from the base <NUM> of the container holding element <NUM>.

The base <NUM> may include a generally square or rectangular shape with four side walls 440A, 440B, 440C, and 440D. The side walls 440A-440D extend upwardly from the bottom <NUM> to define the interior <NUM>. The base <NUM> may be made from rigid or durable material, such as solid aluminum or other metal alloy, which withstands the vacuum forces applied during the vacuum and sealing steps. The side walls 440A-440D of the base <NUM> may form a cross-section just larger than a cross-section of the rack <NUM>, such that the rack <NUM> nests within the side walls 440A-440D. In the aspect shown, the side wall 440A forms a front side, the side wall 440B forms a right side, the side wall 440C forms a rear side, and the side wall 440D forms a left side. In the aspect shown, the side walls 440A and 440C form longer sides than the side walls 440B and 440D.

An upper surface <NUM> of the rack <NUM> may include one or more positioning devices or other engaging members that hold the containers <NUM> in position on the rack <NUM>. For example, the container <NUM> may frictionally fit over a pliable support or positioner to hold the position of the containers <NUM> on the rack <NUM>. In other aspects, the containers <NUM> may threadably engage or removably fit to the upper surface <NUM> of the rack <NUM>. The rack <NUM> is lowered into the interior <NUM> of the base <NUM> and rests on an upper surface <NUM> of the bottom <NUM> of the base <NUM>.

The rack <NUM> may hold the containers <NUM> in a matrix or grid fashion. In the aspect shown, the containers <NUM> are arranged in six columns and four rows for a total of twenty-four containers <NUM>. Of course, in other aspects, fewer or additional columns and/or rows may employed in the container holding element <NUM>, and/or fewer or additional containers <NUM> may be processed in the container holding element <NUM>. The container holding element <NUM> may also be scaled upwards or downwards in size to change the processing capacity of the container holding element <NUM>. The container holding element <NUM> may be adapted or adaptable for various container sizes or shapes.

A sectional view of an aspect of the container holding element <NUM> is shown in <FIG> In the illustrated aspect, the bottom <NUM> of the base <NUM> includes a vacuum passage <NUM> passing from a bottom surface <NUM> of the bottom <NUM> upwards into the interior <NUM> of the container holding element <NUM>. The rack <NUM> includes a vacuum opening <NUM> to allow air and/or gas to pass from the interior <NUM> through the vacuum opening <NUM> and through the vacuum passage <NUM>. As such, a vacuum is drawn through the vacuum passage <NUM> to lower the air pressure in the interior <NUM> of the base <NUM>. The bottom surface <NUM> of the base <NUM> may include a vacuum port <NUM> or other fluidic connections or fittings to sealingly engage with a vacuum source, such as the vacuum source <NUM>.

The positioners <NUM> assist in aligning the rack <NUM> in a proper position in the base <NUM>. The positioners <NUM> also assist in aligning the vacuum opening <NUM> of the rack <NUM> with the vacuum passage <NUM>. The coordinates or position of the containers <NUM> on the rack <NUM> are programmed into the controller <NUM>. The rack <NUM> fits into the same position in the base <NUM>, due to the positioners <NUM> and/or an interior shape of the base <NUM>, which assists the controller <NUM> in locating and/or determining the position of the containers <NUM> on the rack <NUM>.

The controller <NUM> operates the system <NUM>. The controller <NUM> may be programmed via computer numerical control program in order to move the laser source <NUM> to successive containers <NUM>. A position of each container <NUM> of the plurality of containers <NUM> is programmed into the controller <NUM>. The laser source <NUM> moves from position to position in order to weld the openings. The detector <NUM> may include a photo-eye, orientation sensor, or other scanner or sensor to ensure that the laser source <NUM> is in proper position to weld the openings <NUM>. The controller <NUM> may modulate the positioning of the laser welding assembly <NUM> based on input from the detector <NUM>. Once the position of the container <NUM> is verified/confirmed by the detector <NUM>, the controller may activate the laser source <NUM>. The controller <NUM> also may monitor pressure of the container holding element <NUM>. The controller <NUM> may be programmed to confirm that the pressure level within the container holding element <NUM> is acceptable before activating the laser source <NUM>.

The controller <NUM> includes at least one processor <NUM> to process data and a memory <NUM> to store the data. The processor <NUM> processes communications, builds communications, retrieves data from the memory <NUM>, and stores data to the memory <NUM>. The processor <NUM> and the memory <NUM> are hardware. The memory <NUM> may include volatile and/or non-volatile memory, e.g., a computer-readable storage medium such as a cache, random access memory (RAM), read only memory (ROM), flash memory, or other memory to store data and/or computer-readable executable instructions such as the computer numerical control instructions or program. With respect to <FIG>, an exemplary layout of the controller <NUM> is illustrated with respect to the system <NUM>. As an example, the computer numerical control instructions include position data and may be stored in the memory <NUM>. In addition, the controller <NUM> further includes at least one communications interface <NUM> to transmit and receive communications, messages, and/or signals to the laser source <NUM>, laser welding assembly <NUM>, vacuum source <NUM>, and/or container holding element <NUM>, as well as other components, subsystems, and hardware of the system <NUM>, such as, for example, the detector <NUM>, vacuum sensors, position sensors, displays, input controls, drive motors, etc..

The cover <NUM> fits down over the base <NUM> to close the container holding element <NUM>. The weight of the cover <NUM> helps to compress a seal <NUM> that is positioned at an upper surface <NUM> of the side walls 440A-440D. The seal <NUM> may extend all the way around the entirety of the upper surface <NUM>. The cover <NUM> also includes a flange portion <NUM> to further help in sealing the interior <NUM>. The flange portion <NUM> extends downward from the cover <NUM>. An inner flange surface <NUM> of the flange portion <NUM> fits against an inner side surface <NUM> of the side walls 440A-440D. The flange portion <NUM> helps to properly position and/or align the cover <NUM> over the base <NUM>. As the vacuum is drawn in the interior <NUM>, the combination of the cover <NUM>, the seal <NUM>, and the flange portion <NUM> provides for the vacuum to form within the interior <NUM> of the container holding element <NUM>.

The cover <NUM> may be formed from a polycarbonate material or other material that allows for passage of laser light from the laser source <NUM> through the cover <NUM> and to the containers <NUM>. The cover <NUM> may be made from any optical glass that allows sufficient light energy from the laser to pass into the interior <NUM>. In the illustrated aspect, the visual detection and laser welding assembly <NUM> further is positioned over the cover <NUM>, but the visual detection and laser welding assembly <NUM> may be positioned in any configuration that permits the laser source <NUM> to send laser light into the container holding element <NUM>. The laser source <NUM> may move over a top of the cover <NUM>, under direction from the controller <NUM>.

During the forming process, in one aspect, the plurality of unfinished containers <NUM> are placed completely inside of the container holding element <NUM>. In other aspects, the unfinished containers <NUM> are positioned only partially in the container holding element <NUM>. With respect to <FIG>, the unfinished containers <NUM> are completely enclosed by the container holding element <NUM>. The entirety of the unfinished containers <NUM> are placed completely inside of the container holding element <NUM>. For example, a container <NUM> may have a two piece design with an inner shell and an outer shell. During the forming process, both the inner shell and the outer shell may be completely contained inside of the container holding element <NUM>. For example, a four piece design may have an inner shell, an inner bottom shell, an outer shell, and an outer bottom shell. During the forming process, all of the inner shell, the inner bottom shell, the outer shell, and the outer bottom shell may be completely contained inside of the container holding element <NUM>.

In certain aspects, the container holding element <NUM> may mount over the housing <NUM> such that the vacuum source <NUM> of the housing <NUM> draws vacuum through the vacuum passage <NUM>. Similarly, the visual detection and laser welding assembly <NUM> may be positioned over a top of the container holding element <NUM>.

A system <NUM> will now be described with reference to <FIG>. The system <NUM> directs a laser beam from a laser source <NUM> through the container holding element <NUM> of <FIG> to weld up the openings <NUM> in the containers <NUM> that are within the container holding element <NUM>. The system <NUM> operates similarly to the system <NUM>, and provide provides many of the same advantages and benefits.

The system <NUM> includes vertical supports <NUM> and <NUM> that support a positioner <NUM> that operates under computer numerical control program to move the laser source <NUM> in the X and/or Y directions. In this aspect, the laser source <NUM> is positioned at an underneath surface of the positioner <NUM>. The laser source <NUM> may be integrated to the positioner <NUM>. The positioner <NUM> is movably engaged to a central support <NUM> that maintains the positioner <NUM> above the container holding element <NUM>. In this aspect, the central support <NUM> is positioned generally parallel to the sidewalls 440A and 440C, and the positioner <NUM> moves along a length of the central support <NUM> in the X direction.

Ends <NUM> and <NUM> of the central support <NUM> are movably engaged to horizontal supports <NUM> and <NUM>. The vertical supports <NUM> and <NUM> support the horizontal supports <NUM> and <NUM>. In this aspect, the horizontal supports <NUM> and <NUM> are positioned generally parallel to sidewalls 440B and 440D, and the central support <NUM> moves along a length of the horizontal supports <NUM> and <NUM> in the Y direction.

In the embodiment shown, the positioner <NUM> travels along the X axis via the central support <NUM>, while the central support <NUM> moves along the Y axis via the movable engagement between the central support <NUM> and the horizontal supports <NUM> and <NUM>. The positioner <NUM> moves relative to the central support <NUM>, and the central support <NUM> moves relative to the horizontal supports <NUM> and <NUM>. Of course, in other embodiments, the arrangement of travel may be reversed or altered. Also, in this embodiment, the height of the positioner <NUM> is generally fixed. Of course, in other embodiments, the height of the positioner <NUM> is adjustable or may be under computer numerical control program. For example, the vertical supports <NUM> and <NUM> may extend or retract to adjust the height of the positioner <NUM>.

The vertical supports <NUM> and <NUM> may attach or engage to outer surfaces of the side walls 440B and 440D of the container holding element <NUM> to provide support and stability to the system <NUM>. In other aspects, the container holding element <NUM> may be removably placed between the vertical supports <NUM> and <NUM>. In other aspects, the vertical supports <NUM> and <NUM> are positioned proximate the container holding element <NUM>.

A vacuum source <NUM>, such as a pump, draws the vacuum in the system <NUM>. The vacuum source <NUM> is engaged to the vacuum port <NUM> of the vacuum fixture <NUM> via a vacuum line <NUM>. As such, a vacuum is drawn by the vacuum source <NUM>, through the vacuum line <NUM>, through the vacuum passage <NUM> to lower the air pressure in the interior <NUM> of the base <NUM>.

The system <NUM> may include the controller <NUM> of <FIG> or other suitable programmable logic controller to operate at least certain elements of the system <NUM>. For example, the controller <NUM> may cause turning on, turning off, moving the positioner <NUM> relative to the central support <NUM>, moving the central support <NUM> relative to the horizontal supports <NUM> and <NUM>, calibrating or otherwise directing any or all of the laser source <NUM>, the vacuum source <NUM>, or other components of the system <NUM>.

With respect to <FIG>, an exemplary layout of the controller <NUM> is illustrated with respect to the system <NUM>. The controller <NUM> includes the least one processor <NUM> to process the data and the memory <NUM> to store the data. The processor <NUM> processes communications, builds communications, retrieves data from the memory <NUM>, and stores data to the memory <NUM>. The controller <NUM> further includes the at least one communications interface <NUM> to transmit and receive communications, messages, and/or signals to the laser source <NUM>, central support <NUM>, positioner <NUM>, vacuum source <NUM>, and container holding element <NUM>, as well as other components, subsystems, and hardware of the system <NUM>, such as, for example, detectors, vacuum sensors, position sensors, displays, input controls, drive motors, etc..

In the aspects illustrated in <FIG>, the unfinished containers <NUM> are placed completely inside of the container holding element <NUM> or are placed completely inside of the container holding element <NUM>. The systems <NUM> and <NUM> and methods described herein may also be used with container holding elements that only partially enclose the unfinished containers <NUM>. For example, certain container holding elements will seal to or engage with portions of unfinished containers <NUM>. For example, certain container holding elements will seal over or enclose portions of the unfinished containers having the openings <NUM>, and then draw the vacuum to form the vacuum within the space between the inner shell and the outer shell, while other portions of same unfinished containers are not enclosed by the container holding element.

Claim 1:
A method for forming a vacuum insulated container (<NUM>), comprising:
joining an inner shell and an outer shell together to form an unfinished container (<NUM>), wherein the unfinished container has a space between the inner shell and the outer shell;
the method being characterised by the following steps:
creating one or more openings (<NUM>) in any surface of the unfinished container after the joining of the inner shell and the outer shell together to form the unfinished container; placing the entire unfinished container inside of a container holding element (<NUM>, <NUM>);
drawing a vacuum within the container holding element and around the unfinished container by lowering a pressure around the unfinished container to a desired level, and thereby pulling a vacuum through the one or more openings (<NUM>); and
directing a laser beam through a wall (<NUM>, <NUM>) of the container holding element and welding closed the one or more openings to seal the vacuum in the space between the inner shell and the outer shell to form a vacuum space between the inner shell and the outer shell.