阅读说明：本技术 制造容器的方法和相关系统 (Method of manufacturing containers and related system ) 是由 B·佩普 于 2021-01-04 设计创作，主要内容包括：一种制造容器的方法,该方法包括:通过成形内壁形成容器的第一空腔,使得内壁的第一表面限定第一空腔；通过成形外壁形成容器的第二空腔,使得外壁的第三表面围绕内壁的第二表面,从而第三表面和第二表面一起限定第二空腔；并将内壁和外壁连接在一起。该方法然后包括形成穿过外壁的孔,以将第二空腔暴露于外部周围环境,然后施加搪瓷涂层,同时防止搪瓷涂层沉积在孔中。在施加搪瓷涂层之后,该方法包括加热容器以给搪瓷涂层上釉并将涂层固定到一个或多个表面上。(A method of manufacturing a container includes forming a first cavity of the container by shaping an inner wall such that a first surface of the inner wall defines the first cavity; forming a second cavity of the container by shaping the outer wall such that the third surface of the outer wall surrounds the second surface of the inner wall, such that the third surface and the second surface together define the second cavity; and connecting the inner and outer walls together. The method then includes forming a hole through the outer wall to expose the second cavity to an external ambient environment, and then applying the enamel coating while preventing deposition of the enamel coating in the hole. After applying the enamel coating, the method includes heating the vessel to glaze the enamel coating and secure the coating to one or more surfaces.)

1. A method of manufacturing a container, the method comprising:

forming a first cavity of the container by shaping the inner wall such that a first surface of the inner wall defines the first cavity;

forming a second cavity of the container by shaping the outer wall such that the third surface of the outer wall surrounds the second surface of the inner wall, such that the third surface and the second surface together define the second cavity;

connecting the inner wall and the outer wall together;

forming an aperture through the outer wall to expose the second cavity to an external ambient environment;

applying an enamel coating on at least one of the first surface of the inner wall and the fourth surface of the outer wall exposed to the external ambient environment while preventing the enamel coating from being deposited in the hole;

heating the vessel to glaze the enamel coating and secure the coating to one or more surfaces;

after the enamel is glazed, exhausting air from the second cavity; and

the second cavity is sealed while air is being evacuated from the second cavity such that a pressure within the second cavity is less than a pressure in an external ambient environment.

2. The method of claim 1, wherein forming the inner and outer walls comprises forming the walls from a single continuous sheet of material.

3. The method of claim 1, wherein coupling the inner wall and the outer wall together comprises the outer wall extending from an area of the inner wall defining an opening to the first cavity.

4. The method of claim 1, wherein applying the enamel coating comprises immersing the first surface of the inner wall and/or the fourth surface of the outer wall in a liquid enamel bath.

5. The method of claim 1, wherein applying the enamel coating comprises applying the enamel coating with a brush onto the first surface of the inner wall and/or the fourth surface of the outer wall.

6. The method of claim 1, wherein heating the enamel to glaze the enamel comprises heating the enamel to a temperature of approximately 800 ℃.

7. The method of claim 1, wherein removing air from the second cavity comprises heating the second cavity to a temperature of about 400 ℃.

8. The method of claim 1, wherein sealing the second cavity after removing air from the second cavity comprises melting a plug of material disposed in a hole of the outer wall.

9. The method of claim 1, further comprising temporarily sealing the second cavity from an ambient environment external to the outer wall prior to applying the enamel coating.

10. The method of claim 9, wherein temporarily sealing the second cavity comprises inserting a plug into a hole through the outer wall.

11. The method of claim 9, wherein temporarily sealing the second cavity comprises covering an aperture through the outer wall.

12. A container for holding a liquid, the container comprising:

an inner wall comprising a first surface and a second surface, the first surface defining a first cavity in which a liquid can be contained;

an outer wall connected to the inner wall, including a third surface and a fourth surface, the outer wall being positioned relative to the inner wall such that the third surface of the outer wall surrounds the second surface of the inner wall, and the third surface and the second surface together define a second cavity that is sealed from an ambient environment external to the first surface of the inner wall and the fourth surface of the outer wall, and has a pressure less than an external ambient pressure; and

an enamel coating disposed on at least one of the first surface of the inner wall and the fourth surface of the outer wall.

13. The container of claim 12, wherein the first cavity is cylindrical in shape.

14. The container of claim 12, wherein the inner wall has an area defining an opening to the first cavity.

15. The container of claim 12, wherein the inner wall and the outer wall are formed from a single continuous piece of material.

16. The container of claim 12, wherein the outer wall extends from an inner wall region defining an opening to the first cavity.

17. The container of claim 12, wherein the outer wall is configured such that the inner wall nests within the outer wall.

18. The container of claim 12, wherein a distance between the second surface of the inner wall and the third surface of the outer wall is substantially constant throughout the second cavity.

19. The vessel defined in claim 12 wherein the enamel coating is provided on the first surface of the inner wall and the fourth surface of the outer wall.

20. The container of claim 12, further comprising a handle connected to the outer wall.

Technical Field

Many containers for drinking hot and/or cold beverages made of metal comprise a vacuum-sealed outer portion surrounding the portion of the container containing the beverage to be drunk, or an enamel coating covering the surface of the container exposed to the external ambient environment. The outer portion of the vacuum seal helps maintain the temperature of the beverage contained by the container by reducing heat flow into the beverage if the beverage is cooler than ambient or by reducing heat flow out of the beverage if the beverage is warmer than ambient. The enamel coating protects the metal of the container, provides a fresh, clean taste that does not retain or transfer the taste, makes cleaning of the container easier, and provides more options for decorating the container than exposed metal.

Background

Unfortunately, such metal containers do not include a vacuum-sealed outer portion and an enamel coating because the process of including one in the container conflicts with the process of including the other in the container. If the vacuum-sealed outer portion is formed prior to forming the enamel coating, heating the enamel to form a frit on the vessel will deform or explode the vessel by creating a very high pressure inside the vacuum-sealed outer portion. Also, if the enamel coating is formed prior to forming the vacuum-sealed outer portion, the liquid enamel will seep into the cavity to become a vacuum seal and reduce the insulating effect of the vacuum-sealed outer portion.

Accordingly, there is a need for a vessel that includes both a vacuum-sealed outer portion and an enamel coating that covers one or more vessel surfaces that are exposed to the external ambient environment.

Disclosure of Invention

In one aspect of the invention, a method of manufacturing a container includes forming a first cavity of the container by shaping an inner wall such that a first surface of the inner wall defines the first cavity; forming a second cavity of the container by shaping the outer wall such that the third surface of the outer wall surrounds the second surface of the inner wall such that the third surface and the second surface together define the second cavity; and connecting the inner and outer walls together. The method then includes forming an aperture through the outer wall to expose the second cavity to an external ambient environment; an enamel coating is then applied to at least one of the first surface and a fourth surface of the outer wall exposed to the external ambient environment while preventing the enamel coating from being deposited in the hole. After applying the enamel coating, the method includes heating the vessel to glaze the enamel coating and secure the coating to one or more surfaces. After the enamel is glazed, the method includes removing air from the second cavity; the second cavity is then sealed such that the pressure within the second cavity is less than the pressure in the external ambient environment as air is evacuated from the second cavity.

By forming a hole through the outer wall and preventing enamel from being applied to the hole, the enamel coating can be prevented from entering the second cavity. And by glazing the enamel coating with a pressure lower than the external ambient environment before sealing the second cavity, the process of glazing the enamel coating may be prevented from damaging the sealed second cavity. Thus, it is possible to produce a container comprising a sealed second cavity and enamel outside the first cavity and/or the container, so that the container can efficiently maintain the temperature of the beverage contained in the first cavity of the container, while having an attractive and decorative appearance which protects the inner and outer walls, provides a fresh, clean taste without retaining or transferring the taste, and allows easy cleaning of the walls.

In another aspect of the invention, a vessel for containing a liquid includes an inner wall, an outer wall connected to the inner wall, and an enamel coating. The inner wall includes a first surface and a second surface, the first surface defining a first cavity that can contain a liquid. The outer wall includes a third surface and a fourth surface and is positioned relative to the inner wall such that the third surface of the outer wall surrounds the second surface of the inner wall and the third surface and the second surface together define a second cavity. The second cavity is sealed with respect to an ambient environment outside the first surface of the inner wall and the fourth surface of the outer wall, and the second cavity has a pressure less than an external ambient pressure. An enamel coating is disposed on at least one of the first surface of the inner wall and the fourth surface of the outer wall.

Drawings

FIG. 1 shows a perspective view of a container according to an embodiment of the invention.

Fig. 2 illustrates a process for manufacturing the container shown in fig. 1, according to an embodiment of the invention.

FIG. 3 illustrates a cross-sectional view of a portion of the container shown in FIG. 1, in accordance with an embodiment of the present invention.

FIG. 4 illustrates a partially exploded cross-sectional view of a portion of the container shown in FIG. 1, in accordance with an embodiment of the present invention.

Fig. 5 shows a perspective view of another container according to another embodiment of the invention.

Fig. 6 illustrates another process for manufacturing the container shown in fig. 1 and 5 according to another embodiment of the present invention.

Detailed Description

FIG. 1 illustrates a perspective view of a container 10 according to an embodiment of the present invention. The container 10 may be used to hold anything, such as beverages (hot or cold), food (hot or cold), and/or other items that may or may not be consumable. Vessel 10 includes an inner wall 12, an outer wall 14, and an enamel coating 16 covering inner wall 12 and outer wall 14. The container 10 also includes a first cavity 18 defined by the inner wall 12 and a second cavity (not shown here, but shown and discussed in more detail in connection with fig. 3 and 4) defined by the inner wall 12 and the outer wall 14. The second cavity has been air-removed and then sealed to prevent air from the external ambient environment from re-entering therein. Since the second cavity has a smaller air volume than the external surroundings, the pressure of the second cavity is lower than the pressure of the external surroundings. And because the second cavity has a smaller volume of air, heat flows through the second cavity at a slower rate, which allows the second cavity to insulate the first cavity 18 of the container.

By including a sealed second cavity around the container's first cavity 18 and applying an enamel coating to both the inner wall 12 and the outer wall 14, the container 10 can effectively maintain the temperature of the beverage contained in the container's first cavity 18 while having an attractive and decorative appearance that protects the inner wall 12 and the outer wall 14, respectively, and provides a fresh, clean taste that does not retain or transfer taste.

Still referring to fig. 1, the container may be made of any desired material capable of forming a container and capable of withstanding the physical and thermal loads to which the container is subjected during use. For example, in this and other embodiments, the container 10 is made of metal. More specifically, the vessel 10 is made of 304 stainless steel. With such materials, the construction of the container 10 may be formed from a single sheet of material by stamping, forming and/or folding, including bending the material; and/or vessel 10 may be formed in sections or portions and then welded together to form the entire vessel 10.

Enamel coating 16 can be any desired enamel coating. For example, in this and other embodiments, the enamel coating 16 is applied in one or more stages or layers and includes 1) a matrix agent such as silica, zirconia, and titania, 2) a flux agent such as sodium oxide, potassium oxide, and boron oxide, 3) an opacifying agent such as titania, antimony oxide, zirconia, and strontium oxide, 4) a binder such as cobalt oxide, nickel oxide, copper oxide, antimony oxide, and molybdenum oxide, and 5) a colorant such as cobalt oxide (bright blue), copper oxide (green or red), chromium oxide (dark green); and iron oxide (ochre).

The container 10 may also include any other components. For example, here, the container 10 includes a handle 20 that is welded to the outer wall 14 prior to the enamel coating being applied to the outer wall 14, and allows one to more easily handle the container 10 relative to containers that omit such a handle, such as a flat bottom cup (tubbler).

Other embodiments are also possible. For example, the vessel 10 may include an enamel coating covering only the inner wall 12, the outer wall 14, a portion of the inner wall 12, a portion of the outer wall 14, or a portion of the inner wall 12 and the outer wall 14.

FIG. 2 illustrates a process for manufacturing the container 10 shown in FIG. 1, according to an embodiment of the present invention. The process includes three general actions of 1) forming first and second cavities of the vessel 10 (steps 22-26), 2) applying the enamel coating 16 to a portion of the vessel 10 (steps 28-34), and then 3) increasing the insulating properties of the second cavity (steps 36 and 38).

More specifically, a first action of the process includes forming the first cavity 18 of the container 10 by shaping the inner wall 12 such that a first surface (as shown in FIG. 3) defines the first cavity 18 at step 22. The formation of the first cavity 18, the second cavity, and the connection of the inner wall 12 and the outer wall 14, respectively, are discussed in more detail in connection with fig. 3. A second step 24 of the first action of the process comprises forming a second cavity of the container 10 by shaping the outer wall 14 such that a third surface (as shown in fig. 3) of the outer wall 14 surrounds a second surface (also as shown in fig. 3) of the inner wall 12, such that the third surface and the second surface together define the second cavity. Finally, the final step 26 of the first action of the process includes joining the inner wall 12 and the outer wall 14 together.

After the first and second cavities of vessel 10 are formed, enamel coating 16 is applied to vessel 10. More specifically, the second action of the process includes forming an aperture through the outer wall 14 (as shown in FIG. 3) at step 28 to expose the second cavity to the ambient environment outside of the outer wall 14. The process then includes applying 30 an enamel coating 16 on at least one of the first surface of the inner wall 12 (as shown in fig. 3) and the fourth surface of the outer wall 14 (as shown in fig. 3) while preventing the enamel coating from being deposited in the hole. After applying enamel coating 16, the process includes heating the vessel at step 34 to glaze enamel coating 16 and secure coating 16 to one or more surfaces (as shown in fig. 3).

At step 28, holes may be formed through the outer wall 14 using any desired technique. For example, in this and other embodiments, the holes are punched into and through the base (as shown in FIG. 3) and then welded to the end of the outer wall 14 at the bottom of the container 10 (as shown in FIG. 3). In this manner, the base completes the outer wall 14 and encloses the second cavity except for the hole through the base. In other embodiments, the hole may simply be drilled through the outer wall 14 at any other location, or otherwise formed through the outer wall 14.

Still referring to fig. 2, at step 30, enamel coating 16 may be applied using any desired technique, so long as the enamel coating is prevented from being deposited in the holes of the base. For example, in this and other embodiments, enamel coating 16 is applied to a majority of the first surface of inner wall 12 and outer wall 14 defining first cavity 18 by immersing vessel 10 in a liquid enamel bath, and enamel coating 16 is prevented from reaching the holes by not allowing the base regions where the holes are located to immerse in the enamel bath. In other embodiments, the base region where the holes are located may be masked to prevent liquid enamel from depositing in the holes. In such an embodiment, the area adjacent the hole is also masked to ensure that a clean metal surface is available for subsequent filling of the hole and sealing of the plug of the second cavity (as shown in fig. 3 and 4). In other embodiments, the enamel may be applied to only the first surface of the inner wall 12, only the fourth surface of the outer wall 14, or only a portion of each of the first and fourth surfaces. In other embodiments, the enamel may be applied to the container 10 with a paint brush. This may be desirable to provide a unique aesthetic or decorative design for the container 10.

At step 34, enamel coating 16 is heated using any desired technique. For example, in this and other embodiments, the enamel is heated to about 800 ℃ in a conventional furnace to glaze and secure the enamel to the first surface of the inner wall 12 and the second surface of the outer wall 14.

By forming a hole through the outer wall 14 and preventing enamel from being applied to the hole, the enamel coating 16 can be prevented from entering the second cavity. And by glazing enamel coating 16 with less pressure than the external ambient environment before sealing the second cavity, the process of glazing enamel coating 16 may be prevented from damaging the sealed second cavity. Thus, it is possible to produce a container 10 comprising a sealed second cavity and enamel outside the first cavity 18 and/or the container 10, so that the container 10 can effectively maintain the temperature of the beverage contained in the first cavity 18 of the container, while having an attractive and decorative appearance.

Still referring to fig. 2, the insulating properties of the second cavity are enhanced after the enamel 16 is secured to the vessel 10. More specifically, the third action of the process includes removing air from the second cavity at step 36. Then, at step 38, when air is removed from the second chamber, the process includes sealing the second chamber such that the pressure within the second chamber is less than the pressure in the external ambient environment.

Removing air from the second cavity may be accomplished using any desired technique. For example, in this and other embodiments, air may be removed from the second chamber by heating the second chamber to about 400 ℃ in a conventional oven. At 400 ℃, the density of air is much less than 20 ℃ because the heat excites or excites the molecules in the air. This in turn increases the pressure of the air. If air is still trapped in the second cavity, the pressure will increase with increasing temperature. But because the second cavity is exposed to the external ambient environment, hot air exits the second cavity to equalize the pressure within the second cavity and the pressure in the external ambient environment. After the desired amount of air exits the second cavity, the second cavity is sealed. Then, when the remaining air in the second cavity cools back to the temperature of the external ambient environment, the density of the air in the second cavity is fixed, and therefore its pressure decreases to less than the pressure in the ambient environment. And because less air is trapped in the second cavity, the ability of the second cavity to resist heat flow through it is increased.

FIG. 3 illustrates a cross-sectional view of a portion of the container 10 shown in FIG. 1, in accordance with an embodiment of the present invention. As previously described, the container 10 includes a second cavity 46 defined by the inner wall 12 and the outer wall 14, the second cavity 46 reducing heat flow into and out of the first cavity 18 to help insulate the first cavity 18. More specifically, the inner wall 12 includes a first surface 48 and a second surface 50 that define the first cavity 18. The outer wall 14 includes a third surface 52 and a fourth surface 54. As previously described, the first cavity 18 is defined by the first surface 48 of the inner wall 12. The second cavity 46 is defined by a second surface 50 of the inner wall 12 and a third surface 52 of the outer wall 14.

The first and second cavities 18 and 46, respectively, may be configured as desired. For example, in this and other embodiments, the first cavity 18 is cylindrical and includes an opening 56, the opening 56 allowing access to the first cavity 18 and being located in the region of the inner wall 12. The second cavity 46 surrounds the first cavity 18 such that the inner wall 12 nests within the outer wall 14. And, the inner wall 12 and the outer wall 14 are connected to each other at the openings 56, respectively. More specifically, the inner wall 12 and the outer wall 14 are each formed from a single continuous piece of material such that the outer wall 14 extends from the area of the inner wall where the opening 56 is located and then extends down the inner wall 12. In this manner, the second cavity 46 surrounds the entire first cavity 18, effectively insulating the first cavity 18.

The construction of the container 10 can be accomplished as desired. For example, in this and other embodiments, the circular base 60 is welded to the end 62 of the outer wall 14 at the interface formed between the two flanges. The end 62 of the outer wall 14 forms a flange; and the periphery of the base 60 forms another flange. The interface at which the base 60 is welded to the outer wall 14 is the area where the two flanges contact each other when the base 60 is positioned to form the bottom of the container 10. The hole 64 in the base 60 is located at the center of the base 60, at the top of the cone 66. The cone 66 is free of any enamel coating so that the plug 68 can make good contact with the metal surface. This allows the plug 68 to form a good bond with the base 60 and maintain the filling of the hole 64 and the sealing of the second cavity 46.

FIG. 4 illustrates a partially exploded cross-sectional view of the container shown in FIG. 1, in accordance with an embodiment of the present invention. After the enamel coating has been fixed to the fourth surface 54 by heating, the hole 64 is sealed with a plug 68 during the evacuation of air from the second cavity 46. The plug 68 seals the hole 64 by melting and then fills the hole 64 after being exposed to heat for a period of time during venting. A cover 70 is then attached to the fourth surface 54 of the outer wall 14 to protect the plug 68 and cover any liquid enamel deposited on the base, i.e. overspray and/or over-immersion. The cover 70 may be attached to the fourth surface 54 in any desired manner. For example, in this and other embodiments, the lid 70 is releasably held in place by the outer wall 14 gripping a flange 72 of the lid 70, as shown in FIG. 3. In other embodiments, the lid is releasably attached using conventional snaps. In other embodiments, the cover 70 may be secured to the outer wall 14 with an adhesive or by welding the cover 70 to the outer wall 14.

Fig. 5 shows a perspective view of another container 80 according to another embodiment of the present invention. The container 80 is similar to the container 10 shown in fig. 1, 3 and 4 and discussed in connection with fig. 1-4, except that the container 80 is a flat bottom cup. The tumbler typically does not have a handle like the handle 20 shown in fig. 1. Like these tumbler cups, tumbler cup 80 also has no handle. Instead, one simply holds the tumbler by wrapping a finger around the outer wall 82.

Fig. 6 illustrates another process for manufacturing the containers 10 and 80 of fig. 1 and 5, respectively, according to another embodiment of the present invention. This process is similar to that shown in fig. 2 and discussed in connection with fig. 2, except that after the holes 64 (fig. 3 and 4) are formed in the outer wall 14, but before the enamel coating is applied to the inner and outer walls 12 and 14, respectively, the holes 64 are temporarily plugged at step 90 to temporarily seal the second cavity from the external ambient environment. This ensures that liquid enamel does not settle in the bore 64 or in the second cavity 46. Then, after applying the enamel coating, the second cavity 46 is exposed to the ambient environment at step 92.

The second cavity may be temporarily sealed using any desired technique. For example, in this and other embodiments, a plug (not shown) that is elastically deformable and sized to fit into the hole 64 in the outer wall 14 is inserted into the hole 64. When inserted into the bore 64, the plug blocks air and, more importantly, blocks the flow of the enamel coating through the bore 64 and into the second cavity 46. Then, after the enamel coating has been applied to the vessel 10 and/or 80, the plug may be removed to expose the second cavity 46 in preparation for heating the enamel coating to secure the enamel coating to the vessel 10 and/or 80. In other embodiments, the second cavity 46 may be temporarily sealed by releasably attaching a cover (not shown) to the outer wall 14 and/or the area of the base 60 that includes the aperture 64. The lid may extend as far as desired on the second wall 14 to seal the aperture and provide a handle that one can use to hold and manipulate the container 10 while applying the enamel coating 16. Each of the stopper and the lid may be reused in a similar process for manufacturing additional containers 10. In other embodiments, the plug cannot be releasably inserted into the bore 64, and instead of withdrawing the plug prior to heating the enamel coating 16, the second cavity 46 may be exposed by forming another bore through the outer wall 14 and/or the base 60.

The previous discussion is intended to enable any person skilled in the art to make and use the present invention. Various modifications to the embodiments will be readily apparent to those skilled in the art, and the generic principles herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.