GB2052726A - Thermally insulated vessels - Google Patents

Abstract

A thermally insulated vessel, in particular an ice bucket, comprises a transparent plastics outer container 2, 3 and an inner container 8 (e.g. of transparent translucent or opaque plastics material) nested therein. Disposed between the containers are foamed plastics material 15 (e.g. polyurethane) and sheet material 13, 13a (e.g. paper or card) carrying a pattern or design such that the pattern or design is visible through the outer container. Polymeric film material 14 (e.g. of polyethylene) is provided between the sheet material 13, 13a and the foamed plastics material 15 to protect the sheet material when a liquid capable of foaming to form the solid foamed material 15 is introduced. The container may have handles 6 formed therein. <IMAGE>

Description

SPECIFICATION Improvements in or relating to insulated vessels This invention relates to insulated vessels.

According to the present invention there is provided an insulated vessel comprising: (a) an outer container formed from transparent synthetic plastics material, (b) a flexible bag of polymeric film material nested within the outer container, (c) an inner container nested in the bag, the inner and outer containers being joined at their mouths, (d) sheet material carrying a pattern or design and disposed between the outer container and the bag so that the patent or design is visible through the outer container, and (e) foamed plastics material between the bag and the inner container.

According to another aspect of the present invention there is provided a method of making an insulated vessel which comprises the steps of: (a) providing an outer container formed from trasparent synthetic plastics material, (b) inserting into the outer container sheet material carrying a pattern or design so that the pattern or design is visible through the transparent outer container, (c) introducing a bag formed of polymeric film material into the container, (d) introducing into the bag a liquid capable of foaming to form a solid foam, (e) inserting into the bag an inner container formed from synthetic plastics material and allowing said liquid to form a foam which is prevented from contacting the sheet material by the bag, and (f ) joining the inner and outer containers together at their mouths.

The outer container of the insulated vessel is formed from a transparent synthetic plastics material such as styrene-acrylonitrile copolymer, acrylonitrile-butadiene-styrene terpolymer, polystyrene or polycarbonate resin. The inner container is formed from a synthetic plastics material and again may be formed from styrene acrylonitrile copolymer, acrylonitrile-butadienestyrene terpolymer, polystyrene or polycarbonate resin. The inner container may be transparent, translucent or opaque. It is particularly preferred for the materials of the inner and outer containers to be such that they can be welded together by ultrasonic welding techniques.In this case, the inner and outer containers are so shaped that they co-operate together around their whole periphery so as to form an interference fit whereby the cooperating parts become welded together so as to form a continuous seal around the mouths of the containers to prevent ingress of water into the space between the containers. Such ingress of water may have a deleterious affect on the pattern or design carried by the sheet material.

The foamable liquid may be the precursor of for example, a polyurethane foam. During the foam forming process, the sheet material carrying the pattern or design is pressed firmly against the outer container by the foamed plastic material.

Further, the foam enhances the insulative properties of the vessel and, moreover, provides the vessel with increased rigidity in as much as it tends to form a bond with the inner container.

The pattern or design carried by the sheet material, which may be paper, card or the like, is preferably printed onto the sheet material since in this way many varied patterns or designs can be readily produced. The pattern or design may be for example in the form of decorative matter or in the form of written matter such as an advertisement or instructions as to use of the vessel.

A wide variety of insulated vessels can be produced in accordance with the present invention. In one embodiment, the nested containers have a shape such that the resultant insulated vessel is suitable for use as an ice bucket. In this embodiment, the containers may each be frusto-conical in shape. In another embodiment, the nested containers have a shape such that the resultant insulated vessel is suitable for use as a butter dish. In this embodiment, for example, the containers may be of a generally rectangular shape. In a further embodiment, the inner and outer containers may be such that the resultant insulated vessel is in the form of a wine cooler. In this case, the containers may, for example, each be in the form of cylinders having small diameters relative to their lengths so that the interior of the vessel has dimensions such that it can accommodate a wine bottle.

The poiymeric film material from which the bag is formed may be any suitable material which is resistant to the foamable liquid. Thus, in the case where the foamable liquid is a polyurethane foam precursor, the bag may be formed from polyethylene. The shape and dimensions of the bag should be such that the bag may take up a shape corresponding to that defined by the inner surface of the outer container under the influence of the pressure generated during the foam formation. However, the dimensions of the bag are not particuiarly critical since the material of the bag can be readily deformed and stretched and creased as necessary under the pressure exerted by the foaming liquid so that the bag is pressed against the sheet material and thereby presses the sheet material against the outer container.The bag can be readily made from, for example, lay flat tubing of appropriate diameter merely by cutting off an appropriate length of the tubing and heat sealing the end.

For a better understanding of the invention and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawing which shows an exploded vertical cross-section through an insulated vessel in accordance with the present invention.

Referring to Figure 1 , there is shown an ice bucket constructed in accordance with the present invention. The ice bucket comprises an outer container 1 injection moulded from a transparent synthetic plastics material. The outer container 1 comprises a frusto-conical side wall 2 and a substantially flat bottom wall 3. The side wall terminates in a rim 4 around the mouth of the container 1. The outer periphery of the rim 4 carries a continuous lip 5. The walls 2 of the outer container include a pair of integrally formed handles 6 diametrically opposite to one another.

The ice bucket also includes an inner container 7 which is again substantially frusto-conical in shape. The inner container 7 is formed from a transparent, translucent or opaque plastics material. The inner container 7 has a side wall 8 and a substantially flat bottom wall 9. It also has a rim 10 at its mouth and this rim is extended back towards the base of the vessel so as to form a down-turned annular flange 11 carrying on its inner surface a continuous lip 12.

The dimensions of the inner container 7 are such that when it is placed in position in the outer container 1 the side walls of the containers are spaced apart. Similarly the bottom walls of the containers are spaced apart. An insert 13 formed of sheet material and carrying a printed pattern or design is located between the side wall 8 of the inner container 7 and the side wall 2 of the outer container 1 in a manner such that the pattern or design can be seen through the transparent side wall 2. The insert 1 3 is formed by cutting a sheet of paper or card or the like so that it may be bent to form a frusto-conical shape of similar dimensions to the frusto-conical inner surface of the wall 2 of the outer container 1.A circular piece of sheet material 1 3a optionally carrying a pattern or design, for example instructions relating to the use of the ice bucket, is positioned inside the outer container 1 so that it is adjacent to the bottom wall 3. Located between the inserts 13 and 1 3a and the side wall 8 and bottom wall 9 of the inner container 7 is a bag formed of polyethylene film.

The bag is substantially rectangular is plan.

However, the film from which it is made is quite thin such that the bag is not self-supporting but is readily able to take up any disposition under the influence of external forces. A layer of in situ foamed polyurethane 1 5 is provided between the bag 14 and the inner container 7.

The vessel also includes a lid 1 6 of such dimensions that it can be seated in the mouth of the inner container 7.

The ice bucket is assembled by placing the inserts 1 3 and 1 3a into the outer container 1.

Thereafter the bag 14 is inserted into the outer container 1 so that the inserts 13 and 1 3a are between the bag 14 and the outer container 1 and an appropriate amount of a foamable liquid precursor of a polyurethane foam is metered into the bag 14. The inner container 7 is then inserted into the bag 14 whilst the foamable liquid is reacting to form the foamed polyurethane and is pressed into place in an ultrasonic welding machine so that the lips 5 and 12 co-operate, and become welded, together. In this way, the inner and outer containers are welded together at their mouths around their entire periphery so that ingress of water between the inner and outer containers is prevented.As the foamable liquid foams to form the in situ foamed solid polyurethane 15, the pressure exerted on the bag 14 urges it towards the outer container 1 whereby the inserts 1 3 and 1 3a are firmly held against the inner surfaces of the outer container 1. Contact between the foamable liquid and the inserts 13 and 1 3a is however prevented by the bag 14.

There is thus obtained a double-walled ice-bucket with the decorative matter or the like on the inserts 1 3 and 1 3a readily visible through the transparent outer walls of the bucket. The foamed polyurethane enhances the insulative properties of the ice-bucket.

Ice-buckets having widely differing decorative designs or patterns may be produced by using a decorative insert having any desired printed pattern or design. Moreover, these varied icebuckets can be produced utilising two moulds only, one being employed to produce the inner container 7 and the other being employed to produce the outer container 1.

Claims (20)

1. An insulated vessel comprising: (a) an outer container formed from transparent synthetic plastics material, (b) a flexible bag of polymeric film material nested within the outer container, (c) an inner container nested in the bag, the inner and outer containers being joined at their mouths, (d) sheet material carrying a pattern or design and disposed between the outer container and the bag so that the patent or design is visible through the outer container, and (e) foamed plastics material between the bag and the inner container.

2. A vessel as claimed in claim 1 wherein the synthetic plastics material of the outer container is styrene-acrylonitrile copolymer, acrylonitrilebutadiene-styrene terpolymer, polystyrene or polycarbonate resin.

3. A vessel as claimed in claim 1 or 2 wherein the synthetic plastics material of the inner container is styrene-acrylonitrile copolymer, acrylonitrile-butadiene-styrene terpolymer, polystyrene or polycarbonate resin.

4. A vessel as claimed in claim 1, 2 or 3 wherein the synthetic plastics material of the inner container is transparent.

5. A vessel as claimed in claim 1, 2 or 3 wherein the synthetic plastics material of the inner container is translucent of opaque.

6. A vessel as claimed in any one of claims 1 to 5 wherein the inner and outer containers are so shaped that they co-operate together around their whole periphery so as to form an interference fit.

7. A vessel as claimed in any one of the preceding claims wherein the foamed plastics material is a polyurethane foam.

8. A vessel as claimed in any one of the preceding claims wherein the sheet material is paper or card.

9. A vessel as claimed in any one of the preceding claims wherein the pattern or design is printed onto the sheet material.

10. A vessel as claimed in any one of the preceding claims wherein each container is frustoconical in shape.

1 A vessel as claimed in any one of claims 1 to 9 wherein each container is of a generally rectangular shape.

12. Vessel as claimed in any one of claims 1 to 9 wherein each container is in the form of a cylinder having a diameter which is small relative to its length.

13. A vessel as claimed in any one of the preceding claims wherein the polymeric film material is polyethylene.

14. A vessel as claimed in claim 1 substantially as hereinbefore described with reference to and as illustrated in the accompanying drawing.

1 5. A method of making an insulated vessel which comprises the steps of: (a) providing an outer container formed from transparent synthetic plastics material, (b) inserting into the outer container sheet material carrying a pattern or design so that the pattern or design is visible through the transparent outer container, (c) introducing a bag formed of polymeric film material into the container, (d) introducing into the bag a liquid capable of foaming to form a solid foam, (e) inserting into the bag an inner container formed from synthetic plastics material and allowing said liquid to form a foam which is prevented from contacting the sheet material by the bag, and (f) joining the inner and outer containers together at their mouths.

1 6. A method in accordance with claim 1 5 wherein the synthetic plastics materials of the inner and outer containers are such that they can be welded together by ultrasonic welding and the inner and outer containers are so shaped that they co-operate together around their whole periphery so as to form an interference fit wherein the joining together of the inner and outer containers is effected by ultrasonic welding.

1 7. A method in accordance with claim 1 5 or 1 6 wherein the liquid capable of foaming to form a solid foam is a polyurethane foam precursor.

1 8. A method in accordance with claim 15, 1 6 or 17 wherein the bag is formed from layflat tubing.

19. A method in accordance with claim 1 5 substantially as hereinbefore described with reference to the accompanying drawing.

20. An insulated vessel whenever produced by the method claimed in any one of Claims 1 5 to 19.