Reheatable and washproof container with insulation properties

Abstract

The various embodiments herein provide an insulated container. The container comprises a body assembly and a lid assembly. The body assembly comprises of an outer plastic body and a plastic ring insert molded with an inner stainless steel (SS) container. The inner SS container has a non-woven polyester fabric acting as an insulation material. The non-woven polyester fabric is enclosed in between the outer plastic body and the inner SS container. The lid assembly comprises of a plastic top lid, an inner lid and a bowl with non-woven polyester fabric acting as insulation. The polyester fabric is sandwiched between the plastic top lid, the inner lid and the bowl. In the body assembly, the outer plastic body and the inner plastic ring is joined together using a spin welding technique. In the lid assembly the top lid, inner lid and bowl are joined together using spin welding technique.

Claims

1. A heat-resistant and washable container with insulation properties comprising: a body assembly comprising at least three layers: an outer plastic body made of polypropylene filled with at least 20% carbonate based mineral filler; a middle layer, wherein the middle layer is made up of a nonwoven polyester fabric; and an inner stainless steel container comprising a molded plastic ring near an upper portion of the inner stainless steel container; said plastic ring further comprising a first rib; wherein: the outer plastic body is attached to the inner stainless steel container at the plastic ring and the middle layer is positioned between the inner stainless steel container and the outer plastic body; and a lid assembly comprising: a plastic top lid; an inner lid comprising an extended rib; a bowl; and an insulation layer of nonwoven polyester fabric positioned between the top lid and the inner lid beneath the bowl; wherein the top lid is fused to both the inner lid and the bowl; and the extended rib of the inner lid releasably engages with the first rib of the plastic ring.

2. The container of claim 1, wherein the outer plastic body is fused to the plastic ring of the inner stainless steel container by spin welding, thereby completely enclosing the non-woven polyester fabric of the middle layer.

3. The container of claim 2, wherein the spin welding is performed at a pressure range between 1.5 to 4 bar and at a variable spindle rotational speed between 150 to 350 RPM to achieve a leak proof connection.

4. The container of claim 1, wherein the inner stainless steel container is attached to the molded plastic ring by insert molding.

5. The container of claim 1, wherein the plastic top lid, the inner lid, and the bowl are sealed together by spin welding.

6. The container of claim 1, wherein the carbonate based mineral filler comprises calcium carbonate.

7. The container of claim 1, wherein the body assembly is capable of sustaining a temperature range between 40-50 C.

8. The container of claim 1, wherein the body assembly has a heat deflection temperature of 110 C.

9. The container of claim 1, wherein the lid assembly is fused together by leak proof welding at temperatures between 135-155 C.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which:

(2) FIG. 1 is a sectional front view of an insulated container lid assembly, according to one embodiment of the present invention.

(3) FIG. 1A is the exploded view of the top lid of an insulated container lid assembly, according to one embodiment of the present invention.

(4) FIG. 1B is the exploded view of the bowl of an insulated container lid assembly, according to one embodiment of the present invention.

(5) FIG. 1C is the exploded view of the bottom lid of an insulated container lid assembly, according to one embodiment of the present invention.

(6) FIG. 1D illustrates points/joints where top lid, bowl, insulation material and bottom lid are sealed because of plastic to plastic fusion using spin welding technique, according to one embodiment of the present invention.

(7) FIG. 2 is a sectional front view of an insulated container body assembly, according to one embodiment of the present invention.

(8) FIG. 2A is the exploded view of the treated inner stainless steel container of an insulated container body assembly, according to one embodiment of the present invention.

(9) FIG. 2B is the exploded view of the outer plastic body of an insulated container body assembly, according to one embodiment of the present invention is a sectional view of an insulated body assembly, according to one embodiment of the present invention.

(10) FIG. 2C illustrates points/joints where the outer plastic body, insulation material, treated inner stainless steel container and plastic top lid are sealed by using spin welding technique and insert moulding technique, according to one embodiment of the present invention.

DETAILED DESCRIPTION OF DRAWINGS

(11) The various embodiments herein provide a re-heatable and washable container with insulation properties. The container comprises a body assembly (FIG.2) and a lid assembly (FIG.1). The body assembly comprises of at least three layer of an outer plastic body (73), an insulation middle layer (83) and an inner stainless steel (SS) container (60); Wherein the inner stainless steel is insert molded between plastic ring and the other two layers. The inner SS container is wrapped around by a fabric consisting of Polypropylene filled with 20% minerals and nonwoven polyester fabric acting as an insulation material. The nonwoven polyester fabric is enclosed in between the outer plastic body and the inner SS container and is completely sealed using spin welding technique owing to which the insulation material does not come in contact with water or air and the material's shelf life remains almost constant. The said Polypropylene filled with minerals provides high mechanical stiffness, thermal stability, and dimensional stability over wide range of the temperature to the product. The lid assembly comprises of a plastic top lid (10), an inner lid (30) and a bowl (20) with non-woven polyester fabric (53) acting as insulation. The nonwoven polyester fabric is sandwiched between the plastic top lid, the inner lid and the bowl and can withstand at least 100 C. temperature. In the body assembly, the outer plastic body and the inner plastic ring (63) is joined together using a spin welding technique. Also the plastic top lid, the inner lid and the bowl are joined together using the spin welding technique, so that both, the body assembly and the lid assembly becomes absolutely sealed to any particulates, liquids and is dishwasher safe and at the same time re-heatable. The container lid is provided with an inbuilt handle (1) in the top lid and a projection in the inner lid for locking and unlocking of container lid with the container body.

(12) The insulated container body according to the present invention comprises three main components. The three main components are a plastic outer body (73), insert molded inner ring (63) with SS container (60) and an insulation material (83) in between, assembled/joined using spin welding technique to bring plastic-plastic fusion to make the container absolutely sealed from external environment to avoid water seepage between the layers of the body during washing and avoiding unhygienic condition. The insulated container body is provided with a projection in the insert molded inner ring for locking and unlocking with the container lid. It also comprises of two side handles in the outer plastic body for the ease of handling the insulated container. The container lid and container body are designed to be able to lock and unlock easily and to avoid the slippage accidents. The container lid and the container body also have a good fitting which enhances the heat retention of the food. The Container body is capable of accommodating any kind of container lid made up of steel, plastic or glass which may or may not be insulated and may or may not be microwave and dishwasher safe.

(13) FIG. 1 illustrates a sectional front view of an insulated container lid assembly and FIG. 2 illustrates a sectional front view of an insulated container body assembly. With respect to FIG. 1, the insulated container lid comprises a top lid (10), a bowl (20) and an inner lid (30). The inner lid (30) comprises a small extended rib (32) which insert-ably gets locked with rib (62) of the ring (63). The top lid (10) is welded with the bowl (20) at the location 2 in the top lid and (21) in the bowl with the spin welding technique. The top lid (10) has an inbuilt handle 1 for rotating the insulated lid for locking and unlocking purpose. The top lid (10) is welded with the inner lid (30) at the locations (3) in top lid and (31) in inner lid. The insert molded inner ring (63) is welded with plastic outer body (73) at locations (61) in insert molded ring (63) and (71) in plastic outer body (73).

(14) With respect to FIG. 1), the insulation fabric (53) is placed in between the welded lid assembly of the top lid (10), the bowl (20) and the inner lid (30).

(15) With respect to FIG. 2, the insulation fabric (83) is wrapped around the SS container of the insert molded ring (63) and is enclosed in between the welded assembly of the insert molded plastic ring (63) and outer body (73). An outer handle fitting (72) is molded into the outer body (73) to hold the casserole.

(16) Experimental Data

(17) The present invention passed the standard reliability test wherein the visual parameters were judged after each predetermined wash cycle for physical damages, deformation, distortion, weight gain or loss of the container etc after the container was washed with water having water temperature of 72-degree C for 110 minute using Cascade detergent and dried at a temperature of 60-degree C.

ADVANTAGE OF THE INVENTION

(18) The conventional insulated containers are neither dish washer safe nor they can be used in microwave in technical sense. The present invention provides an insulated container designed and developed in such a way that along with existing function of keeping food warm for longer period of time, it has an added advantage of reheating stored food in a microwave oven, and can be cleaned in a dish-washing machine.

(19) The welding/fusing of plastic-plastic is easier than the other material, since plastic requires low energy and force for assembling. The implementation of spin welding technique eliminates the seepage of water inside the container. The insert moulding of ring with SS container eliminates sharp edge, in turn avoids the arcing issues common in microwave use. The assembly technique makes the product more rigid than the conventional mechanical push/snap fits.

(20) The conventional insulated container uses rigid PU as insulation material, which is non-recyclable, hazardous to environment and non-eco-friendly. The present invention uses non-woven polyester based fabric as an insulation medium, which is recyclable and nonhazardous to environment.

(21) The spin welding technique requires advance machineries designed to suit this specific product application. The production and assembly process requires more time than the conventional products.