VACUUM-INSULATED CONTAINER BODY, CONTAINER AND METHODS ASSOCIATED

Abstract

A vacuum-insulated container (1) comprises a container body (2) and a container lid (3). The container body (2) is formed from an inner body shell (8) and an outer body shell (6), which are both made of a metal material. A core (7) is provided between the inner body (shell 8) and the outer body shell (6), and a seal (11) connects to (flanges 12) of the inner body shell (8) and the outer body shell (6), so as to define an intermediate vacuum space (10) surrounding the core (7). A compressible gasket (17) is provided to protect the seal (11). The lid (103) has two pair of fasteners (122) hingedly connected to opposing sides of the lid (103). Each of the fasteners (122) is releasably connectable to the body (102) whilst the lid is in a closed position with respect to the body.

Claims

1-32. (canceled)

33. A vacuum-insulated container body, comprising: an inner body shell and an outer body shell, wherein the inner body shell and the outer body shell are each made of a metal material; a core provided between the inner body shell and the outer body shell; and a seal connecting the inner body shell and the outer body shell, wherein the inner body shell, the outer body shell and the seal define an intermediate space surrounding the core, the intermediate space being at a pressure below atmospheric pressure; and wherein each of the inner body shell and the outer body shell comprises a flange bonded to the seal, the seal comprising a metallised foil extending between the flanges.

34. The vacuum-insulated container body according to claim 33, wherein the flanges of the inner body shell and the outer body shell both being in a common plane.

35. The vacuum-insulated container body according to claim 33, wherein the inner body shell and the outer body shell are each made from aluminium or an aluminium alloy.

36. The vacuum-insulated container body according to claim 33, wherein the inner body shell and the outer body shell each have an average thickness of less than 1.5 mm.

37. The vacuum-insulated container body according to claim 33, wherein the inner body shell and the outer body shell have each been formed by a deep drawing process.

38. The vacuum-insulated container body according to claim 33, wherein the inner body shell and the outer body shell each comprises a base, and a wall extending from the base in a direction substantially perpendicular to the base.

39. The vacuum-insulated container body according to claim 38, wherein the plane of the flanges is substantially perpendicular to the direction in which the walls of the inner and outer body shells extend.

40. The vacuum-insulated container body according to claim 33, wherein the core comprises one of polystyrene foam, polyurethane foam, precipitated silica and fumed silica.

41. The vacuum-insulated container body according to claim 33, wherein the seal is formed from a multi-layer metallised foil.

42. The vacuum-insulated container body according to claim 33, wherein the seal has been cut from a sheet of material.

43. The vacuum-insulated container body according to claim 33, further comprising: a gasket mounted to both of the flanges with the seal between the gasket and the flanges.

44. The vacuum-insulated container body according to claim 33, in which the seal is formed of flexible material.

45. The vacuum-insulated container body according to claim 33, wherein the seal is not formed of solid metal.

46. The vacuum-insulated container body according to claim 33, wherein the seal is formed as a layer less than about 0.3 mm thick.

47. The vacuum-insulated container body according to claim 33, wherein the seal is formed as a multi-layer construction which includes multiple individual barriers layers, each individual barrier layer being about 100 nanometres thick.

48. The vacuum-insulated container body according to claim 33, wherein the seal is formed as a layer less than about 50% of a thickness of at least one of the inner and outer body shells.

49. The vacuum-insulated container body according to claim 33, wherein a shield is provided and associated with the outer shell for shielding the seal.

50. The vacuum-insulated container body according to claim 49, further comprising: a gasket mounted to both of the flanges with the seal between the gasket and the flanges, wherein the shield runs around an outer periphery of the gasket to shield the gasket.

51. A vacuum-insulated container comprising: a vacuum-insulated container body according to claim 33; and a vacuum-insulated container lid configured to engage the container body.

52. The vacuum-insulated container according to claim 51, wherein the vacuum-insulated container lid comprises: an inner lid shell and an outer lid shell, wherein the inner lid shell and the outer lid shell are each made of a metal material; a core provided between the inner lid shell and the outer lid shell; and a seal connecting the inner lid shell and the outer lid shell, wherein the inner lid shell, the outer lid shell and the seal define an intermediate space surrounding the core, the intermediate space being at a pressure below atmospheric pressure; and wherein each of the inner lid shell and the outer lid shell comprises a flange bonded to the seal, the flanges of the inner lid shell and the outer lid shell both being in a common plane.

53. The vacuum-insulated container according to claim 51, wherein the vacuum-insulated container lid comprises: an inner lid shell and an outer lid shell, wherein the inner lid shell and the outer lid shell are each made of a metal material; a core provided between the inner lid shell and the outer lid shell; and a seal connecting the inner lid shell and the outer lid shell, wherein the inner lid shell, the outer lid shell and the seal define an intermediate space surrounding the core, the intermediate space being at a pressure below atmospheric pressure; and wherein each of the inner lid shell and the outer lid shell comprises a flange bonded to the seal, the seal which connects the inner lid shell and outer lid shell being a flexible seal comprising a flexible material.

54. The vacuum-insulated container according to claim 52, wherein the flanges of the vacuum-insulated container lid are configured to engage the flanges of the vacuum-insulated container body, this engagement optionally being indirect via respective seals and further optionally gaskets associated with the respective flanges

55. The vacuum-insulated container according to claim 51, wherein a shell of at least one of the lid and body includes a positioner for assisting in positioning the lid and body relative to one another.

56. The vacuum-insulated container according to claim 51, wherein a shield is provided and associated with the outer shell for shielding the seal, wherein a lid shield is provided for shielding the seal of the lid, the lid shield being at least partially internested or overlapped within the shield of the body of the container.

Description

[0105] Certain preferred embodiments of the present invention will now be described in greater detail, by way of example only and with reference to the accompanying drawings, in which:

[0106] FIGS. 1a and 1b show a first embodiment of a vacuum-insulated container comprising a body and a lid in a closed position and an open configuration, respectively;

[0107] FIG. 2 shows a side view of the vacuum-insulated container of the first embodiment in the closed configuration highlighting an interface surface between the lid and the body;

[0108] FIG. 3 is a cross-section through the vacuum-insulated container of the first embodiment in the closed position.

[0109] FIGS. 4 and 5 are partial cross-sections showing a seal of the body of the vacuum-insulated container of the first embodiment, with a gasket not shown and shown, respectively;

[0110] FIGS. 6 and 7 are detailed views of an interface between the lid and the body of the vacuum-insulated container of the first embodiment;

[0111] FIG. 7b shows a modification to the first embodiment with modified structural frame parts or shields;

[0112] FIG. 7c shows a modification to the first embodiment to provide a modified internal shell of a lid thereof;

[0113] FIG. 8 shows a second embodiment of a vacuum-insulated container comprising a body and a lid in a closed position;

[0114] FIG. 9 is a cross-section through the vacuum-insulated container of the second embodiment in the closed configuration;

[0115] FIGS. 10a and 10b are partial cross-sections showing a fastener of the vacuum-insulated container of the second embodiment in latched and unlatched configurations, respectively;

[0116] FIG. 10c is a partial cross-section showing hinge operation of a fastener of the vacuum-insulated container of the second embodiment;

[0117] FIG. 10d is a partial cross-section showing over-extension hinge operation of a fastener of the vacuum-insulated container of the second embodiment;

[0118] FIG. 10e is a perspective view showing latching operation of a fastener of the vacuum-insulated container of the second embodiment; and

[0119] FIG. 10f is a perspective view showing hinge operation of a fastener of the vacuum-insulated container of the second embodiment.

[0120] FIGS. 1 to 7 illustrate a first embodiment of an insulated container 1.

[0121] FIGS. 1a and 1b show a body 2 and a lid 3 of the insulated container 1. The body 2 and the lid 3 fit together along an interfacing surface 21, shown in FIG. 2, by means of mechanical fastenings (not shown).

[0122] The primary function of the insulated container 1 is to maintain the temperature of an internal air volume 4 of the insulated container 1, together with any contents, for a period of time, independent of the temperature of the external ambient environment 5.

[0123] With reference to FIG. 3, the body 2 and lid 3 are both constructed with a multi-layered wall construction comprising an external shell 6, a core 7 and an internal shell 8.

[0124] The internal and external shells 6, 8 are made of thin, thermally-conductive aluminium. The internal and external shells 6, 8 have a thickness of approximately 0.6 mm, and contribute to the structural integrity of the container 1. The internal and external shells 6, 8 are manufactured by a deep drawing process, in which a sheet metal blank is radially drawn into a die by the mechanical action of a press.

[0125] The core 7 is constructed with a porous material that provides mechanical structure when the chamber construction is evacuated down to low pressure. In a preferred embodiment, fumed silica is used for the core 7.

[0126] The low pressure impedes heat transfer by means of conduction and convention. As well as providing stability to the shells 6, 8, the core 7 also restricts movement of the remaining gas molecules, further impeding heat transfer by convection.

[0127] An optional phase change material (PCM) module 9 may be added to the base of the internal air volume 4, which functions as a thermal energy bank. Direct contact between the PCM module 9 and the aluminium internal structural shell 8 provides fast transfer of thermal energy between the internal air volume 4 of the containers and the PCM module 9 by means of conduction along the aluminium internal shell 8 and subsequent convection into the internal air volume 4. This efficient energy transfer results in a more even temperature distribution within the internal air volume 4.

[0128] Referring now to FIG. 4, to create optimal insulation performance of an intermediate vacuum space 10 between the external structural shell 6 and the internal structural shell 8, the gasses within the porous structure of the insulation core 7 must be evacuated.

[0129] The internal and external shells 6, 8 and the core 7 are assembled at atmospheric pressure and a chamber seal 11 is bonded to the shells 6, 8 to form the intermediate vacuum space 10. The chamber seal 10 is bonded to the flanges using a pressure sensitive adhesive that is pre-applied to the seal 10.

[0130] The intermediate vacuum space 10 is then evacuated to a target pressure through a small hole left in the chamber seal 11, which is then sealed after reaching the target pressure. Alternatively, however, the intermediate vacuum chamber 10 may be evacuated by applying the target pressure to the entire ‘ring’ opening between the two flanges 12 prior to applying the chamber seal 11.

[0131] Typically, the intermediate vacuum space 10 is evacuated to approximately 1 mbar, as further pressure reduction below this point provides little additional insulating benefit due to thermal insulating bridging elsewhere in the insulated container 1.

[0132] The intermediate vacuum space 10 maintains the vacuum by means of the chamber seal 11 applied to horizontal flange surfaces 12 of the inner and outer structural shells 6, 8. The chamber seal 10 in this embodiment comprises a multi-layer metallised film, which is composed of laminated layers of metal-coated polymer films, with the coating metal usually comprising aluminium. The chamber seal 11 minimises vapour and gas diffusion into the intermediate vacuum space 10 over the lifespan of the insulated container 1.

[0133] At the location of the horizontal flanges 12, the space between the outer and inner structural shells 6, 8, known as the thermal insulating bridge, directly affects the thermal insulating performance of the vacuum chamber 10. A wider bridge reduces heat transfer between the internal air volume 4 and the external ambient environment 5.

[0134] The surface area of the chamber seal 11 constitutes under 1% of the total surface area of the intermediate vacuum space 10, meaning that internal pressure change due to gas diffusion across the chamber seal 11 is greatly reduced compared to existing vacuum-insulated panels that are completely enclosed by multi-layer metallised foil.

[0135] Referring now to FIG. 5, due to the fragility of multi-layer metallised foil, the entire surface of the chamber seal 11 is covered with a compressible gasket 14, which protects the multi-layer metalized foil of the chamber seal 11. The chamber seal 11 is substantially planar. The compressible gasket 14 is substantially planar. The seal 11 and compressible gasket 14 of each shell engage one another substantially continuously all of the way between the flanges 12 of each shell at a substantially planar interface therebetween.

[0136] The chamber seal 11 is flexible. In this example the chamber seal 11 has a thickness of about 100 microns, although different thicknesses are contemplated. Within the multi-layer metallised foil, metal layers present are of aluminium although other materials are contemplated. The chamber seal 11 may include multiple individual layers of vapour/gas barrier, such as of aluminium, plus layers of other material such as polymer which may be incorporated e.g. for puncture protection, in one example the individual vapour/gas barrier layers each being less than 100 nanometres thick. The polymer layers may be laminated between barrier layers and vice versa.

[0137] In this example with at least one of the shells 6, 8 being an average of about 0.6 mm thick, the flexible chamber seal 11 is less than 20%, for example about 15 to 20%, of the thickness of at least one of the shells 6, 8.

[0138] Furthermore, the exposed flange edges of the external shell 6 may optionally be covered by a structural frame 15, fixed to the external shell 6 by means of an adhesive. This protects the structural integrity of the flange 12 and the chamber seal 11.

[0139] The chamber seal 11, the flanges 12, the gasket 14 and the structural frame 15 are collectively referred to as the vacuum seal 16. The general construction principles and geometry of the vacuum seal 16 may remain consistent over multiple embodiments of the design, though minor changes in geometry can be implemented depending on the container shape and other requirements.

[0140] Referring now to FIG. 6, it can be seen that the overall shape of the inner and outer shells 6, 8 of the lid 3 and the body 2 are adjusted based on functional requirements of the lid 3 and the body 2, respectively. Furthermore, the lid 3 employs a vacuum seal 16 having a similar construction to the vacuum seal 16 of the body 2, except that the optional structural frame 15 has a slightly different shape, as will be discussed below.

[0141] In order to create a sealed internal air space 4, the lid 3 and body 2 are brought together so that the vacuum seals 16 of both the lid 3 and the body 2 are aligned with one another. Sealing surfaces 17 of the compressible gaskets 14 meet when a mechanical downward force 18 is applied to the lid 3 pressing it onto the body 2.

[0142] FIG. 7 shows the lid 3 and the body 2 assembled together. The flexible natures of the gaskets 14 allow absorption of minor unevenness in the flange geometry, allowing the container to maintain an airtight seal 19.

[0143] The structural frame 15 of the lid 3 is optionally provided with a lip edge 20 located around the outer perimeter of the structural frame 15. The lip edge 20 extends vertically downwards past the flange 12 of the body 2, when the lid 3 and body 2 are assembled together. The lip edge 20 allows for alignment of the vacuum seals 16 of the lid 3 and body 2. The lip edge 2 further covers the airtight seal 18 from external physical access.

[0144] In a modification shown in FIG. 7b, the structural frame 15 of the lid 3 and the structural frame 15 of the body 2 may each overlap (a) fully with its respective gasket 14 in a direction normal (e.g. vertical) to a direction in which its respective gasket 14 extends (e.g. horizontal). Thus, good physical shielding protection for each gasket is assured.

[0145] Furthermore, the structural frames 15 of the lid 3 and body 2 may internest or overlap with one another in the up/down direction when the lid 3 is positioned above the body 2. In this case, lip edge 21 of the structural frame 15 of the body 2 may be nested within the lip edge of 20 of the structural frame 15 of the lid 3. This may assist, for example, in keeping falling rain, snow or other potential unwanted materials away from the gaskets 14 while also providing good physical protection for the gaskets 14 and chamber seals 10, also assisting advantageously in positioning the lid 3 on the body 2.

[0146] FIG. 7b also shows an optional downward extent portion 22 of the structural frame 15 of the body which may be optionally incorporated to provide additional support on the body 2 in the region of the gasket 14 and chamber seal 11. Thus, the structural frame 15 of the body 2 may have a greater vertical extent than that of the lid 3 in a configuration with the lid 3 placed above the body 2.

[0147] The optional structural frames 15 when present may run fully round or substantially fully round outer peripheries of the lid 3 and body 2.

[0148] FIG. 7c shows a modification of the first embodiment in which a locator means or member 23 is incorporated into the lid 3. The locator member 23 when present may be formed as a rib 23. The rib 23 may run fully or substantially fully around the lid 3 near a peripheral outer edge of the inner shell 8 thereof, and may extend from the inner shell 8 of the lid 3, being positioned so as to overlap with the inner shell 8 of the body 2, sitting close to or engaging with the same in order to assist in well positioning the lid 3 on the body 2. When the gaskets 14 of the lid 3 and body 2 have substantially the same cross section as one another at sealing interface surfaces thereof, this may therefore assist in placing the lid 3 on the body 2 in a desired engagement configuration thereof with a full engagement between the gaskets 14.

[0149] The structural frames 15 of FIGS. 7, 7b and 7c may instead be called shields or shield members. They serve well to perform a shielding function for the gaskets 14 and chamber seals 11.

[0150] FIGS. 8 to 10 illustrate a second embodiment of an insulated container 101.

[0151] The structure of the insulated container 101 of the second embodiment is similar to that of the insulated container 1 of the first embodiment and, in particular, may include similar flexible seals and gaskets and inner and outer shell parts with flanges in a common plane (for each of the body and lid). Accordingly, features that have already been described will not be described again, and only those features that differ from the first embodiment will be described. Features present in both embodiments are indicated in the second embodiment using the same reference number as the first embodiment, but incremented by 100.

[0152] FIG. 8 shows the insulated container 101 comprising a body 102 and a lid 103, where the lid 103 is fastened to the body 102 by means of an even number of fasteners 122. Fasteners 122 are placed on opposing sides of the insulated container 101 in equal numbers. In usage, the opposing sides of the container 101 represent a latch side 123 and a hinge side 124 and these sides are interchangeable. For the purpose of these drawings, the latch side 123 is shown on the left and the hinge side 124 is shown on the right.

[0153] Referring to FIG. 9, each fastener 122 is permanently mounted to the lid 103 and the fasteners 122 are identical for both the latch side 123 and the hinge side 124. The design of the insulated container 101 is laterally symmetrical about a centre line 125.

[0154] FIG. 10a shows how the fastener 122 functions when on the latch side 123. The fastener 122 comprises two pins mounted to a fastener body 127. The fastener 122 interfaces with a mount block 131 by means of two pins 128, 129 each providing a specific function. A hinge pin 128 provides an axis of rotation for the fastener 122 to rotate with respect to the lid 103. A lock pin 129 mechanically locks the position of the fastener 122 in relation to the mount block 131. The mount block 131 is constructed in a semi-flexible material allowing plastic deformation under high load without resulting in permanent deformation of the mount block 131.

[0155] The process of latching the fastener 122 involves applying a manual rotation force 132 to the fastener 122 in towards the mount block 131 by a user. When the lock pin 129 reaches the mount block 131, it engages a compression ramp surface 133 of the mount block 131 causing the fastener 122, and consequently the lid 103, to be pulled downwards applying a downwards compression force 118 from the manual rotation force 132 applied by the user. This downwards force 118 acts on the opposing gaskets 114 of the lid 103 and body 102. The compression force 118 results in a tight seal along the gasket interface surface 119.

[0156] FIG. 10b shows the fastener 122 in a fully opened position 134 when it has reached a predefined maximum angle of rotation in relation to the lid 103. In the present embodiment the maximum angle is slightly beyond 90 degrees (approximately 95 degrees) from the locked position. This maximum angle is controlled by a hard stop mechanical interface 135 between the fastener 122 and a stop 130 provided on the lid 103. In the present embodiment, the stop 130 is formed as part of the structural frame 115 of the lid 103. Additional upwards or rotational force 136 of the fastener 122 after it has reached the fully open position 134 will result in lifting of the entire lid 103 away from the body 102.

[0157] FIG. 10c depicts how the fastener 122 functions when on the hinge side 124. The hinge pin 128 rests in a hinge pin resting track 138. On the side of the insulated container 101 acting as the hinge side 124, the hinge pin resting track 138 provides support for the hinge pin 128 during normal rotation of the lid 103. When the lid 103 reaches the predetermined maximum angle of rotation, as shown in FIG. 10d, further rotation will be prevented by the rotational hard stop interface 135 between the fastener 122 and the stop 130.

[0158] Referring to FIG. 10d, in the event of the lid 103 being subject to excessive mechanical lateral force 140 once it has reached its maximum rotation angle, the hinge pin 128 will begin to apply pressure to a hinge pin break away compression edge 139 of the mounting block 131. When this pressure is sufficiently high, it will result in temporary, elastic deformation of this compression edge 139, allowing the lid 103 and fastener 122 to over-rotate and break away from the body 102 of the insulated container 101.

[0159] In this action, a lock pin stop surface 141 engages with the lock pin 129 to cause the fastener body 127 to act as a lever arm that concentrates the rotational forces at the hinge pin on the hinge pin break away compression edge 139.

[0160] The fastener 122 is therefore capable of acting as both a latch, as shown in FIG. 10e, or as a hinge as shown in FIG. 10f. This advantageously allows for the insulated container 101 to be hingedly opened from either side. Furthermore, the breakaway function of the fastener 122 prevents excessive opening force being applied to the fastener 122. This is important because excessive load could damage the flanges 112 of the outer shells 106, thereby risking damage to the chamber seal 111.

[0161] Whilst not shown in the figures, the containers 1, 101 of both the first and second embodiments described above may be provided with a handle or carrying strap to facilitate lifting of the container 1, 101.