Double-Wall Cup Spacer Structure for Thermal Insulation
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Solution Overview
Problem
Existing thermally insulated containers, particularly single-use cups, fail to maintain beverages at optimal temperatures while protecting the user's hand from heat and preventing condensation issues, and they often require expensive manufacturing processes and equipment.
Innovation Solution
A double-wall container construction with a minimal number of spacer elements, such as dots or lines, applied to the exterior of a paper cup to create an insulating air gap, using materials like acrylics or hot melt adhesives, which can be processed on conventional equipment, allowing for a lightweight, cost-effective, and high-speed manufacturing system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a double-wall construction is used to improve thermal insulation, then temperature maintenance is improved, but device complexity increases
Solution Approach 1:
The container is divided into two separate walls (inner and outer) with an air gap between them, creating a segmented structure that improves thermal insulation. The spacer elements further segment the air gap into controlled regions, enhancing the insulation effect while maintaining manufacturing simplicity.
Solution Approach 2:
Air acts as an intermediary insulating medium between the inner and outer walls. The air gap, maintained by spacer elements, serves as a thermal barrier that reduces heat transfer, allowing the container to maintain beverage temperature without requiring complex active insulation systems.
2Temperature
If spacer elements are added to maintain air gap distance, then thermal insulation is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of maintaining a uniform air gap throughout the entire container, spacer elements are strategically placed at specific locations where the air gap distance is most critical for thermal insulation. This local approach provides effective insulation while minimizing the number of additional components and manufacturing steps.
Solution Approach 2:
The spacer elements are designed as simple, inexpensive components that can be easily manufactured and integrated into the container. These disposable-like elements are made from basic materials and can be attached using simple methods, keeping the overall manufacturing process straightforward and cost-effective.
3Ease of manufacture
If minimal spacer elements are used, then manufacturing simplicity is maintained, but insulation effectiveness may be compromised
Solution Approach 1:
Rather than providing continuous spacing throughout the entire container, the invention uses a partial approach with minimal spacer elements placed at key locations. This partial action is sufficient to maintain the air gap where it matters most for thermal insulation, achieving effective temperature maintenance without the complexity of complete coverage.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively maintains beverage temperatures, protects the user's hand from heat, and prevents condensation, while being simpler and less expensive to produce than traditional methods, enhancing both thermal insulation and user comfort.
Implementation Method 1
the air gap which provides good thermal insulation properties
Implementation Method 2
internal spacer elements are provided to maintain a minimum distance between the individual walls of the double wall construction
Data Source
AI summary
A container according to a preferred embodiment of the present invention provides an inner wall and an outer wall wrapped therearound so as to define a double-wall container construction. A plurality of spacer elements are interposed between the inner and the outer walls so as to maintain a minimum thickness of an air space defined therebetween. In normal use conditions, the spacer elements do not contact the inner wall; however, the spacer elements prevent the outer wall from contacting the inner wall during non-standard use conditions.