Insulated Cup Bonding Spots That Preserve the Air Gap
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing insulated containers for hot drinks lack an efficient and reliable method for bonding the inner cup and outer shell, leading to potential separation during handling and assembly, and do not effectively maintain the air gap for thermal insulation.
Innovation Solution
The use of a thermo-sealable plastic coating on the inner cup or outer shell, which is heated and molded into bonding spots or areas to securely fasten the cup and shell together, allowing for minimal fastening force retention of the inner cup within the shell, even when filled with a hot beverage, while maintaining an air gap for insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the inner cup and outer shell are fastened together by gluing or heat sealing at strategic locations, then the bonding strength is improved, but the air gap for thermal insulation is compromised
Solution Approach 1:
The bonding interface is segmented into discrete bonding spots rather than continuous bonding. The heating element contacts the cup at specific localized spots to create bonds, leaving gaps between bonding locations that preserve the air gap for thermal insulation while providing sufficient bonding strength to prevent separation during handling.
Solution Approach 2:
The heating element provides localized heating only at the bonding spots where contact occurs between the cup and shell. This creates strong bonds at specific locations while leaving the rest of the air gap intact, achieving both bonding strength and thermal insulation requirements through spatially differentiated treatment.
2Reliability
If multiple bonding spots are created around the circumference, then the reliability of bonding is improved, but the device complexity increases
Solution Approach 1:
The heating element automatically creates multiple bonding spots as it rotates with the cup during the molding process. The bonding spots are formed by the self-contained interaction between the heating element and the cup material, eliminating the need for complex external positioning systems or multiple separate bonding operations.
Solution Approach 2:
The heating element is pre-positioned to contact the cup at multiple locations around the circumference before the bonding process begins. As the cup rotates into the molding apparatus, all bonding spots are created in a single continuous operation, simplifying the overall process while ensuring reliable bonding around the entire circumference.
3Strength
If the plastic coating is heated and molded into bonding spots, then the bonding strength is improved, but the energy consumption increases
Solution Approach 1:
Heating is segmented to occur only at the specific bonding spots where the heating element contacts the cup, rather than heating the entire cup or shell. This localized heating approach minimizes energy consumption while still achieving strong bonds at the critical bonding locations.
Solution Approach 2:
The plastic coating undergoes a phase transition from solid to molten state during brief contact with the heating element, then solidifies to form a strong bond. This phase change bonding mechanism creates strong bonds with minimal energy input compared to alternative bonding methods, as the energy is concentrated only during the brief heating period at each bonding spot.
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
This method provides a strong, yet minimal, bonding between the cup and shell, ensuring the container's integrity during handling and assembly, while maintaining effective thermal insulation by preventing heat transfer through the bonding areas, thus enhancing the overall performance and usability of insulated containers.
Implementation Method 1
The coating is heated and the cup body is seated within the shell, after which at least one bonding spot and/or bonding area for fastening the shell to the cup body with the plastic coating is formed
Implementation Method 2
Because the corresponding thermo-sealable plastic coating is melted prior to inserting the cup in the shell, the cup and shell are bonded in the corresponding bonding spots and/or bonding areas by hardening of this coating as it cools
Implementation Method 3
the cup and shell are bonded in the corresponding bonding spots and/or bonding areas by hardening of this coating as it cools
Implementation Method 4
Each of the containers disclosed there includes an inner cup and an outer shell separated by an air gap
Data Source
AI summary
The invention relates to an insulated container for hot drinks or the like comprising an inner cup having a generally frusto-conical cup body and a generally frusto-conical outer shell. The cup is seated within the shell so that a contact path is disposed near the upper edge of the shell, along which contact path the outer surface of the cup body and inner surface of the shell are in contact. At least one bonding spot and/or bonding area for bonding said shell to said cup body is locally formed within said contact path.