Overwrap Container Clamping to Preserve a Uniform Air Gap
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Solution Overview
Problem
Existing thermally insulated containers with double wall construction and air gaps fail to maintain a uniform air gap between inner and outer walls, leading to discomfort when holding hot or cold beverages due to mechanical clamping during the overwrap formation process, which eliminates the air gap in seam areas and creates an uneven holding surface.
Innovation Solution
A method and apparatus for forming an overwrap container by providing a base container with connecting elements and an overwrap, clamping the overwrap along specific seams and areas to create compressed zones, and then reforming these zones to establish a substantially uniform air gap between the inner and outer walls except at the compressed areas, using a mechanized arrangement with clamping and reforming mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical clamping is applied during overwrap formation, then the overwrap is securely joined to the base container, but the air gap is eliminated in seam areas creating an uneven holding surface
Solution Approach 1:
The patent applies different clamping forces to different areas of the overwrap. The seam areas receive full clamping force for secure joining, while the area 180° removed from the seam receives reduced or no clamping force to preserve the air gap. This localized differentiation of clamping intensity resolves the contradiction between secure joining and air gap uniformity.
Solution Approach 2:
The overwrap formation process is segmented into multiple clamping zones: a first clamping zone at the seam area for strong joining, and a second clamping zone 180° removed from the seam with modified clamping characteristics. This segmentation allows independent optimization of joining strength and air gap preservation in different regions.
2Reliability
If uniform clamping is applied around the entire overwrap, then consistent joining is achieved, but the air gap is eliminated at the area 180° removed from the seam creating discomfort
Solution Approach 1:
The patent implements location-dependent clamping characteristics where the first clamping zone at the seam provides consistent joining, while the second clamping zone 180° removed from the seam provides modified clamping (reduced force or extended duration) to preserve the air gap for holding comfort. This local quality differentiation resolves the contradiction between joining consistency and holding comfort.
3Strength
If the overwrap is tightly clamped to ensure secure attachment, then the container structure is strengthened, but the thermal insulation performance is reduced due to air gap elimination
Solution Approach 1:
The patent applies strong clamping at the seam area to ensure structural strength and secure attachment, while applying modified clamping at the area 180° removed from the seam to preserve the air gap for thermal insulation. This localized approach maintains structural integrity where needed while preserving thermal performance where the air gap is most effective for insulation.
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 ensures a comfortable and uniform air gap around the periphery of the container, maintaining thermal insulation while preventing discomfort from holding hot or cold contents, and addressing the issue of air gap elimination in previous designs.
Implementation Method 1
The second mechanized arrangement includes a reforming arrangement, such as a vacuum reformer, which acts to separate the overwrap from the base container at the second clamped position, thereby, reestablishing the air gap
Data Source
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AI summary
A method for forming an overwrap container includes the steps of a) providing a base container having a first side seam on a side wall that extends along a longitudinal axis to define an internal volume, and a bottom secured to the side wall; b) providing the side wall of the base container with connecting elements on an outer periphery of the side wall; c) providing an overwrap having a second side seam over the side wall of the base container such that the overwrap is joined in spaced apart relationship by the connecting elements to the side wall of the base container; d) clamping the overwrap to the base container along the second side seam to form a first compressed area; e) clamping the overwrap to the base container in an area 180° removed from the second side seam to form a second compressed area: and f) reforming the second compressed area to define an overwrap container having a substantially uniform spacing and air gap between the base container and the overwrap except in the first compressed area.