Unitary double walled container and method for making

Abstract

A single-piece seamless construction container formed from a thermoformable material, the container including a vessel, at least one wing, and at least one hinge coupling the wing to the vessel. The wings comprise a patterned surface, although only the vessel, or the wings and the vessel may also be configured to include a patterned surface. The wings are configured to wrap about the container with the patterned surface serving to trap air between an outer surface of the vessel and an inner surface of the wing. The trapped air and the wing forms an insulative air gap between a surface of the container and the wing. The container may be nestably stacked in a wing open or wing closed position.

1 . A container comprising: 
 a single-piece two walled beverage container.    
   
   
       2 . A single-piece two walled nestable seamless container comprising: 
 a bottom and a side-wall integral therewith;    a rim located distal to the bottom;    at least one wing; and,    at least one hinge coupling the rim and the wing.    
   
   
       3 . A container comprising: 
 a vessel having an upper surface;    at least a first wing; and,    means for coupling the upper surface of the vessel and the first wing.    
   
   
       4 . A container according to  claim 3 , wherein the coupling means is a hinge.  
   
   
       5 . A container according to  claim 3 , the container further including a sidewall.  
   
   
       6 . A container according to  claim 3 , wherein the first wing is in surrounding contact with the vessel.  
   
   
       7 . The container according to  claim 3 , wherein the vessel further comprises: 
 a closed bottom, the closed bottom having a punt formed therein;    an open top located distal to the closed bottom;    an upper sidewall and a lower sidewall; and,    ribbing formed on the lower sidewall.    
   
   
       8 . A container according to  claim 7 , wherein the first wing is in surrounding contact with the upper sidewall portion of the vessel.  
   
   
       9 . The container according to  claim 3 , wherein the upper surface comprises a rim.  
   
   
       10 . The container according to  claim 3 , wherein the container is made of polyethylene.  
   
   
       11 . The container according to  claim 3 , wherein one of the first wing and the vessel is transparent.  
   
   
       12 . The container according to  claim 3 , wherein the first wing and the vessel are transparent.  
   
   
       13 . The container according to  claim 3 , the container further comprising: 
 a tab disposed on a first edge of the first wing; and    a receiver disposed a second edge of the first wing.    
   
   
       14 . The container according to  claim 13 , wherein the tab is selectively coupled with said receiver.  
   
   
       15 . The container according to  claim 13 , wherein the tab disposed on the first edge of the first wing is an adhesive tab attachable to the second edge of the first wing.  
   
   
       16 . The container according to  claim 3 , the container further comprising: 
 a surface pattern disposed on one of the first wing and the vessel.    
   
   
       17 . The container according to  claim 3 , the container further comprising: 
 a surface pattern disposed on the first wing and the vessel.    
   
   
       18 . The container according to  claim 16 , said surface pattern trapping air between said first wing and said vessel.  
   
   
       19 . The container according to  claim 17 , said surface pattern trapping air between said first wing and said vessel.  
   
   
       20 . The container according to  claim 16 , wherein said surface pattern is a hemisphere.  
   
   
       21 . The container according to  claim 16 , wherein said surface pattern is a slogan.  
   
   
       22 . The container according to  claim 16 , wherein said surface pattern is fluted.  
   
   
       23 . The container according to  claim 16 , wherein said surface pattern is ridged.  
   
   
       24 . A container comprising: 
 a container having a rim;    a first wing and at least a second wing;    a hinge coupling the rim of the container and the first wing; and    a hinge coupling the rim of the container and the second wing.    
   
   
       25 . The container according to  claim 24 , the container further comprising: 
 a tab disposed on an edge of the first wing; and    a receiver disposed an edge of the second wing.    
   
   
       26 . The container according to  claim 25 , wherein the tab is selectively coupled with the receiver.  
   
   
       27 . The container according to  claim 24 , wherein the first wing and the second wing are selectively coupled about the container.  
   
   
       28 . The container according to  claim 24 , the container further comprising: 
 a surface pattern disposed on said first wing and said second wing.    
   
   
       29 . The container according to  claim 28 , said surface pattern trapping air between said first and second wings and said container.  
   
   
       30 . The container according to  claim 28 , wherein said surface pattern is a hemisphere.  
   
   
       31 . The container according to  claim 28 , wherein said surface pattern is a slogan.  
   
   
       32 . The container according to  claim 28 , wherein said surface pattern is fluted.  
   
   
       33 . The container according to  claim 28 , wherein said surface pattern is ridged.  
   
   
       34 . A hinge for use in a unitary double walled container comprising: 
 a rim;    a rim arm attached to the rim, the rim arm being shorter than the diameter of the rim; and    a wing arm attached to the rim arm and forming an acute angle.    
   
   
       35 . A container comprising: a cup formed by thermoforming, stamping, and then thermoforming.  
   
   
       36 . A method for manufacturing a container, the method comprising the steps of: 
 a) providing a sheet of thermoformable material;    b) placing the sheet of thermoformable material on a container making machine to thermoform at least one vessel from the thermoformable material sheet;    c) thermoforming the vessel;    d) stamping the outline of at least one wing;    e) stamping the outline of the means for coupling at least one wing to the vessel;    f) thermoforming the contour of at least one wing;    thermoforming a rim on the vessel; and,    thermoforming at least one coupling means, the coupling    means coupling at least one wing to the vessel.    
   
   
       37 . The method of  claim 36 , further comprising: 
 g) wrapping at least one wing about the vessel.    
   
   
       38 . The method of  claim 37 , further comprising: 
 h) securing the wing about the vessel by way of fastening means.    
   
   
       39 . The method of  claim 36 , wherein the means for coupling is a hinge.  
   
   
       40 . The method of  claim 36 , wherein step (c) further includes: thermoforming a lower sidewall, the lower sidewall including support ribbing; and thermoforming a punt.  
   
   
       41 . The method of  claim 36 , wherein step (f) further includes thermoforming a surface pattern on a wing.