Methods and systems for forming vacuum insulated containers

Abstract

Methods and systems for forming vacuum insulated containers, such as beverage and food containers, are described. The methods and systems include using a laser to close openings in walls of the container while the container is held at vacuum conditions. The closing of the opening forms the vacuum space within the walls of the container.

What is claimed is: 
     
         1 . A vacuum insulated container, comprising:
 an inner shell;   an outer shell;   an intershell space between the inner shell and the outer shell;   a portion of the outer shell forms a side of the container;   a bottom portion generally opposite of an upper portion;   one or more openings in the portion of the outer shell forming the side of the container; and,   one or more welds sealing the one or more openings to form a vacuum in the intershell space.   
     
     
         2 . The vacuum insulated container according to  claim 1 , wherein a bottom shell covers the one or more welds and forms the bottom portion of the container. 
     
     
         3 . The vacuum insulated container according to  claim 1 , wherein the container has a two-piece construction of only the inner shell and the outer shell. 
     
     
         4 . The vacuum insulated container according to  claim 1 , wherein the inner shell forms an interior of the container configured to hold a beverage or a food item. 
     
     
         5 . The vacuum insulated container according to  claim 1 , wherein the container has a four-piece construction, and the container further comprises an inner bottom shell and an outer bottom shell. 
     
     
         6 . The vacuum insulated container according to  claim 1 , wherein the one or more openings correspond with a design element of the container. 
     
     
         7 . The vacuum insulated container according to  claim 1 , wherein the side of the container is curved, and the one or more openings are in the curved side of the container. 
     
     
         8 . A vacuum insulated container, comprising:
 an inner shell;   an outer shell;   an intershell space between the inner shell and the outer shell;   the inner shell forms an interior of the container configured to hold a beverage or a food item;   the outer shell forms an exterior of the container;   one or more openings along an edge of the container; and,   one or more welds sealing the one or more openings to form a vacuum in the intershell space.   
     
     
         9 . The vacuum insulated container according to  claim 8 , wherein the edge of the container is between a side and a bottom portion of the container. 
     
     
         10 . The vacuum insulated container according to  claim 9 , wherein a bottom shell covers the one or more welds. 
     
     
         11 . The vacuum insulated container according to  claim 8 , wherein the edge of the container is an inside edge of the container. 
     
     
         12 . The vacuum insulated container according to  claim 8 , wherein the edge of the container is an outside edge of the container. 
     
     
         13 . The vacuum insulated container according to  claim 8 , wherein the edge of the container is curved. 
     
     
         14 . The vacuum insulated container according to  claim 8 , wherein the edge is part of the outer shell. 
     
     
         15 . A method for forming a vacuum insulated container, comprising:
 joining an inner shell and an outer shell together to form a container, wherein a portion of the outer shell forms an outer side wall of the container;   forming an intershell space between the inner shell and the outer shell;   cutting one or more openings in the portion of the outer shell forming the outer side wall of the container;   applying a vacuum to the container;   directing a laser beam at the one or more openings;   sealing the one or more openings; and,   sealing the vacuum in the intershell space.   
     
     
         16 . The method for forming a vacuum insulated container according to  claim 15 , further comprising cutting the one or more openings in the portion of the outer shell forming the outer side wall of the container wall after the joining of the inner shell and the outer shell together to form the container. 
     
     
         17 . The method for forming a vacuum insulated container according to  claim 15 , further comprising cutting the one or more openings in the portion of the outer shell forming the outer side wall of the container wall along an edge of the container. 
     
     
         18 . The method for forming a vacuum insulated container according to  claim 15 , further comprising joining a bottom shell to the container and covering the one or more openings that were sealed. 
     
     
         19 . The method for forming a vacuum insulated container according to  claim 15 , further comprising sealing the one or more openings by welding the one or more openings. 
     
     
         20 . The method for forming a vacuum insulated container according to  claim 15 , further comprising sealing the one or more openings without using solder.