Multi-layered insulated cup formed of one continuous sheet

Abstract

A thermally insulated cup or container (30) includes a smooth outer shell (12S), a smooth inner shell (13S), a corrugated layer (11L) sandwiched therebetween, and a bottom closure (14). The inner shell, corrugated layer, and outer shell are formed by simply winding a continuous elongated paper sheet (10) in a three-layered spiral, then sealing them together. The corrugated layer forms many air pockets between the shells to thermally insulate the contents of the cup, and also provide structural strength. The paper construction of the cup makes it biodegradable and recyclable, and the simple construction method of the cup makes it easy and inexpensive to manufacture.

I claim: 
     
       1. A thermally insulated container, comprising: a smooth outer shell,   a smooth inner shell concentrically positioned within said smooth outer shell,   a corrugated layer sandwiched between said smooth outer shell and said smooth inner shell, and   a bottom closure attached to a bottom portion of said smooth inner shell,   said smooth outer shell, said smooth inner shell, and said corrugated layer all formed of one continuous elongated sheet wound in a spiral,   whereby said smooth outer shell, said corrugated layer, and said smooth inner shell cooperate to define plural air pockets therebetween for providing thermal insulation for any material disposed within said container, yet said container is easy and economical to fabricate.   
     
     
       2. The thermally insulated container of claim 1 wherein said one continuous elongated sheet is paper. 
     
     
       3. The thermally insulated container of claim 1, further including a waterproof coating disposed on said smooth inner shell and said bottom closure. 
     
     
       4. The thermally insulated container of claim 3 wherein said waterproof coating is plastic. 
     
     
       5. The thermally insulated container of claim 3 wherein said waterproof coating is wax. 
     
     
       6. The thermally insulated container of claim 1, further including a reflective coating disposed on said corrugated layer for reflecting radiant heat. 
     
     
       7. The thermally insulated container of claim 1 wherein said smooth outer shell, said smooth inner shell, and said corrugated layer are formed from three separate pieces which are attached together to form said one continuous elongated sheet. 
     
     
       8. The thermally insulated container of claim 1 wherein said one continuous elongated sheet is homogeneous. 
     
     
       9. A thermally insulated container, comprising: a tapered smooth cylindrical outer shell,   a tapered smooth cylindrical inner shell concentrically positioned within said smooth cylindrical outer shell,   a corrugated layer sandwiched between said smooth cylindrical outer shell and said smooth cylindrical inner shell, and   a bottom closure attached to a bottom portion of said smooth cylindrical inner shell,   said smooth cylindrical outer shell, said smooth cylindrical inner shell, and said corrugated layer all formed of one continuous elongated sheet wound in a spiral,   whereby said smooth cylindrical outer shell, said corrugated layer, and said smooth cylindrical inner shell cooperate to define plural air pockets therebetween for providing thermal insulation for material disposed within said container, yet said container is easy and economical to fabricate.   
     
     
       10. The thermally insulated container of claim 9 wherein said one continuous elongated sheet is paper. 
     
     
       11. The thermally insulated container of claim 9, further including waterproof coating disposed on said tapered smooth cylindrical inner shell and said bottom closure. 
     
     
       12. The thermally insulated container of claim 11 wherein said waterproof coating is plastic. 
     
     
       13. The thermally insulated container of claim 11 wherein said waterproof coating is wax. 
     
     
       14. The thermally insulated container of claim 9, further including a reflective coating disposed on said corrugated layer for reflecting radiant heat. 
     
     
       15. The thermally insulated container of claim 9 wherein said smooth cylindrical outer shell, said smooth cylindrical inner shell, and said corrugated layer are formed from three separate pieces which are attached together to form said one continuous elongated sheet. 
     
     
       16. The thermally insulated container of claim 9 wherein said one continuous elongated sheet is homogeneous. 
     
     
       17. A method of making a thermally insulated container, comprising: providing a continuous elongated sheet having spaced apart first and second smooth portions connected by a corrugated portion therebetween, each of said smooth portions having two end portions,   winding said continuous elongated sheet into a three-layered spiral,   joining said end portions of said first smooth portion to form a cylindrical inner shell with a bottom portion,   joining said end portions of said second smooth portion to form a cylindrical outer shell, so that said corrugated portion is sandwiched between said cylindrical inner shell and said cylindrical outer shell, and   sealing said bottom portion of said inner shell with a bottom closure,   whereby said cylindrical outer shell, said corrugated portion, and said cylindrical inner shell cooperate to define plural air pockets therebetween for providing thermal insulation for any substance disposed within said container, yet said container is easy and economical to fabricate.   
     
     
       18. The method of claim 17 wherein said elongated sheet is paper. 
     
     
       19. The method of claim 17 wherein said smooth portions and said corrugated portion each have a predetermined length and a predetermined width, said smooth portions being wider than said corrugated portion. 
     
     
       20. The method of claim 17 wherein said smooth portions are arc-shaped so that said cylindrical shells will be tapered. 
     
     
       21. The method of claim 17, further including disposing a reflective coating on said corrugated portion for reflecting radiant heat. 
     
     
       22. The method of claim 17, further including providing said first and second smooth portions and said corrugated portion as three separate pieces and attaching said three separate pieces together to form said continuous elongated sheet. 
     
     
       23. The method of claim 17 wherein said first and second smooth portions and said corrugated portion are provided as one homogeneous sheet. .Iadd. 
     
     
       24.  A thermally insulated container, comprising: an outer shell,   an inner shell concentrically positioned within said outer shell,   a deformed layer sandwiched between said outer shell and said inner shell, and   a bottom closure attached to a bottom portion of said inner shell,   said outer shell, said inner shell, and said deformed layer all formed of one continuous elongated sheet,   whereby said outer shell, said deformed layer, and said inner shell cooperate to define plural air pockets therebetween for providing thermal insulation for any material disposed within said container, yet said container is easy and economical to fabricate. .Iaddend..Iadd.   
     
     
       25.  The thermally insulated container of claim 24 wherein said one continuous elongated sheet is paper. .Iaddend..Iadd.26. The thermally insulated container of claim 24, further including a waterproof coating disposed on said inner shell and said bottom closure. .Iaddend..Iadd.27. The thermally insulated container of claim 26 wherein said waterproof coating is plastic. .Iaddend..Iadd.28. The thermally insulated container of claim 26 wherein said waterproof coating is wax. .Iaddend..Iadd.29. The thermally insulated container of claim 24, further including a reflective coating disposed on said deformed layer for reflecting radiant heat. .Iaddend..Iadd.30. The thermally insulated container of claim 24 wherein said outer shell, said inner shell, and said deformed layer are formed from three separate pieces which are attached together to form said one continuous elongated sheet. .Iaddend..Iadd.31. The thermally insulated container of claim 24 wherein said one continuous elongated sheet is homogeneous. .Iaddend..Iadd.32. A thermally insulated container, comprising: a tapered cylindrical outer shell,   a tapered cylindrical inner shell concentrically positioned within said cylindrical outer shell,   a deformed layer sandwiched between said cylindrical outer shell and said cylindrical inner shell, and   a bottom closure attached to a bottom portion of said cylindrical inner shell,   said cylindrical outer shell, said cylindrical inner shell, and said deformed layer all formed of one continuous elongated sheet,   whereby said cylindrical outer shell, said deformed layer and said cylindrical inner shell cooperate to define plural air pockets therebetween for providing thermal insulation for material disposed within said container, yet said container is easy and economical to fabricate.   
     
     
        .Iaddend..Iadd.33.  The thermally insulated container of claim 32 wherein said one continuous elongated sheet is paper. .Iaddend..Iadd.34. The thermally insulated container of claim 32, further including waterproof coating disposed on said tapered cylindrically inner shell and said bottom closure. .Iaddend..Iadd.35. The thermally insulated container of claim 34 wherein said waterproof coating is plastic. .Iaddend..Iadd.36. The thermally insulated container of claim 34 wherein said waterproof coating is wax. .Iaddend..Iadd.37. The thermally insulated container of claim 32, further including a reflective coating disposed on said deformed layer for reflecting radiant heat. .Iaddend..Iadd.38. The thermally insulated container of claim 32 wherein said cylindrical outer shell, said cylindrical inner shell, and said deformed layer are formed from three separate pieces which are attached together to form said one continuous elongated sheet. .Iaddend..Iadd.39. The thermally insulated container of claim 32 wherein said one continuous elongated sheet is homogeneous. .Iaddend..Iadd.40. A method of making a thermally insulated container, comprising: providing a continuous elongated sheet having first and second portions and a deformed portion, each of said first and second portions having two end portions,   winding said continuous elongated sheet into a three-layered arrangement,   joining said end portions of said first portion to form a cylindrical inner shell with a bottom portion,   joining said end portions of said second portion to form a cylindrical outer shell, so that said deformed portion is sandwiched between said cylindrical inner shell and said cylindrical outer shell, and   sealing said bottom portion of said inner shell with a bottom closure,   whereby said cylindrical outer shell, said deformed portion, and said cylindrical inner shell cooperate to define plural air pockets therebetween for providing thermal insulation for any substance disposed within said container, yet said container is ease and economical to   
     
     
        fabricate. .Iaddend..Iadd.41.  The method of claim 40 wherein said elongated sheet is paper. .Iaddend..Iadd.42. The method of claim 40 wherein said first and second portions and said deformed portion each have a predetermined length and a predetermined width said first and second portions being wider than said deformed portion. .Iaddend..Iadd.43. The method of claim 40 wherein said first and second portions are arc-shaped so that said cylindrical shells will be tapered. .Iaddend..Iadd.44. The method of claim 40, further including disposing a reflective operating on said deformed portion for reflecting radiant heat. .Iaddend..Iadd.45. The method of claim 40, further including providing said first and second portions and said deformed portion as three separate pieces and attaching said three separate pieces together to form said continuous elongated sheet. .Iaddend..Iadd.46. The method of claim 40 wherein said first and second portions and said deformed portion are provided as one homogeneous sheet. .Iaddend..Iadd.47. A blank for forming a multi-layered shell of an insulated container, comprising: a continuous sheet having first and second portions, each of said portions being of a predetermined size for forming respective inner and outer layers of said shell,   said sheet having a third portion of a predetermined size suitable for forming, as part of said shell, a middle layer which is sandwiched between said inner and outer layers when said shell is formed,   said third portion having integral means which provide plural deformities therein for providing air space between said inner and outer layers of said shell, when said middle layer is sandwiched between said inner and   
     
     
        outer layers. .Iaddend..Iadd.48.  The blank of claim 47 wherein said continuous sheet is homogeneous, and said integral means are selected from the group consisting of corrugations, ribs, and dimples. .Iaddend..Iadd.49. The blank of claim 47 wherein said continuous sheet is homogeneous and comprises essentially paper, and said integral means comprises a plurality of corrugations. .Iaddend..Iadd.50. The blank of claim 47 wherein said continuous sheet is formed from one homogeneous starting sheet comprising essentially paper, said integral means comprise a plurality of ribs. .Iaddend..Iadd.51. The blank of claim 47 wherein said first and second portions each are arch shaped so as to form respective tapered shaped inner and outer layers of said shell. .Iaddend..Iadd.52. A method of making a blank for forming a multi-layered shell of an insulated container, comprising: providing one continuous sheet having first and second portions, each of said first and second portions being of a predetermined size for forming respective inner and outer layers of said shell,   said sheet having a third portion of a predetermined size suitable for forming, as part of said shell, a middle layer which is sandwiched between said inner and outer layers when said shell is formed, and   forming plural deformities in said third portion for providing air space between said inner and outer layers of said shell when said middle layer is sandwiched between said inner and outer layers. .Iaddend..Iadd.53. The method of claim 52 wherein said one continuous sheet is homogeneous, and said deformities are selected from the group consisting of corrugations, ribs, and dimples. .Iaddend..Iadd.54. The method of claim 52 wherein said one continuous sheet is homogeneous and comprises essentially paper, and said deformities comprise a plurality of corrugations. .Iaddend..Iadd.55. The method of claim 52 wherein said one continuous sheet is formed from one homogeneous starting sheet comprising essentially paper, and said deformities comprise a plurality of ribs. .Iaddend..Iadd.56. The method of claim 52 wherein said first and second portions each are arch shaped so as to form respective tapered shaped inner and outer layers of said shell. .Iaddend.