Vacuum insulated container

Abstract

A two component box has a lid and a lower body portion; both the lid and the lower body portion have an interior compartment substantially surrounded by at least one interior wall and at least one exterior wall. At least one interior wall and at least one exterior wall of the lid are attached one to the other by a first connecting portion and at least one interior wall and at least one exterior wall of the lower body portion being attached one to the other by a second connecting portion. Disposed between the at least one interior wall and the at least one exterior wall is a vacuum.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable

FIELD OF THE INVENTION

This invention relates to an insulated box for substantially maintaining the temperature within the box through use of a vacuum.

BACKGROUND OF THE INVENTION

Hauling temperature sensitive freight over long distances or storing it for an extended period of time is problematic in that the freight often times must either be kept cooler or warmer than the outside environment. A total vacuum does not conduct heat nor are there molecules within a vacuum to transfer heat through convection. A container having a vacuum or semi-vacuum significantly improves the insulating qualities of the container. Energy savings are very desirable and there is a need for a container that reduces energy requirements while maintaining a desired temperature range. This need can be filled by the vacuum container of the instant invention as it provides a vacuum chamber or annulus for heightened insulating qualities.

The instant invention, as disclosed within this application, fills this need. The art referred to and/or described within this application is not intended to constitute an admission that any patent, publication or other information referred to herein is “prior art” with respect to this invention. In addition, this section should not be construed to mean that a search has been made or that no other pertinent information as defined in 37 C.F.R. §1.56(a) exists.

All US patents and applications and all other published documents mentioned anywhere in this application are incorporated herein by reference in their entirety.

Without limiting the scope of the invention a brief summary of some of the claimed embodiments of the invention is set forth below. Additional details of the summarized embodiments of the invention and/or additional embodiments of the invention may be found in the Detailed Description of the Invention below.

A brief abstract of the technical disclosure in the specification is provided as well only for the purposes of complying with 37 C.F.R. 1.72. The abstract is not intended to be used for interpreting the scope of the claims.

BRIEF SUMMARY OF THE INVENTION

In at least one embodiment, a box can comprise an outer bottom case disposed about a bottom interior set of walls (e.g. having an open side and/or an open top as shown in FIG. 6), an upper interior cover, an upper exterior cover, a front inner panel, and a front outer panel. The outer bottom case can have elongated support struts extending along the outer bottom case from the bottom case floor towards the bottom case top. The bottom interior set of walls can be constructed to have a lip which alone engages the bottom case. In the space between the bottom case and the bottom interior set of walls a vacuum can be produced. A vacuum can also exist in the void spaces between the upper interior cover and the upper exterior cover and between the front inner panel and the front outer panel. The inner compartment of the box can be substantially defined by the bottom interior set of walls and the upper interior cover and the front inner panel.

In at least one embodiment the front inner panel can be a portion of the bottom interior set of walls and the front outer panel can be a portion of the outer bottom case.

In at least one embodiment, a vacuum valve can be included and used to create a vacuum within the void spaces. The vacuum valve can be directly engaged to the box such that a void space is in fluid communication with a vacuum pulling device through the vacuum valve.

In at least one embodiment, a pallet portion can be attached to the bottom of the outer bottom case, the pallet portion having slots spaced and sized for being carried by a forklift.

In at least one embodiment, insulating material can also fill the void spaces. Insulating material can include an amorphous volcanic glass (e.g. perlite).

These and other embodiments which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for further understanding of the invention, its advantages and objectives obtained by its use, reference should be made to the drawings which form a further part hereof and the accompanying descriptive matter, in which there is illustrated and described embodiments of the invention.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

A detailed description of the invention is hereafter described with specific reference being made to the drawing.

FIG. 1 is a schematic perspective view of an embodiment of the invention.

FIG. 2 is a schematic perspective view of an embodiment of the invention in cross-section.

FIG. 2a is a cross-sectional view of a wall portion including a valve.

FIG. 3 is a flat view of a wall of an embodiment of the invention.

FIG. 3a is a cross-sectional view of a wall of an embodiment of the invention.

FIG. 4 is a perspective view of the outer walls of and embodiment of the invention.

FIG. 5 is a perspective view of an embodiment of the invention.

FIG. 6 is a perspective view of an embodiment of the invention.

FIG. 7 is a perspective view of an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

While this invention may be embodied in many different forms, there are described in detail herein specific preferred embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated. It should be noted that the term “vacuum” does not indicate that the vacuum be perfect or complete. As used here, a vacuum exists at 200 torrs or less. In some embodiments the vacuum has a substantially lower pressure; in some embodiments the vacuum has a pressure of 1 to 10⁻³ torr, in some embodiments the vacuum has a pressure of 10⁻³ to 10⁻⁸ torr, and in some embodiments substantially equal to or substantially less than 10⁻⁹ torr. As used herein the term “connecting portion” identifies a portion of the lid and/or lower body portion that connects the panels or walls between which a vacuum is formed. Some examples are part identifiers 29, 29′, and 32.

In the embodiment of FIG. 1 a perspective view of a box 10 having an inventive vacuum space is illustrated. The box 10 is illustrated in FIG. 2 in cross-section. In FIG. 2 the embodied box 10 has a lid 85, a lower body portion 80, and a storage space 20. The lid 85 and/or lower body portion 80 can comprise composite wall(s) 30 having a vacuum between two substantially parallel surfaces. The structure of the composite wall 30 is shown in more detail in FIG. 2a which is a wall portion 40 of the lower body portion 80 of FIG. 2 and further includes a valve 45 for pulling a vacuum within vacuum space 30c. In FIG. 2a composite wall 30 is better detailed to illustrate components, namely, interior wall 30a and exterior wall 30b which are separated by vacuum space 30c. The lid 85 can have the same components including the valve as shown in FIG. 2a. It should be noted that in some embodiments interior wall 30a and exterior wall 30b are not substantially parallel.

As shown in FIG. 2b walls 30a and 30b of lower body portion 80 can be connected by connecting portions 29 and interior wall 30a′ and exterior wall 30b′ of lid 85 can be connected by connecting portions 29′. The connecting portions 29 and 29′ can be constructed of the same piece of material as that of the interior and exterior walls that they connect. In some embodiments the connecting portions 29 and 29′ can be constructed of a different material and/or piece of material as that of the interior and exterior walls that they connect.

In some embodiments the vacuum space(s) 30c and/or 30c′ has perlite or some other insulating material disposed therein.

In some embodiments, the box 10 can have a height, width, and/or depth of greater than 2 feet. In some embodiments the box 10 can have a height, width, and/or depth of greater than 20 feet. In some embodiments the box 10 is integral to a truck (e.g. the storage portion of a tractor trailer). In some embodiments, the box 10 is the entire box of a railroad boxcar, or the entire cargo portion of a van, truck, or trailer of a tractor trailer. In some embodiments the box 10 is only a portion of a box of a railroad boxcar or only a portion of the cargo portion of a van, truck, or trailer of a tractor trailer. In some embodiments, the box 10 is an entire room, storage facility, and/or warehouse. There are multiple other structures and storage facilities that can be constructed with walls having a vacuum as this invention can be used in place of other temperature insulating walls, panels, and/or barriers.

In some embodiments, as shown in FIG. 3, the box 10 has handles 50 for lifting. The handles 50 are shown disposed in a recessed portion 57 in a wall of the lower body 80 of the box 10. In some embodiments one or more handles can be disposed within the lid 85. In some embodiments, one or more handles 50/50′ are disposed on multiple walls of the box 10. As shown in FIGS. 3 and 3a multiple types of handles 55/55′ can be disposed on a single wall 30 of the box 10. A wall can have a recessed portion 57 having a handle 55. A hand can enter the recessed portion 57 and grasp the handle 55. The handle 55 can be tubular. The handle 55 can be a separate piece that is disposed within the recessed portion 57.

In some embodiments the recessed portion 57′ is configured such that it has a finger space 58′ and forms a handle 55′. As noted previously one or more handles and/or types of handles can be on a given wall 30. In some embodiments one handle can be on one wall 30 and another handle on the wall 30 directly opposite. Handles can be disposed on any of the boxes disclosed in this application.

In FIG. 4 an embodied box 10 is shown in cross-section. The lower body portion 80 has a composite wall 30 comprising exterior walls 30b and interior walls 30a and a vacuum 30c there between the interior and exterior walls. The lid 85 has a composite wall comprised of interior wall 30a′ and exterior wall 30b′ and vacuum 30c′ there between interior wall 30a′ and exterior wall 30b′. As shown, interior wall 30a is constructed from a separate work piece than that of exterior wall 30b. Here, interior wall 30a includes an interior lip 32 that contacts or rests on an exterior lip 33 of exterior wall 30b. The lower body seal 34 can assist in maintaining the vacuum 30c between the interior wall 30a and exterior wall 30b. The bottom portion of inner walls 30a and/or exterior walls 30b′ can include struts or support bosses 65 as shown. These struts/bosses 65 can provide added support between interior walls 30a and exterior walls 30b. In some embodiments the struts/bosses 65 are not included and separation between the bottom portion of interior walls 30a and exterior walls 30b is maintained in large part by support at the interface of interior lip 32 and exterior lip 33. In some embodiments, the lower body seal 34 is not used and inner wall 30a and/or exterior wall 30b are not readily separable (e.g. the walls are designed to fixedly remain connected). In some embodiments, interior walls 30a and exterior walls 30b are formed of the same integral piece. In some embodiments, interior walls 30a and exterior walls 30b are affixed together by welding.

Lid 85 as illustrated in FIG. 4 is also shown to have interior wall 30a′ constructed from a separate work piece than that of exterior wall 30b′. Here, interior wall 30a′ engages exterior wall 30b′. The lid seal 36 can assist in maintaining the vacuum 30c′ between the interior wall 30a′ and exterior wall 30b′. Interior wall 30a′ and/or exterior wall 30b′ can include struts or support bosses 65 as shown. These struts/bosses 65 can provide added support between interior walls 30a′ and exterior walls 30b′. As with the lower body 80, in some embodiments the struts/bosses 65 are not used in the construction of the lid 85. In some embodiments, the lid seal 36 is not used and inner wall 30a′ and/or exterior wall 30b′ are not readily separable (e.g. the walls are designed to fixedly remain connected). In some embodiments, interior walls 30a′ and exterior walls 30b′ are formed of the same integral piece. In some embodiments, interior walls 30a′ and exterior walls 30b′ are affixed together by welding.

As shown in FIG. 4, the lid 85 contacts the lip 32 of interior wall 30a. Storage seal 31 can be used to assist in maintaining the temperature within the storage space 20. The portion of the lid 85 contacting the lip 32 of interior wall 30a can be constructed of a material with a high R-value such that heat is exchanged more slowly through this point of contact. In some embodiments a rubber and/or plastic is used at the point of contact between the lip 32 of inner wall 30a and lid 85. The rubber and/or plastic used at the point of contact can be part of the lip 32 and/or part of the lid 85. It should be noted that seals 31, 34, and 36 can extend around the entire circumference of lips 33, 32, and outer wall 30b′. In some embodiments the seals 31, 34, and 36 are not recessed within lips 33, 32, and outer wall 30b′. In some embodiments rubber and/or plastic in the form of a flat gasket is used in place of seals 31, 34, and 36. The gaskets can extend about a portion or the entire circumference of lips 33, 32, and/or outer wall 30b′. The rubber and/or plastic can be in the form of a sheet in some embodiments. In some embodiments the sheet of rubber and/or plastic inhibits heat transfer between the contacting surfaces. In some embodiments multiple seals and/or gaskets can be used on lips 32 and/or 33. In some embodiments one or more seal and/or gasket can be applied to the horizontal portion and the vertical portion of the lip 32 to form a seal between the lid 85 and the interior wall 30a. In some embodiments one or more seal and/or gasket can be applied to the horizontal portion and the vertical portion of the lip 33 to form a seal between the exterior wall 30b and the interior wall 30a. In some embodiments of any of the boxes disclosed the sealing of the vacuum portion 30c/30c′ is facilitated by the pulling of the vacuum as the surfaces being sealed are brought closer to one another through the vacuum creation process.

In some embodiments as illustrated in FIG. 4 the lid 85 is secured to the lower body 80 by clasps 90. In some embodiments the clasp 90 snaps over ridge 92 to secure the lid 85 to the lower portion 80. In some embodiments a single clasp 90 is used as the lid 85 is hinged to the lower body 80 on one side. Many forms of securing the lid 85 to the lower body 80 are contemplated within this invention; screwing or bolting, adhesives, soldering or welding, clamping, magnetism, and any combination thereof.

The use of the terms “lower body portion” and “bottom portion” are merely used in describing the details based on the orientation of FIGS. 1-4 and any other applicable figures herein which are identified as having a “lower body portion” and/or “bottom portion”. In use the box 10 may rest on the exterior wall adjacent the lid or may even rest on its lid.

In FIG. 5 a portion of an embodied lower body portion 80 having a top and side opening is shown. The exterior walls 30b with support struts 60 are shown. The lower body portion 80 includes a seal within seal groove 81. The seal can be an o-ring vacuum seal that in some embodiments is compressed when a vacuum is applied. The exterior walls 30b can have interior walls 30a disposed within the space formed by exterior walls 30b as shown in FIG. 6. The wall support struts 60 can provide support for the exterior walls 30b when a vacuum is pulled in the vacuum space disposed between exterior wall 30b and interior wall 30a. In some embodiments as shown in FIG. 5, bottom support struts 65 can be used. They can have a grid pattern as shown in FIG. 5 or struts extending in a single direction. The struts 60 are shown to taper from the bottom to top. In some embodiments, there is no taper, the taper is less pronounced, or the taper extends from top to bottom. In some embodiments the wall struts 60 and/or the bottom struts 65 taper differently from other wall struts 60 and/or bottom struts 65.

The support struts 60 and 65 shown in FIG. 5 can also be applied to the interior walls 30a. The struts 60 and 65 can be applied to the inside and/or outside of the interior walls 30a and exterior walls 30c. In some embodiments, the support struts applied to the interior walls do not contact the support struts applied to the exterior walls. In some embodiments contact between the support struts applied to the interior walls and to the exterior walls does occur. In some embodiments, the support struts supporting the exterior walls also support the interior walls.

In some embodiments, skid openings 68 are included with the box 10 as shown in FIG. 5. The skid openings 68 can be used by a lift truck or pallet jack when moving the box 10.

As shown in FIG. 5, a material port 96 can be disposed within port recess 94 on lower portion 80. A material port 96 can be disposed on all of the boxes disclosed within this application and can provide fluid communication between the vacuum portion and the outside of the box 10. The port 96 can be used in the lid 85 or lower portion 80 and can be used to introduce insulating material within the vacuum portion (identified as 30c or 30c′ throughout the application). As shown, the port 96 is disposed on the opposite side of the lower portion 80 from the vacuum valve 45 (e.g. shown in FIG. 7). In some embodiments disposing the vacuum valve 45 and that material port 96 on opposite sides of the box facilitates a more complete and/or even distribution of the insulating material within the vacuum portions.

In some embodiments a material port 96 is not disposed on the box 10. In some embodiments, the material port 96 and the vacuum valve 45 can be disposed in a wide range of configurations and/or distances from one another on the box 10 (e.g. there can be one or more vacuum valves and/or material ports also and/or they can be disposed immediately beside one another and/or at the furthest points from one another on the box).

The insulating material can be included in the vacuum portion for purposes of maintaining a better thermal barrier in case the vacuum is weak, punctured, damaged, and/or fails. In some embodiments a filter is included in the vacuum valve port 45 to prevent insulating material passing through the vacuum valve port. In some embodiments an access door is attached to the recessed pocket and/or the port recess 94. Though a recessed pocket is desirable in many embodiments, the valves, gauges, indicator lights, and ports need not be within the recessed pocket 90. In some embodiments some are within the recessed pocket while others are not.

In some embodiments as shown in FIG. 6, the box 10 has an interior opening 70 that comprises the top 72 and a side 74 of the box 10. The opening 70 of FIG. 6 can allow items to be placed in and taken out of the box more easily than with a box having an opening in only the top as the box of FIGS. 1-4. As shown, the lid 85 folds up. In some embodiments the lid 85 is rigid and does not fold. In some embodiments, the lid only comprises a portion of a top and/or side rather than an entire side or top as illustrated in FIGS. 1-6. In some embodiments, the lid 85 can be secured or latched to the body portion of the box 10 (e.g. as used by securement device 90 as shown in FIG. 4). In some embodiments two or more securement devices (e.g. latches, clasps, snaps, etc.) can be used on each side of the box 10. In some embodiments one or more securement devices 90 are used on the top of the lid 85 and/or one or more securement devices 90 are used on the side of the lid 85.

In some embodiments the lid 85 and/or lower body portion 80 each include a single vacuum valve 45. In some embodiments multiple vacuum valves can be included. In some embodiments a recessed pocket 90 is included in the lid 85 and/or lower body portion 80. FIG. 7 illustrates a recessed pocket 90, here disposed in the lower body portion 80. A vacuum valve port 45 is included as well as a “vacuum indicator gauge”/“warning indicator light” 92. Other equipment that can be placed within the pocket 90 is a material port (as shown in FIG. 5) for inserting insulating material within the vacuum portion (identified as 30c or 30c′ throughout the application). The insulating material can be included in the vacuum portion for purposes of maintaining a better thermal barrier in case the vacuum is punctured, damaged, and/or fails. In some embodiments a filter is included in the vacuum valve port 45 to prevent insulating material passing through the vacuum valve port. In some embodiments an access door is attached to the recessed pocket. Though a recessed pocket is desirable in many embodiments, the valves, gauges, indicator lights, and ports need not be within the recessed pocket 90. In some embodiments some are within the recessed pocket while others are not.

Throughout this application it should be understood that the shapes used for the box 10 are illustrative. In some embodiments the box is cylindrical.

The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. The various elements shown in the individual figures and described above may be combined or modified for combination as desired. All these alternatives and variations are intended to be included within the scope of the claims where the term “comprising” means “including, but not limited to”.

Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly from claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific claim listed in such dependent claim below.

This completes the description of the preferred and alternate embodiments of the invention. Those skilled in the art may recognize other equivalents to the specific embodiment described herein which equivalents are intended to be encompassed by the claims attached hereto.

Claims

1. A two component box having a lid and a lower body portion; both the lid and the lower body portion having an interior compartment substantially surrounded by at least one interior wall and at least one exterior wall, the at least one interior wall and the at least one exterior wall of the lid being attached one to the other by a first connecting portion and the at least one interior wall and the at least one exterior wall of the lower body portion being attached one to the other by a second connecting portion; disposed between the at least one interior wall and the at least one exterior wall is a vacuum, the interior walls of the lid and lower body portion substantially defining an inner compartment, the interior walls and the exterior walls of the lower body portion having elongated support struts engaging the interior walls and the exterior walls, both the lower body portion and the lid including a vacuum valve.

2. The box of claim 1 having at least one orifice, the at least one orifice sized such that insulating material can pass from outside the box to inside the interior compartment, the interior compartment having insulating material therein.

3. The box of claim 2 wherein the insulating material is fine low density material.

4. The box of claim 2 wherein the insulating material is an amorphous volcanic glass.

5. The box of claim 1 wherein a valve recess within the lid is sized to house the vacuum valve of the lower body portion.

6. A box having an interior compartment substantially surrounded by interior walls, the interior walls surrounded by exterior walls; disposed between the interior walls and the exterior walls is a vacuum space, the box having a lower body portion and a lid, the lid sealingly engaging the lower body portion, the lower body portion having a vacuum valve disposed therein.

7. The box of claim 6 wherein the lid includes a vacuum valve disposed therein.

8. The box of claim 6 having at least one orifice, the at least one orifice sized such that insulating material can pass from outside the box to an interior space between the interior wall and the exterior wall, the interior space having insulating material therein.

9. The box of claim 8 wherein the insulating material is fine low density material.

10. The box of claim 8 wherein the insulating material is perlite.

11. The box of claim 6 wherein a valve recess within the lid is sized to house the vacuum valve of the lower body portion.

12. The box of claim 6 having a height of greater than 2 feet and a width of greater than two feet,

13. The box of claim 6 wherein the interior walls and the exterior walls of the lower body portion having elongated support struts engaging the interior walls and the exterior walls, both the lower body portion and the lid including a vacuum valve.

14. The box of claim 6 wherein the lower body portion has an upper compartment rim about the top of the lower body portion, the lid having a protruding portion that extends into or onto the upper compartment rim and contacts the upper compartment rim.

15. The box of claim 6 wherein the interior walls define a plane and the exterior walls define a plane, at least one recessed handle disposed within a recessed portion of the exterior walls, the at least one handle disposed substantially between the plane of the interior wall and the plane formed by the exterior wall.

16. A box having an outer bottom case disposed about a bottom interior set of walls, an upper interior cover, an upper exterior cover, a front inner panel, and a front outer panel, the outer bottom case having elongated support struts extending along the outer bottom case from the bottom case floor towards the bottom case top, the bottom interior set of walls having a lip which alone engages the bottom case such that a vacuum exists between the bottom case and the bottom interior set of walls, the upper interior cover and the upper exterior cover forming a void space that is a vacuum, the front inner panel and the front outer panel forming a void space that is a vacuum; the bottom interior set of walls and the upper interior cover and the front inner panel defining a compartment.

17. The box of claim 16 wherein the front inner panel is a portion of the bottom interior set of walls and the front outer panel is a portion of the outer bottom case.

18. The box of claim 16 having a vacuum valve for use in creating a vacuum within at least one of the void spaces.

19. The box of claim 16 wherein a pallet portion is attached to the bottom of the outer bottom case, the pallet portion having slots spaced and sized for being carried by a forklift.

20. The box of claim 16 wherein the compartment is substantially sealed from the outside environment.