CLEAR CHAFFER FUEL CANISTER

Abstract

The clear chaffer fuel canister of the present invention allows the users to determine the hours of burn time remaining in relation to the volume of fuel remaining. Visual indicators on the clear base vessel correspond to the predetermined burn time remaining. The volume of fuel, as it reaches the visual indicators provides the user a quick and reliable means of determining the burn time remaining with the clear chaffer fuel canister. The burn time remaining is an essential feature, as clear chaffer fuel canisters are generally used in the food industry in maintaining the proper temperature of prepared food. The burn time remaining provides an indication to the users and allows the users to determine the optimal time to replace the clear chaffer fuel canister and maintain the appropriate temperature of the displayed food.

Description

FIELD OF THE INVENTION

The present invention relates to the field of chaffer fuel canisters that allow the user to assess the level of chafing fuel. More specifically, the invention relates to a clear chaffer fuel canister and method of constructing the same.

BACKGROUND

A chafer system is a portable food or beverage warmer. Chafer system is commonly found in buffets of dinning rooms, hotels, and other institutions. A chafer system is primarily comprised of: stacked chafing dishes; a stand; and a heating source. The stacked chafing dishes allow for the prepared food to be housed in the inner chafing dish and a heat conductor that is in contact with the inner chafing dish to be housed within the outer chafing dish. The heating source is placed under the stacked chafer dishes and maintains the appropriate temperature of the heat conductor and the prepared food housed within the inner chafing dish.

Chafer system function as a heat retention system, permitting prepared food to be kept warm for a prolonged period of time. Maintaining the proper heat of the prepared food in for a prolonged period of time is imperative for proper maintenance and handling of food products. In a typical buffet type environment, food is prepared and subsequently set in chaffing dishes which are designed to maintain legal serving temperature of the prepared food. If food goes below the legal serving temperature, then the food runs the risk of spoiling, which is unsanitary and potentially dangerous for users consuming the food.

A common heating source used within the industry is a chafing fuel canister. A chafing fuel canister employs a flame to maintain the heat of food within the chafing dish. Chafing fuel canisters maintain heat only when a fuel source is present within the chafing fuel canister. The fuel source is typically comprised of an ethanol, whether liquid or gel based, which is common in the industry. The use of a chafing fuel canister can often cause problems with respect to the maintenance of legal serving temperature of the food housed within the inner chafing dish as it is not clear when the chafing fuel canister is running low on fuel and under performing. When the fuel is low, the chafing fuel canister is not maintaining sufficient heat to the prepared food.

Typically, the way the hotel or establishment employees determine that fuel in the chafer fuel canister is low is through assessment of the food temperature. By assessing the prepared food temperature within the inner dish of the chafer system an employee can determine whether the chafer fuel canister is not providing sufficient heat, which is directly correlated to the fuel remaining within the chafer fuel canister. This method of fuel level assessment is inefficient and often leads to unsanitary food conditions as the temperature can fall below the legal serving range. Additionally, replacing the chafer fuel canister once the food temperature has fallen is often not recommended as the new chafer fuel canister will require some time before it can maintain the proper heat of the chafing dish, causing the food temperature to fall even further. There is a need to provide an efficient means of determining the fuel level of the chafer fuel canister.

Various attempts have been made to provide an efficient use and means of determining the fuel level of the chafer fuel canister. Devices such as U.S. Pat. No. 5,797,739 (Lioi); U.S. Pat. No. 6,592,363 (Hoffmann); and, U.S. Pat. No. 6,694,912 (Wesley) provide such examples of efficient use and means of determining fuel levels.

All three patents described below have a number of inherent deficiencies. Firstly, none of the patents contain an efficient means of assessing the level of fuel in the chafer fuel canisters. The patents attempt to maximize the use of the fuel within the chafer fuel canister or attempt to correlate the heat emanating from the chafer fuel canister to the amount of fuel remaining. This method, like the method of measuring the temperature of food within the chafer system is not efficient and suffers from a large amount of variation.

Lioi discloses a fuel cell, or a chafer fuel canister, for use in warming or heating of food in a chafer dish. The chafer fuel canister described in Lioi contains multiple wicks that extend into the base of the canister in multiple directions to ensure complete use of the fuel. The wicks connect at a point and extend out through the lid aperture. Lioi ensures complete use of the fuel within the chafer fuel canister, thereby limiting variation between burn time as a result of angled placement.

Lioi does not provide for an efficient means of determining the amount of fuel remaining within the chafer fuel canister, and as such suffers from the same drawbacks associated with a loss of heat based on depleted fuel level within the chafer fuel canister.

Wesley discloses a safety label for use with chafing fuel cans capable of providing the user with information about the current physical characteristics of the can, including as they related to temperature. The safety label employs thermochromic materials dispersed within a media such as ink or paint. The thermochromic material is capable of undergoing a sharp, reversible visible metachromism between the temperatures of −40° C. and 80° C. When chafing fuel can is ignited, the media with the thermochromic material visually undergoes a metachromism, rending the media invisible, thereby revealing the information indicia applied with the non-thermochromic ink. The safety label can inform the hotel or establishment employees of the varying degree of heat that is being produced by the chafing fuel canister. Wesley falls short as the safety label cannot indicate minor changes in heat nor can it indicate changes in heat at high operating temperature.

Hoffmann discloses a chafing dish fuel canister with a side wall having a lower section, a middle section and an upper section wherein the lower section and the upper section are substantially vertically extending and the middle section is an angled wall. The walls are constructed in a manner that when the fuel is depleted, the chafing dish fuel canister can be placed on its side wherein the depleted fuel can collect and continue to burn. The chafing dish fuel canister is preferably constructed of a transparent plastic material made of polyvinyl chloride (PVC) or polyethylene terephthalate (PET). Hoffmann fails to disclose the method of constructing the chafing dish fuel canister with PVC or PET and as such, fails to disclose a chafing dish fuel canister constructed of transparent material. As alluded in Hoffmann, the PVC or PET would be required to be heat resistant and be able to bond with the metal cap housing the wick. To construct such a chafing dish fuel canister requires innovating steps that are not described within Hoffmann.

As such, there is a need for a clear chafing fuel canister that can overcome the drawbacks as described above. Indeed, there is a need for a clear chafing fuel canister that is constructed from PVC or PET that can withstand the high heat emanating from the chafing fuel canister while also maintaining a waterproof seal with the metal cap of the chafing fuel canister. A clear chafing fuel canister resolves the drawbacks associated with the drawbacks of current chafing fuel canisters by allowing hotel and establishment employees to quickly assess the fuel level of the chafing fuel canisters and determining the proper time to replace in order to maintain legal serving temperature of the prepared food housed in the chafing system.

SUMMARY

The present invention provides a clear chaffer fuel canister. The clear chaffer fuel canister is primarily comprised of a clear base vessel, a chafer vessel lid, fuel, and, a flame cap 25. The clear chaffer fuel canister functions as a heating device for a variety of applications but found primarily in the food industry. The clear chaffer fuel canister allows the users to visually determine the volume of fuel remaining. The volume of fuel remaining can provide the user an approximate burn time remaining through alignment of the volume of fuel with the visual indicators positioned on the clear base vessel.

BRIEF DESCRIPTION OF THE DRAWINGS

It will now be convenient to describe the invention with particular reference to one embodiment of the present invention. It will be appreciated that the drawings relate to one embodiment of the present invention only and are not to be taken as limiting the invention.

FIG. 1 is a front view of a clear chaffer fuel canister, according to one embodiment of the present invention;

FIG. 2 is a front view of a clear base vessel, according to one embodiment of the present invention;

FIG. 3 is a front view of a chaffer canister lid, according to one embodiment of the present invention;

FIG. 4 is a cross sectional view of the clear chaffer fuel canister, according to one embodiment of the present invention;

FIG. 5 is a cross sectional view of the clear chaffer fuel canister with the cap removed, according to one embodiment of the present invention;

FIG. 6 is a bottom view of the clear chaffer fuel canister, according to one embodiment of the present invention; and,

FIG. 7 is a method of manufacture flow chart of the clear chaffer fuel canister, according to one embodiment of the present invention.

DETAILED DESCRIPTION

The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred and other embodiments of the invention are shown. No embodiment described below limits any claimed invention and any claimed invention may cover processes or apparatuses that are not described below. The claimed inventions are not limited to apparatuses or processes having all the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below. It is possible that an apparatus or process described below is not an embodiment of any claimed invention. The applicants, inventors or owners reserve all rights that they may have in any invention claimed in this document, for example the right to claim such an invention in a continuing application and do not intend to abandon, disclaim or dedicate to the public any such invention by its disclosure in this document.

The terms “coupled” and “connected”, along with their derivatives, may be used herein. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical or electrical contact with each other. “Coupled” may be used to indicated that two or more elements are in either direct or indirect (with other intervening elements between them) physical or electrical contact with each other, or that the two or more elements co-operate or interact with each other (e.g. as in a cause and effect relationship).

With reference to FIG. 1 and according to one embodiment of the present invention, a clear chaffer fuel canister is shown 10. The clear chaffer fuel canister 10 is comprised of: a clear base vessel 15; a chafer vessel lid 20; and, a flame cap 25. The clear chaffer fuel canister 10 functions as a heating device for a variety of applications. To act as a heating device, the fuel (not shown) contained within the clear chaffer fuel canister 10 is ignited and consumed. The resultant flame produces the heat that heats elements placed directly above. Longer burn time of the resultant flame is desired and economical, but is usually tempered loss of heat due to lack of fuel. To ensure that emanating heat remains constant, a user is required to determine the amount of fuel remaining within the clear chaffer fuel canister. The physical properties of the clear base vessel 15 provide for the ability for a user to visually determine the amount of fuel remaining in the clear chaffer fuel canister 10. The transparent and/or translucent nature of the clear base vessel 15, which houses the fuel (not shown) allows the user to visually inspect the amount of fuel remaining within the clear chaffer fuel canister 10, and determine the approximate amount of time remaining wherein the clear chaffer fuel canister 10 can maintain its optimal heat production. To translate fuel volume to amount of burn time remaining, the clear base vessel 15 contains indicators (not shown) corresponding to hours and half hours. The location for each indicator (not shown) is predetermined based on the type of fuel and wick used (not shown) which relates to the burn rate. As such, when the volume of fuel (not shown) reaches an indicator, the user will be able to determine the amount of burn time remaining. The predetermined location of the indicators was determined through a number of test runs that were timed and calculated based on volume, burn rate and shape of the clear base vessel 15. As such, the user is no longer required to guestimate the amount of fuel remaining based on the height of the resultant flame produced or through continuous monitoring of the temperature of the article that is required to be continuously heated. The fuel (not shown) is contained within clear chaffer fuel canister 10 through the sealing of the clear base vessel 15 by the chafer vessel lid 20. The orifice (not shown) that exposes the fuel contained within the clear chaffer fuel canister 10 is capped by the flame cap 25.

With reference to FIG. 2 and according to one embodiment of the present invention, the clear base vessel 15 is shown in greater detail. The clear base vessel 15 is comprised of a transparent or translucent material, that allows a user to clearly and with little effort see directly through the walls of the clear base vessel 15. The clear base vessel 15 is comprised of a plastic material that is capable of withstanding the pressures associated with its use in the clear chaffer fuel canister (not shown). The plastic that comprises the clear base vessel 15, is required to withstand high temperatures without melting or reaching its softening point. This is especially true at the upper end of the clear base vessel 15, at this is the closes point to the flame of the clear chaffer fuel canister (not shown). The plastic is also required to resist cracking from external pressures that are associated with the day to day operation of clear chaffer fuel canister. The plastic that has been identified to contain such characteristics and is incorporated in one embodiment of the present invention is polypropylene (“PP”) plastic. To further increase strength and elasticity of the clear base vessel 15, 5.0% to 10.0% EVA resin is added to the PP. The EVA resin reduces the probability of the clear base vessel 15 from cracking as a result to impact. The impact can be caused in very day use and handling of the clear chaffer fuel canister 10, such as but not limited to: dropping, knocking and collisions with other canisters and walls. For simplicity when PP+EVA is referenced, the plastic is comprised of PP that includes the additive EVA resin at 5.0% to 10.0%. In the one embodiment of the present invention, PP plastic was used comprising of a thickness range of 0.60 cm to 1.20 cm. Under this thickness range, the PP along with the EVA resin contains the strength and rigidity required to withstand the pressures associated with its use in the clear chaffer fuel canister (not shown). Additionally, at the 0.60 cm −1.20 cm thickness range, the PP was tested to have a softening point between 120-125° C., which has been found to be sufficient to withstand the heat that emanates from the clear chaffer fuel canister (not shown) while in use. The softening point temperature also alludes to a higher melting point, which is crucial in a plastic that is in close proximity to a flame and is in contact with tin, a heat transducer. In the preferred embodiment, the clear base vessel 15 is comprised of PP+EVA at a thickness of 0.8 cm. The attachment lip (not shown) of the clear chaffer fuel canister extend outwards by 0.35 cm and increases the overall thickness at that location to 1.15 cm.

A worker skilled in the relevant would appreciate that the use of other plastics alone, or in combination with resins, can provide similar structural and thermal rigidity. The ingenuity in testing various combinations is identifying the right combination. In identifying the key thickness and plastic material, a number of iterations were constructed and subsequently tested. One iteration of the clear base vessel 15 was constructed from polyethylene terephthalate (“PET”) of various thicknesses. PET plastic of various thicknesses failed structural testing as PET was unable to maintain structural rigidity at operating temperatures. It was determined that the melting temperature of PET was too low for the indication. The resultant clear chaffer fuel canisters in the first iteration, while in operation caused the clear base vessel 15 to warp, deform and melt. The use of PET as applied in the first iteration was not effective. In another iteration, the clear base vessel contained various resins PET plastic. The resins added resins to PET did provide additional structural and physical integrity but was found to cloud the resultant clear base vessel 15, thereby prohibiting the user from visually identifying the amount of fuel (not shown) remaining.

The critical element that required from the plastic used to form the clear base vessel 15 in the clear chaffer fuel canister (not shown) is structural rigidity and optimal heat softening point. The plastic is required to maintain structural rigidity when a force is applied to any location of the clear chaffer fuel canister (not shown). Force is generally the result of the clear chaffer fuel canister (not shown) is dropped or falls from a shelf when not in use. If structural rigidity is not maintained, just force can lead to cracking of the clear base vessel 15, which results in a fuel leak. Furthermore, the plastic cannot deform at temperatures below 100° C. If deformed at lower temperatures, the clear base vessel will deform when the chaffer fuel canister (not shown) is in operation, which could lead to disastrous results and can be a potential fire hazard.

Additionally, various manufacturing methods were attempted to ensure the clear base vessel 15 is characterized with a clear or translucent form. PP and PET, based on its method of manufacture, can contain clear final plastic characteristics. Different cooling means, various cooling speeds and modified pressure forming techniques were investigated. The various manufacturing methods can result in various visual characteristics of the resultant PP+EVA plastics that is used in the creation of the clear base vessel 15. One method that was identified to be effective in producing transparent

PP based clear based vessel 15 is the use of directional cooling. By insulating the cooling device and allowing the cooling process to proceed from the top, the PP has been shown to be less likely to contain a cloudy characteristic when solidified.

In another embodiment, the clear base vessel 15 is manufactured in a stepwise fashion. Firstly. A die is constructed that forms the mold of the clear base vessel 15. The PET+EVA is melted at 165° C. and poured into a water-cooled injection molding machine. The water-cooled injection molding machine injects out the liquified PP+EVA into the die and cooled. The clear base vessel 15 is removed form the die and inspected.

The clear base vessel contains a cavity capable of receiving fluid (not shown) that is framed by a cavity orifice. The cavity orifice of the clear base vessel 15 contains an attachment lip 35. The attachment lip 35 protrudes out from the clear base vessel 15 and provides for a connection point for the chaffer vessel lid (not shown). For optimal attachment, the attachment lip 35 is of a thickness between 0.25-0.55 cm. In the preferred embodiment, the attachment lip 35 is of a thickness of 0.35 cm. A secure, water tight attachment between the clear base vessel 15 and the chaffer vessel lid (not shown) is an integral element for the proper operation of the clear chaffer fuel canister (not shown). The need for a water tight seal is essential, as the clear chaffer fuel canister (not shown) is exposed to an open flame, and leaks of the fuel from within the clear base vessel 15 can have a disastrous effect. A worker skilled in the relevant art would appreciate the various means of attachment between the clear base vessel 15 and the chaffer vessel lid (not shown).

A pressure resistant support arc 85 is located at the base of the clear base vessel 15. The arc of the pressure resistant support arc 85 increases the strength and rigidity of the clear base vessel 15 to help improve the clear chaffer fuel canister (not shown) strength during operation. The pressure resistant support arc 85 help disperse any pressure that is placed on the clear base vessel 15, and helps reduce the possibility of the formation of a stress fracture on the clear base vessel 15.

Maintenance of the structural integrity of the clear base vessel 15 and the clear chaffer fuel canister is essential for the proper operation. Any damage that results from general use and handling needs to be minimized.

With reference to FIG. 3 and according to one embodiment of the present invention, the chaffer vessel lid 20 with the attached corresponding flame cap 25 is shown in greater detail. The chaffer lid vessel 20 is attached at the cavity orifice of the clear base vessel (not shown) thereby encapsulating the fuel (not shown) contained within. To ensure a tight seal around the orifice of the clear base vessel (not shown) the circumference of the chaffer vessel lid 20 contains a lid shoulder 42. The lid shoulder 42 is designed to set perfectly within the orifice of the clear base vessel (not shown). As such, the chaffer vessel lid 20 is not set on top of the clear base vessel (not show), but is inserted, by the depth of the lid shoulder 42 within the clear base vessel (not shown). The radius of the bottom of the chaffer vessel lid 20, at the lid shoulder 42 is slightly larger than the radius of the orifice of the clear base vessel (not shown). As such, and during setting process, the chaffer vessel lid 20 stretches the orifice of the clear base vessel (not shown) thereby further ensuring that the fuel within the clear base vessel (not shown) is secured. The elasticity and flexibility of the PP+EVA ensures the fitment. In another embodiment, the chaffer vessel lid 20 is inserted into the orifice of the clear base vessel when either the lid chaffer vessel lid 20, the clear base vessel (not shown) or both are at temperature which allows for PP+EVA partial molding. The step hook 40 further seals the chaffer vessel lid 20 onto to clear base vessel (not shown). The step hook 40 interacts with the attachment lip of the chaffer vessel (not shown). The step hook 40 is mechanically molded around the attachment lip through the use of a modified chuck during the manufacturing process. The process of molding the step hook 40 around the attachment lip 35 occurs in a two-step process. First, the modified chuck moves over the rim of the step hook 40 while it is in place. Second, the modified chuck moves over the rim to now complete the seam. The PP+EVA is required to be sufficiently flexible to bend and accept the seaming process while also have the rigidity to seam effectively. If the PP+EVA is too rigid, the molding of the step hook 40 is not effective as the seaming does not catch or the PP+EVA would crack. The thickness of the attachment lip of the chaffer vessel (not shown) is essential to ensure the complete sealing of the step hook 40. The thickness of the attachment lip of the clear base vessel (not shown) allows for optimal seaming. The thickness of the attachment lip is between 0.25-0.55 cm. The mechanical pressure applied by the modified chuck presses the step hook 40 against the attachment lip of the clear base vessel (not show) which causes the deformation of the attachment lip of the clear base vessel. Deformation is an essential element of the molding of the step hook 40 around the attachment lip of the clear base vessel (not shown) to create a water tight seal. Without the deformation of the attachment lip, the connection between the chaffer vessel lid 20 and the clear base vessel (not shown) would be solely dependant on the vessel lid 20. The deformation of the attachment lip of the clear base vessel (not shown) further ensures a tight seal as it presses against the lid shoulder 42 further ensuring a water tight seal. As the chaffer vessel is designed to withstand impact, the flexibility of the clear base vessel (not shown) might cause the vessel lid 20 to dissociate thereby impacting the water tight seal. Once the watertight seal is lost, the fluid contained within the cavity of the clear base vessel (not shown) can escape, posing a potential fire hazard when then clear chaffer fuel canister is in operation. The deformation of the attachment lip of the clear base vessel (not shown) results in the loss of the 0.25-0.55 cm thickness of the attachment lip. The resultant clear chaffer fuel canister (not shown) displays an almost flush outer side wall, with minimal protrusion relating to the step hook 40 of the chaffer vessel lid 20. The deformation of the attachment lip of the clear base vessel allows for a tighter seal, as it molds around the step hook 40 and the lid shoulder 42. The step hook 40 sealing not only prevents leakage of the fuel (not shown) from within the clear base vessel 15 but also limits any slippage or movement of the chaffer vessel lid when pressure and stress is placed onto the clear chaffer fuel canister (not shown). The clear base vessel (not shown) in comprised of PP plastic, a plastic that produces resonance or vibration frequencies once a force is applied. As such, if the chaffer fuel canister (not shown) is dropped, the impact will cause the clear base vessel (not shown) to vibrate, which could cause movement and dislodging of the chaffer vessel lid 20. The sealing of the step hook 40 of the chaffer vessel lid 20 prevents such movement and as such, dramatically reduces any leakage of the fuel (not shown) within the clear chaffer fuel canister (not shown).

The chaffer vessel lid 20, contains an aperture (not shown) that allows the fuel to be exposed to the surface, which is the location wherein the flame is ignited. The aperture, when the clear chaffer fuel canister (not shown) is not in operation, is fastened through the flame cap 25. The flame cap is fastened onto a protruding neck (not shown) of the chaffer vessel lid 20 by a number of means. In one embodiment of the present invention, the flame cap 25 is fastened onto the chaffer vessel lid 20 through the use of a screw spindle 45. A worker in the relevant art would appreciate the various means of fastening the flame cap 25 onto the chaffer vessel lid 20 including but not limited to: the use of a resealable glue, rivet, a latch, and a pin. The flame cap 25 contains ribs 50 that aid in the user handling.

With reference to FIG. 4 and according to one embodiment of the present invention, a cross sectional view of the clear chaffer fuel canister 10 is shown. A wick 55, is positioned partially within the cavity of the clear chaffer fuel canister 10. The wick is partially within the cavity of the clear base vessel 15 and a large portion of the wick is submerged in the fuel 60. The fuel 60 is comprised of diethylene Glycol (“DEG”). A worker skilled in the relevant art would appreciate the various forms of fuels, having combustible properties, that can be used within the clear chaffer fuel canister 10. The wick 55 transverses the aperture 57 of the chaffer vessel lid 20. The flame cap 25 prevents the outer portion of the wick 55, which extends partially out of the neck (not shown), from exposure to the environment when the clear chaffer fuel canister 10 is not in operation. The wick 55 is primarily comprised of an interwoven and/or braided cloth like material fibers that have absorbent properties. A worker skilled in the relevant art would appreciate the various cloth like materials fibers that the wick 55 can be comprised of, including but not limited to cotton, and fiberglass. The wick 55, through capillary action, draws fuel from within the body of the clear base vessel 15 to the external environment when the flame cap 25 is unfastened. Due to the nature of the clear chaffer fuel canister (not shown), in that it is to be efficient and provide the user an optimal use of the fuel (not shown), the wick 55 is designed to maximize the use of the fuel (not shown). The wick 55 is in contact with the base of the clear base vessel and the portion of the wick that is within the clear base vessel (not shown) is unravelled and is in fluid connection with all of the bottom edges. As such, the wick 55 ensures that all of the fuel (not shown) is efficient used.

With reference to FIG. 5 and according to one embodiment of the present invention, a cross sectional view of the clear chaffer fuel canister 10 with the flame cap 25 unfastened is shown. The unfastening the flame cap 25 from the chaffer vessel lid 20 exposes the external portion of the wick 55 to the environment. In doing so, the fuel 60, which was drawn up through capillary action has saturated the external portion of the wick 55. The flame cap 25 unfastens from the protruding neck 65 of the chaffer vessel lid 20. In one embodiment of the present invention, the protruding neck 65 contains a screw spindle 65 on its outer surface, which mates with the screw spindle 45 of the flame cap 25. The flame cap 25 is unfastened from the neck 65 by a rotating motion that is aided by the ribs 50. A worker skilled in the relevant art would appreciate the various fastening means of attaching the flame cap. The worker skilled in the relevant art would also appreciate the physical requirements needed by the flame cap 25 and the protruding neck 65 to accomplish the various fastening means. The bore 70 of neck 65 houses the exposed portion of the wick 55 and provides space for the wick 55 when the flame cap 25 is fastened. The bore 70 also reduces the potential for exposed fuel to spread to the outer regions of the clear chaffer fuel canister 10, thereby limiting potential spread of the flame once the wick 55 is ignited. By exposing the external portion of the wick 55 to a flame, the fuel 60 on the wick 55 ignites, which subsequently evaporates and causes more fuel 60 to be drawn from the body of the clear base vessel 15 through capillary action. As such, the fuel 60 within the cavity of the clear base vessel 15 is consumed when the extended portion of the wick 55 is ignited.

The consumption of the fuel 60 within the cavity of the clear base vessel 15 can be characterized as a constant and gradual while the extended portion of the wick 55 is ignited. Through analysis of the consumption rate and burn rate with respect to the wick 55 and fuel 60 employed within the clear chaffer fuel canister, the volume of fuel remaining in the clear base vessel corresponds to the amount of burn time remaining. The clear base vessel 15 contains visual indictors (not shown) that correspond to a specified amount of burn time remaining once the fuel 60 volume reaches the visual indicator. As such, a user will be able to, through visual inspection, assess the amount of burn time remaining by aligning the volume of fuel with a visual indicator (not shown).

With reference to FIG. 6 and according to one embodiment of the present invention, a bottom view of the clear chaffer fuel canister 10 is shown. The perimeter of the base of the chaffer fuel canister 10 is framed with a number of linear fins 80. The fins 80 act to stabilize the clear chaffer fuel canister 10, by limiting slippage and allowing for minor imperfections on the surface where the clear chaffer fuel canister 10 is placed upon. As the clear chaffer fuel canister 10 is primarily used in association with a chaffer dish, the surface upon which the clear chaffer fuel canister 10 is placed is often cluttered with prepared food bits and their oils or liquids. The fins 80 help the clear chaffer fuel canister 10 from traversing the food bits and the associated oils in a manner that allows the clear chaffer fuel canister 10 to remain stationary and provide for a continuous vertical flame when in operation. The fins 80 frame the pressure resistant arc support 85.

With reference to FIG. 7 and according to one embodiment of the present invention, the method of manufacture of the clear chaffer fuel canister is shown. The PP+EVA or a combination thereof (“plastic mix”) is chosen for use in the construction of the clear base vessel of the clear chaffer fuel canister (not shown). In one embodiment of the present invention, the plastic used is PP. The plastic or plastic mix is heated to 165° C. and, if resin is used, the plastic mix is mixed thoroughly to allow for complete resin dispersion. The plastic or plastic mix is assessed to determine whether the plastic or plastic mix is in liquid form. If the plastic or plastic mix is not completely liquified, then the plastic or plastic mix is maintained at 165° C. for an additional 15 to 30 minutes or until such time as the plastic or plastic mix have completely liquified. Once liquified, the liquid plastic or plastic mix is injected into a mold die. The mold die contains the appropriate characteristics of clear base vessel, including but not limited to the width of the walls (not shown), the width and protrusion of the attachment lip (not shown), the arc of the pressure resistant support (not shown) and the fins (not shown). Pressure is applied to the liquified plastic or plastic mix and allowed to set for 15 to 45 minutes to ensure the mold die is completely filled with plastic or plastic mix. The liquified plastic or plastic mix is allowed to settle thereby removing any air bubbles. The mold die is cooled allowing the for liquified plastic or plastic mix to solidify. There are various cooling techniques that can be employed that further assure that the resultant solid plastic is transparent and devoid of any crystal formation, which can clause the solid plastic to appear cloudy. The preferred means of cooling requires directional slow cooling. In doing so, the cooling process limits the formation of crystallization, which often causes the appearance of a foggy or translucent appearance to the solid plastic. This is accomplished through the use of a cooling bath, which gradually decreased the temperature of the plastic or plastic mix. As the plastic or plastic mix is cooling, the plastic is visually inspected for solidification. Once the plastic or plastic mix is solidified, the clear base vessel (not shown) has formed. The clear base vessel (not shown) is removed from the mold die and inspected for any irregularities and proper thickness of the walls and attachment lip. If any irregularities are observed, the clear base vessel is reheated to 165° C. and the method of manufacture process is repeated. A precast chaffer vessel lid is selected and set within the orifice of the clear base vessel. The step hook of the chaffer vessel lid is aligned with the attachment lip of the clear base vessel. A modified chuck is run across the step hook, thereby sealing the step hook of the chaffer vessel lid onto the attachment lip of the clear base vessel. The fitment of the chaffer vessel lid within the orifice of the clear base vessel and the sealing of the step hook onto the attachment lip produces a water tight seal between the clear base vessel and the chaffer vessel lid. Fuel is poured into the clear base vessel through the aperture in the chaffer vessel lid. A wick is partially set into the aperture of the chaffer vessel lid and the wick is sealed into the aperture. The flame cap is fastened into the neck of the chaffer vessel lid and the clear chaffer fuel canister is packaged and boxed for distribution.

While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the relevant art that various modification may be made and equivalents substituted without departing from the scope and the spirit of the invention. It is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the claims provided.

Claims

1. A clear chaffer fuel canister comprising:

a) a clear base vessel having a transparent composition and constructed with an attachment lip surrounding a cavity orifice defining a cavity;

b) a chaffer vessel lid set within the cavity orifice of the clear base vessel and sealed to produce a water tight seal through an interaction between a step hook of the chaffer vessel lid and the attachment lip of the clear base vessel;

c) fuel encapsulated within a cavity of the clear base vessel;

d) a protruding neck formed on an outer surface of the chaffer vessel lid for receiving a wick partially submerged into the fuel within the clear base vessel cavity and extending partially out of the protruding neck; and,

e) the fuel within the cavity of the clear base vessel consumed when an extended portion of the wick is ignited;

wherein the fuel housed within the clear base vessel can be viewed and its current volume assessed in relation to burn time remaining through visual inspection.

2. The clear chaffer fuel canister of claim 1, further comprising a clear base vessel with a wall thickness between 0.60 cm and 1.20 cm.

3. The clear chaffer fuel canister of claim 1, further comprising a clear base vessel with an attachment lip thickness between 0.25 cm and 0.45 cm.

4. The clear chaffer fuel canister of claim 1, further comprising a clear base vessel with a plastic composition containing polypropylene.

5. The clear chaffer fuel canister of claim 1, further comprising a clear base vessel with a plastic composition containing polypropylene and a resin.

6. The clear chaffer fuel canister of claim 1, wherein the clear base vessel comprises a plastic material having a softening point between 120° C. and 130° C.

7. The clear chaffer fuel canister of claim 1, wherein the fuel is diffused to the extending portion of the wick through capillary action of the wick.

8. The clear chaffer fuel canister of claim 1, further comprising a clear base vessel with visual indicators outlining the burn time remaining as based on fuel remaining within the clear base vessel.

9. The clear chaffer fuel canister of claim 1, wherein the step hook of the chaffer vessel lid is mechanically molded around the attachment lip of the clear base vessel to produce a water tight seal.

10. A method of manufacture of the clear chaffer fuel canister of claim 1 comprising of the following steps:

a) a plastic or plastic mix is chosen and liquified through addition of heat up to 165° C. for 15-30 minutes;

b) the liquified plastic or plastic mix is inspected for complete liquification and mixed thoroughly;

c) the liquified plastic or plastic mix is injected into a precast mold die representing the clear base vessel;

d) pressure is applied to the liquified plastic or plastic mix which has been injected into the precast mold die;

e) the liquified plastic or plastic mix is allowed to set within the mold die for 15 to 45 minutes;

f) the liquified plastic or plastic mix is allowed to cool, using a cooling technique that prevents formation of crystals within the plastic;

g) the solid clear base vessel, which is formed from the solidification of the liquified plastic or plastic mix is removed from the mold die;

h) the clear base vessel is inspected for any irregularities and if found, is recycled back to the plastic or plastic mix that is to be heated to 165° C.;

i) the precast chaffer vessel lid is set within the cavity orifice of the clear base vessel;

j) the step hook of the precast chaffer vessel lid is aligned with the attachment lip of the clear base vessel;

k) a modified chuck is run across the step hook thereby mechanically sealing the step hook onto the attachment lip of the clear base vessel;

l) fuel is poured into the aperture of the chaffer vessel lid and a wick is set partially within the cavity of the clear base vessel;

m) the wick is sealed within the bore of the protruding neck of the chaffer vessel lid; and,

g) a flame cap is fastened onto the protruding neck of the chaffer vessel lid.