GB2218897A - Carafe - Google Patents

Description

X 1 SERVER IN THE NATURE OF A CARAFE r%. I 2 2i 8 8 qv".

This invention relates to a server in the nature of a carafe and to a method of manufacture thereof.

It is important for servers in the nature of carafes, of the type used with heating elements and/or consumer coffee makers having heating covered elemepts on which the carafes are placed, to be able to withstand the elevated temperatures of the heating elements and at the same time not to be too fragile to resist breakage. While plastic containers satisfy the latter requirement, up to now they have not been useful as carafes of the type under discussion because the elevated temperatures to which they would be exposed would result in a deterioration of the physical characteristics of the carafe. Simply, such carafes have not be made of plastics materials because they would soften and deform, or simply melt down. The alternative, however, has likewise not been satisfactory. Thus, without the ability to use plastics for carafes, manufacturers have continued to make such carafes from appropriate glass materials, such as heat-resistant Borisilicate glass. However, such carafes are relatively fragile and breakage is very common. Users of such servers have, accordingly, expended substantial amounts of money annually in replacing broken glass carafes.

While some attempts have been made to utilize plastics in the manufacture of carafes or cups for 1 k the preparation of coffee, these uses have almost exclusively been confined to the manufacture of containers to be used in microwave oven environments, where the plastics materials are substantially transparent to the microwaves and, therefore, do not become excessively heated. Such a container is described in U.S. Patent No. 4,721,835, where a microwave brewing cup is described as being constructed from plastics materials such as polyester, polysulfone, polycarbonate or polypropylene. While such plastics materials may be useful in microwave oven environments, they would not be adequate for use as servers which are placed on covered, heating elements which can easily reach temperatures of approximately 2000C.

The present invention provides a server in the nature of a carafe for use with coffee makers and/or hot water warmers having covered heating elements on which the carafe is placed while coffee is being made or coffee or hot water is maintained at a desired hot temperature, the carafe comprising a main central enlarged section for receiving liquid to be heated having an upper opening including a spout and a lower base for maintaining said carafe in an upright position when placed on a generally flat horizontal surface, such as a heating element, and a handle secured to said carafe suitable for gripping, said carafe being made of a polyetherimide resin, and said main central enlarged section consisting of a series of integrally formed adjacent panels or facets which extend generally vertically between the region of 1 c is said opening and the region of said base, adjacent panels meeting at longitudinal ridges or ribs, said panels and ridges serving to reinforce and strengthen the wall forming said main central enlarged section, whereby the carafe wall may be decreased in thicknessand the weight of polyetherimide resin may be reduced while maintaining the integrity and strength of the carafe under elevated temperature conditions during use as a server.

The invention also provides a method of forming a server in the nature of a carafe comprising the steps of blow molding a main central enlarged section having an opening at one end and a base at the opposite end, the carafe being blow molded from a polyetherimide resin, and said main central enlarged section consisting of a series of integrally formed adjacent panels which extend generally vertically between the region of said opening and the region of said base, adjacent panels meeting at longitudinal ridges or ribs, said panels and ridges serving to reinforce and strengthen the wall forming said main central enlarged section, whereby the carafe wall may be decreased in thickness and the weight of polyetherimide resin may be reduced while maintaining the integrity and strength of the carafe under elevated temperature conditions during use as a server.

The invention further provides apparatus such as a coffee maker or hot water warmer incorporating a server in the nature of a carafe as defined herein.

By way of example, embodiments of the invention will now be described with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a coffee maker/warmer having a covered heating element, and showing the server or carafe in accordance with the present invention resting on the covered heating element; FIG. 2 is a side elevational view of the carafe in accordance with the present invention, as shown in FIG. 1; FIG. 3 is a top plan view of the carafe as shown in FIG. 2; FIG. 4 is a cross-sectional view of the main central enlarged section shown in FIG. 2, taken along line 4-4; FIG. 5 is a cross-sectional view of the lower portion of the carafe shown in FIG. 4, taken along line 5-5. showing the details of the construction of the base of the carafe; FIGS. 6 and 7 are side elevational views of opposite sides of the handle shown in FIGS. 2 and 3, prior to attachment to the server; FIGS. 8 and 9 are side elevational views of opposite sides of a clamping member associated with the handle shown in FIGS. 2, 3, 6 and 7, used to attach the handle to the server; FIG. 10 is a cross-section of the handle shown in FIG. 3, taken along line 10-10; and FIG. 11 is an exploded view of the handle shown in FIG. 10, showing the manner of assembly of the -handle and attachment thereof to the server.

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Referring now to the Figures, in which identical or similar parts are designated by the same reference numerals throughout, and first referring to FIG. 1, an institutional server or carafe in accordance with the present invention is generally designated by the reference numeral 10. Such a server, as noted, may be used for both institutional and/or consumer applications, such as automatic drip coffee makers.

The carafe 10 is shown in the environment of a coffee maker and/or hot water warmer 12 having a covered heating element 14 on which the carafe is placed while coffee is being made or coffee or hot water is maintained at a desired hot temperature.

Referring to FIGS. 2 and 3, the carafe 10 includes a main central enlarged section 16 for receiving coffee or liquid to be heated.

At the upper end of the main section 16 there is provided a neck 18 joined to the main section 16 by means of an upwardly inwardly-tapered portion 20. The neck 18 includes an upper edge 22 which defines an upper opening or mouth 24 formed with a spout 26.

At its lower end, opposing the neck 18, the main section 16 is formed with a base 28 joined to the main section 16 by means of a downwardly inwardly-tapered portion 30, as shown. The base 28, which will be more fully described below, is arranged for maintaining the carafe 10 in an upright position when placed on a generally flat horizontal surface, such as the heating element 14-.

An important feature of the present invention 4 is that the carafe, exclusive of the handle which will be separately discussed below, is made of a polyetherimide resin (hereinafter referred to as "Resin"). A specific Resin from which a carafe in accordance with the present invention has been made, and which has proved to perform satisfactorily, is a resin sold by the General Electric Company under its mark ULTEM. This is a plastics material which offers chemical Resin a combination of mechanical strength is resistance and temperature stability. The proposed to be used, therefore, is a superior alternative to metal or polysulfone (PSO).

Characteristics which are particularly important for the application intended. include the Resin's HTD which is 264 psi (1820 kPa) at 2000C (3920F).

The HTD of a resin is an indication of how well it will retain its physical properties at elevated temperatures under the load. Additionally, the Resin has superior stain resistance properties, and it has been established that the Resin can be cleaned of coffee stains.

While the Resin is, therefore, an extremely desirable material for hot coffee and hot water servers, the cost of the Resin is substantially higher in cost than other comparable plastics materials. Currently, the price of ULTEM Resin is approximately $5.00/1b ($11/kg). This represents a substantial cost factor in the use of this material for the intended purpose. Accordingly, it has been necessary to create a construction or design for a server of this type which can minimize the quantity h of the Resin which is used while maintaining the integrity and physical strength or properties of the server.

Referring to FIG. 2-4, it will be noted that the main central enlarged section 16 has a wall 31 which consists of a series of integrally formed adjacent panels or facets 32 which extend generally vertically between the region of the upper opening or mouth 24 and the region of the base 28. Adjacent panels 32 meet at longitudinal ridges or ribs 34, the panels 32 and ridges 34 serving to reinforce and strengthen the wall 31 forming the main central enlarged section 16. In this manner, the wall thickness of the carafe wall may be decreased and the weight of the polyetherimide resin may be reduced while maintaining the integrity and strengthen of the carafe under elevated temperature conditions during use as a server on a covered heating element.

With the panelled or faceted wall construction as shown and described, the panels 32 may have a thickness selected from the range of 0.020-0.12011 (0.5-3.1mm). The panels may have a thickness approximately 0.070 + 0.05011 (1.8 1.3mm). It will be appreciated, therefore, that the objective is to minimize the wall thickness to thereby reduce the quantity or weight of the Resin, while maintaining the integrity and strength of the carafe under elevated temperature conditions. A typical thickness for the panels 32 is approximately.03011 (0.8mm).

In the Figures, the main central enlarged 1 section 16 is shown to be generally cylindrical in shape, although, clearly, the main central enlarged section can assume any conventional configuration, such as spherical.

The carafe which has been made by the applicant had a main central enlarged section of a maximum diameter in a horizontal section of approximately 6.511 (165mm), and was formed with 23 integrally formed panels or facets 32.

Advantageously, although clearly optionally, the main central enlarged section includes at least one smooth surface 36 extending over a plurality of panels 32 suitable for application of an institutional name or logo. In the embodiment shown, two smooth surfaces 32 are provided at substantially diametrically opposite sides of the main central enlarged section.

For aesthetic, as well as mechanical reasons, the wall thicknesses of the upper edge 22 is greater than the thickness of the panels 32. Similarly, the wall thickness of the base is greater than the panels 32. The increased thickness of the upper edge 22 improves the aesthetic appearance of the unit, while the increased wall thickness of the base permits the carafe to better resist deformation due to elevated temperatures to which it is exposed when placed on a covered heating element 14. The increase in the wall thicknesses at the axial upper and lower ends of the carafe is almost naturally achieved when the carafe is blow molded in accordance with well known blow molding techniques.

4 Y Referring to FIG. 5, the base is shown to include a central upwardly extending recess 38 which forms an annular ridge or rim 39. The central recess may, for example, be formed by a downwardly facing concave surface as shown. The primary purpose of the annular ridge or rim 39 is to provide stability to the carafe. This is.particularly true since a carafe made by blow molding would not normally have a perfectly smooth or flat surface which would provide any degree of stability to the unit. A handle 40 is injection molded from any suitable plastic material and may be attached to the carafe in any known or conventional manner, including by mechanical means, by the use of adhesives or ultrasonics or heat fusion. However, in the embodiment as shown, the handle 40 includes a gripping portion 42 suitable for gripping, and a securing portion 44. The securing portion 44 includes a recess or slot dimensioned to receive a generally vertical flat fin or tab 46 formed proximate to the opening 24. Suitable securing means is used for securing the handle 40 to the tab 46, such as a rivet 48.

However, clearly, any other fastener may be used, such as a bolt and nut or a plastic rivet ultrasonically sealed.

While, in accordance with the broader aspects of the invention, any suitable handle 40 may be attached to the server in any known or conventional manner. Another feature of the present ewbodirent is the formation of the flat, thin or tab 46 and molding of the handle 40 to A relieve the stresses or strains from the rivet or other attaching means 48, and distribute such stresses throughout the region of attachment so as to minimize the stresses in the unit and, in time, the formation and damage thereto.

Referring more specifically to FIGS. 6-11, the handle 40 is shown to consist of a generally flat clamping member 44a whidh is integrally formed with a gripping portion 42 at the upper end thereof as shown. The clamping member 44a has an upper laterally offset portion is 44b to provide an elongate recess or groove 44c. Below the of f set portion 44b, there is provided a hole or opening 44d dimensioned to receive an internally threaded rivet portion 48a. The planar configuration and dimensions of the clamping member 44a are selected to generally correspond to the planar dimensions of the flat. fin or tab 46 integrally formed on the server.

Forming part of the handle, although detachable from the main portion thereof, is a clamping member 44e which has planar dimensions and configuration substantially corresponding to the planar dimensions of the clamping member 44a. The clamping member 44e, however, is substantially a mirror image of the clamping member 44a and, therefore, is provided with a laterally offset portion 44f thereby creating a recess or groove 44g. Similarly, hole or opening 44h is formed within the clamping member 44e dimensioned to receive'an externally 1 1 -1 1 threaded rivet portion 48b. The flat fin or tab 46 is provided with a vertical portion 46a which, as noted, has planar dimensions and a configuration which generally corresponds to those of the clamping members 44a and 44e. Provided in the upper region of the vertical portion 46a is a horizontal or transverse portion 46b, to form a fin or tab generally having a T-cross-section, as shown in PIGS. 10 and 11. As best shown in FIG. 10, the dimension of the transverse portion 46b is selected so that when the vertical portion 46a is clamped by the clamping members 44a and 44e, the transverse portion 46b is securely received within the recesses or grooves 44c and 44g, preferably with little or no clearance, as suggested in FIG. 10. During assembly, the clamping members 44a and 44e are aligned on opposite sides of the fin or tab 46, as shown in FIGS. 10 and 11, and the rivets 48a and 48b are passed through the holes 44d, 44e and 46c so that the internally threaded rivet 48a can receive and engage the externally threaded rivet 48b. A washer 50, such as a lock washer, may be used if desired. It will be appreciated that once the mating rivets are secured to each other and the clamping members 44a and 44e abut against the flat fin or tab 46 in pressure relationship, the weight of the server, together with any water that may be contained therein, is distributed over the surface of the clamping members and, in particular, assumed to a substantial degree by the horizontal or transverse portion C 46b. This removes a considerable amount of the stress or strain from the attaching member, here the rivets 48a. 48b, as compared with such rivets,, pins or screws assuming all or most of the weight in known handle attaching arrangements.

The carafe in accordance with the present embodiment satisfies both primary criteria for carafes of this type, namely, ability to withstand elevated temperatures as well as to resist breakage. Because the resin resists coffee stains ahd complies with applicable provisions of the U.S. Food, Drug and Cosmetic Act, the server or carafe in accordance with the present embodiment is ideal for the intended purpose.

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Claims (21)

CLAIMS:

1. A server in the nature of a carafe for use with coffee makers and/or hot water warmers having covered heating elements on which the carafe is placed while coffee is being made or coffee or hot water is maintained at a desired hot temperature, the carafe comprising a main central enlarged section for receiving liquid to be heated having an upper opening including a spout and a lower base for maintaining said carafe in an upright position when placed on a generally flat horizontal surface, such as a heating element, and a handle secured to said carafe suitable for gripping, said carafe being made of a polyetherimide resin, and said main central enlarged section consisting of a series of integrally formed adjacent panels or facets which extend generally vertically between the region of said opening and the region of said base, adjacent panels meeting at longitudinal ridges or ribs, said panels and ridges serving to reinforce and strengthen the wall forming said main central enlarged section, whereby the carafe wall may be decreased in thickness and the weight of polyetherimide resin may be reduced while maintaining the integrity and strength of the carafe under elevated temperature conditions during use as a server.

2. A server in the nature of a carafe as defined in claim 1, wherein said panels have a thickness selected from the range. 0.020-0.120 inches (0.5-

3.1mm).

A 3. A server in the nature of a carafe as defined in claim 1 or claim 2, wherein said panels have a thickness of 0.050 + 0.020 inches (1.3min + 0. 5mm).

4. A server in the nature of a carafe as defined in claim 1, claim 2 or claim 3 wherein said polyetherimide resin is ULTEM.

5. A server in the nature of a carafe as defined in any preceding claim, wherein a flat generally vertical tab is formed proximate said opening, said handle being configured and dimensioned to receive said tab with little clearance; and securing means for securing said handle to said tab.

6. A server as defined in claim 5, wherein said vertical tab has a generally T-shaped cross-section, and said handle includes means defining agenerally T-shaped opening dimensioned to receive said vertical tab in pressure relationship.

7. A server in the nature of a carafe as defined in any preceding claim, wherein said main central enlarged section is generally cylindrical in shape.

A server in the nature of a carafe as defined in any one of claims 1 to 6, wherein said main central enlarged section is generally spherical in shape.

9. A server in the nature of a carafe as defined 4 11 - 15 in any preceding claim, wherein said main central enlarged section has a maximum diameter in a horizontal section of approximately 6.5 inches (165mm) and is formed of approximately 23 integrally formed panels or facets.

10. A server in the nature of a carafe as defined in any preceding claim, further comprising at least one smooth surface extending over a plurality of panels suitable for application of a name or logo.

11. A server in the nature of a carafe as defined in any preceding claim, wherein two smooth surfaces are provided at substantially diametrically opposite sides of said main central enlarged section.

12. A server in the nature of a carafe as defined in any preceding claim, wherein the wall thickness at said upper opening is greater than the thickness of said panels.

13. A server in the nature of a carafe as defined in any preceding claim, wherein the wall thickness of said base is greater than the thickness of said 30 panels.

14. A server in the nature of a carafe as defined in any preceding claim, wherein said base includes a central upwardly extending recess forming an annular 35 ridge or rim.

4 A 16 -

15. A server in the nature of a carafe as defined in claim 14, wherein said central recess is formed by a downwardly facing concave surface.

16. A server in the nature of a carafe as defined in any preceding claim, further comprising an upwardly inwardly tapered conical portion between said main central enlarged section and said opening.

17. A server in the nature of a carafe as defined in any preceding claim, further comprising a downwardly inwardly tapered conical portion between said main central enlarged section and said base.

18. A server in the nature of a carafe substantially as hereinbefore described with reference to the accompanying drawings.

19. A method of forming a server in the nature of a carafe comprising the steps of blow molding a main central enlarged section having an opening at one end and a base at the opposite end, the carafe being blow molded from a polyetherimide resin, and said main central enlarged section consisting of a series of integrally formed adjacent panels which extend generally vertically between the region of said opening and the region of said base, adjacent panels meeting at longitudinal ridges or ribs, said panels and ridges serving to reinforce and strengthen the wall forming said main central enlarged section, -whereby the carafe wall may be decreased in thickness 4, 1 and the weight of polyetherimide resin may be reduced while maintaining the integrity and strength of the carafe under elevated temperature conditions during use as a server.

20. A method of forming a server in the nature of carafe as defined in claim 18, further comprising the step of injection molding said handle.

21. A method of forming a server in the nature of a carafe substantially as hereinbefore described with reference to the accompanying drawings.

Published 1989 at The Patent Office, State House, 65f7l High Holbom,Iondon WC1R4TP. Further copies maybe obtained from The Patent Office. Sales Branch, St Mary Cray, Orpington, Kent BR5 3RD. Printed by Multiplex techniques ltd, St Mary Cray, Kent, Con. 1/87 4