HK1239481B - Composite cookware handle - Google Patents

Description

Composite cookware handles

Cross-reference to related applications

This application claims the benefit of the filing date under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Serial No. 62/295,642, filed on February 16, 2016, which is incorporated herein by reference in its entirety.

Technical Field

The present disclosure generally relates to handles for cookware articles, such as cookware containers, and methods of making and installing the same.

Background Art

Cookware items often include handles to allow users to move and operate the item. Known cookware handles utilize a metal flange mounted to the cookware item, combined with a non-metallic (e.g., plastic or rubber) grip portion extending away from the flange and intended for the user to grasp. The grip may be overmolded onto a portion of the flange, which is not intended to be visible. Such grips are used because they are more comfortable and cooler to the touch than bare metal handles and help reduce the weight of the handle.

SUMMARY OF THE INVENTION

In one aspect, a handle for a cookware item includes a metal flange, an insert, and a grip member. The metal flange may have an inner face and an outer face. The inner face is adapted to contact a curved outer wall of the cookware item. A hole extends from the inner face toward the outer face and defines at least a first cavity therebetween. The insert may have a proximal end and a distal end. The proximal end is adapted to be received within the first cavity of the hole and secured therein when the proximal end is affixed to the flange within the hole. The grip member has a proximal end and a distal end and includes a polymer material overmolded with at least a portion of the distal end of the insert. The grip member has an outer surface profile at the proximal end adapted to lie flush with an adjacent portion of the flange when the proximal end of the insert is secured in the first cavity.

In various embodiments, the proximal end of the insert comprises a sheet metal portion having a cross-sectional dimension complementary to the cross-sectional dimension of the aperture. The sheet metal portion, when received therein, can engage with the aperture along the corresponding complementary cross-sectional dimension of the aperture. The proximal end can be attached to the flange by welding along the interface between the sheet metal portion and the aperture. In one configuration, the aperture can define a channel extending from the first cavity toward the proximal end of the inner face of the flange. The channel can have at least one cross-sectional dimension that is smaller than the cross-sectional dimension of the first cavity. The complementary cross-sectional dimension of the aperture is positioned along the channel.

In some embodiments, the aperture may extend from the outer face of the flange to the inner face. The first cavity may be adjacent to the outer face, and the aperture may define a second cavity adjacent to the inner face. In one configuration, the proximal end of the insert includes a sheet metal portion that extends at least partially into the second cavity. The sheet metal portion may be attached to the portion of the aperture defining the second cavity by welding.

In certain embodiments, the aperture defines a passage extending between the first cavity and the second cavity. The passage has at least one cross-sectional dimension that is smaller than a cross-sectional dimension of the first cavity. In one configuration, the length of the proximal end of the insert is adapted to fill at least a portion of the length of the passage when the proximal end of the insert is secured within the first cavity. In this or another configuration, the length of the proximal end of the insert and the length of the passage comprise complementary cross-sections such that when the proximal end of the insert is secured to the first cavity, the length of the proximal end of the insert fills the length of the passage. In either or both of the above configurations, the proximal end of the insert comprises a sheet metal portion, a flared wedge portion, and a proximal portion. The sheet metal portion may have at least one cross-sectional dimension that is complementary to the cross-sectional dimension of the passage. The flared wedge portion may be the distal end of the sheet metal portion and have a distal tapering cross-section that is adapted to complement the distal tapering cross-section of the first cavity along a corresponding length of the aperture when the proximal end of the insert is secured within the first cavity. The distal portion is spaced apart from the surrounding portion defining the first cavity when the proximal end is secured therein.

In one embodiment, when the proximal end of the insert is secured in the first cavity, the length of the distal end within the first cavity is spaced apart from a surrounding portion defining the first cavity.

In various embodiments, the proximal length of the distal end of the insert defines a cavity adapted to accommodate the distal length of the proximal end of the insert. The outer face of the flange includes a mating structure adapted to mate with a mating structure arranged along the proximal length of the distal end of the insert. When the proximal end of the insert is secured in the first cavity, the distal end of the insert is flattened between the flange and the distal end of the insert. The mating structure arranged along the proximal length of the distal end of the insert may be the proximal end of the grip member. The mating structure may include threads adapted to threadably engage the distal end of the insert with the distal face of the flange. The distal end of the insert may further include a cavity defined along a distal portion thereof. The handle assembly may further include a closure cap having a mating structure adapted to mate with the mating structure arranged along the distal portion of the distal end of the insert to close the cavity.

In another aspect, a cookware vessel includes a vessel having a bottom and a surrounding sidewall extending upward to form a rim and defining an interior volume between the bottom and the surrounding sidewall for receiving and retaining liquid. A handle assembly may be joined to the exterior of the surrounding sidewall at the flange thereof. The handle assembly may include a metal flange, an insert, and a grip member. The metal flange may have an inner face and an outer face. The inner face is adapted to contact a curved outer wall of a cookware item. A hole extends from the inner face toward the outer face and defines at least a first cavity therebetween. The insert may have a proximal end and a distal end. The proximal end is adapted to be received within the first cavity of the hole and secured therein when the proximal end is abutted against the flange within the hole. The grip member has a proximal end and a distal end and comprises a polymer material overmolded with at least a portion of the distal end of the insert. The grip member has an outer surface contour at the proximal end adapted to lie flush with an adjacent portion of the flange when the proximal end of the insert is secured in the first cavity.

In yet another aspect, a process for forming a cookware vessel may include: (a) providing a metal flange having a curved inner face and an outer face, the curved inner face being adapted to contact a curved outer wall of a cookware vessel, wherein an aperture extends from the outer face toward the inner face; (b) providing an insert having a proximal end and a distal end, wherein the proximal end is adapted to be received in a portion of the aperture extending from the outer face of the flange toward the inner face, and wherein the distal end is adapted to extend out of the outer face of the flange when the proximal end is inserted into the aperture at the outer face; (c) providing a grip portion, the grip portion (d) inserting the proximal end of the metal insert into the hole of the flange at the outer face so that the grip portion contacts the outer face of the flange; (e) securing the proximal end of the insert to the flange within the hole; and (f) attaching the inner face of the flange to a curved outer wall of a cookware vessel to provide the grip molded as a handle for the cookware vessel.

In various embodiments, securing the proximal end of the insert to the flange within the aperture may include welding the proximal end of the insert to the flange along a portion adjacent the aperture. In one embodiment, the handle for the cookware vessel is one of an elongated handle or a U-shaped handle. In another embodiment, the metal flange has first and second side holes for accommodating rivets, the first and second side holes being arranged on opposite sides of the aperture. Attaching the inner face of the flange to the curved outer wall of the cookware vessel to provide a grip molded as a handle for the cookware vessel may include: (a) inserting a rivet through each of the first and second holes in the side wall of the vessel and the corresponding first and second side holes in the flange, wherein the tail of each rivet extends beyond the corresponding side hole, and (b) deforming the distal end of the tail portion of each rivet extending beyond the corresponding side hole to secure the rivet, wherein the deformed distal end of the tail portion extends beyond the perimeter of each of the first and second side holes in the flange.

The above and other objects, effects, features and benefits of the present invention will become more apparent through the following description of the embodiments of the present invention with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth with particularity in the appended claims. However, the various embodiments of the invention herein described, both as to organization and mode of operation, may be best understood by reference to the following description taken in conjunction with the accompanying drawings, in which:

FIG1A is a top plan view of a handle for a cookware article, and FIG1B is an exterior elevation view of the handle showing a portion of the cookware vessel;

2A is a cross-sectional front view of the handle taken along section line 2A-2A in FIG. 1A , and FIG. 2B is a cross-sectional view thereof taken along section line 2B-2B in FIG. 2A ;

3A and 3B are plan cross-sectional views and side cross-sectional elevation views, respectively, of an embodiment of a handle and a cookware vessel;

4A and 4B are plan cross-sectional views and side cross-sectional elevation views, respectively, of an embodiment of a handle and a cookware vessel;

FIG5A is a cross-sectional plan view of components for constructing another embodiment of a handle and cookware vessel, which is shown in plan cross-sectional view and side cross-sectional elevation view in FIG5B and FIG5C;

6A-6E are plan cross-sectional views illustrating methods of forming and attaching a handle to a cookware article according to various embodiments;

FIG7A is a top plan view of another embodiment of a handle, wherein FIG7B and FIG7C are different cross-sectional elevation views taken along section lines 6B-6B (in FIG6C ) and 6C-6C (in FIG9A );

FIG8A is a perspective view of the flange and handle components of the embodiment of FIG7A-7C before attachment, and FIG8B is a perspective view after attachment; and

Figure 9A is a side elevational view of the embodiment of Figures 7A and 8A, wherein Figure 9B is a cross-sectional elevational view taken along section line 9B-9B in Figure 7A, and Figure 9C is a cross-sectional elevational view taken along section line 9C-9C in Figure 9A.

Detailed Description of the Invention

Current technology for secondary coating, which covers the flange to create handles for cookware items, works well only with simple forged metal flanges with simple shapes and generally flat grips. These simple shape limitations imposed by current technology often lack the grip comfort and artistic potential to allow users to differentiate cookware items through ergonomic and stylistic distinctions. Furthermore, the simple construction can give the entire cookware item a low-price feel. While the handle can be co-cast or molded with the flange, secondary coating is difficult, especially after the metal flange has been trimmed and polished from the casting process. Post-cast coating can also scratch the polished surface, and post-coating polishing is difficult because polishing compound can become embedded in the edges of the coating plastic. The coating plastic can also be damaged. Cast and polished metal flanges used to create handles for cookware items can be manufactured in a wide variety of shapes to create diverse physical and artistic objects, and expanding current technology would further these goals. According to various embodiments described herein, a composite cookware handle assembly for a cookware article may include a polished metal flange and a grip portion that extends flush with the edge of the flange, thereby giving the entire handle a three-dimensional cast appearance.

Various embodiments of the inventive composite cookware handle assemblies, components, and methods thereof are described herein with reference to Figures 1A-9C, wherein like reference numerals represent like components throughout the various views.

1A and 1B illustrate an elongated handle assembly 100 attached to a culinary article 200. The handle 100 includes a flange 110 positioned along a proximal end 100a adapted to be attached to the culinary article 200 ( FIG. 1B ). The flange 110 may generally include an inner surface 110a adapted to contact and mount to an outer wall 210 of the culinary article 200. For example, the inner surface 110a may have one or more complementary dimensions relative to the wall 210, e.g., the dimensions may be adapted to approximate upon interfacing to allow for flush mounting to the wall 210 along the complementary dimensions. In the illustrated embodiment, the inner surface 110a has a curved profile dimensioned to contact a correspondingly curved outer wall 210 of the culinary article 200.

The handle 100 further includes a grip member 130 positioned along the distal end 100b of the handle 100. The grip member 130 includes a proximal end 130a adjacent to the flange 110 and extends to a distal end 130b. An outer surface profile 130c, defined by a proximal face 130d of the grip member 130, is dimensioned to be flush with an adjacent portion 110c of the flange 110 (e.g., an outer face 110b thereof). As described above, the flange 110 can comprise a polished metal flange 110. For example, the adjacent portion 110c or other visible portion can comprise polished metal.

With further reference to the cross-sectional views shown in Figures 2A and 2B, handle 100 may also include an insert 120 positioned between flange 110 and grip member 130. Insert 120 may be adapted to be received by flange 110 and attached thereto to secure insert 120, and thereby grip member 130, to the flange. Insert 120 includes a proximal end 120a adapted to be inserted into flange 110 and a distal end 120b adapted to be received by grip member 130 along outer surface 120c. For example, proximal end 120a may include one or more cross-sectional dimensions adapted to be received by flange 110. Distal end 120b may include one or more cross-sectional dimensions adapted to cushion grip member 130. In the illustrated embodiment, for example, proximal end 120a has a generally uniform height dimension (see Figure 2A) and a generally uniform width dimension (see Figure 2B). The distal end 120b includes a tongue 121 having a reduced height dimension (see FIG2A ) and an increased width dimension (see FIG2B ). Other dimensions along the distal end 120b may also be used. For example, the width dimension along the distal end 120b (e.g., its tongue 121 ) may be larger or smaller than the width dimension along the proximal end 120a. The height dimension along the distal end 120b may also be larger or smaller than the height dimension along the proximal end 120a. In one embodiment, the grip member 130 does not include the tongue 121 (see, e.g., FIG3A and 3B ). In some embodiments, the height dimension along the distal end 120b of the insert 120 may be similar to the height dimension along the proximal end 120a. For example, the height dimensions along the proximal and distal ends 120a, 120b may be defined by the generally planar upper and lower sides of the insert 120 (see, e.g., FIG3A and 3B ).

The flange 110 and insert 120 preferably comprise a rigid material, preferably metal, including alloys thereof. In some embodiments, the flange 110 or insert 120 may include a metal portion, surface, or layer. As described above, the flange 110 may include a polished metal surface. The flange 110 or insert 120 may comprise a solid metal construction or may be hollow. For example, the insert 120 may be solid or may include a cavity, such as a tube for a hollow handle, as shown in Figures 5A-5C. In various embodiments, the flange 110 may be partially hollow to receive the insert 120 and may have other hollow portions to minimize overall heat capacity and weight and improve heat dissipation. For example, the flange 110 may define an aperture 115 through which the insert 120 may be received. The aperture 115 may typically extend between the outer surface 110b and the inner surface 110a and include at least a first cavity 111.

Continuing with reference to Figures 2A and 2B, a hole 115 extends from the outer surface 110b to the inner surface 110a of the flange 110. The portion of the flange 110 defining the hole 115 extends inward from the inner surface 110a, defining a second cavity 112. The first cavity 111 is adjacent to the outer surface 110b, and the second cavity 112 is adjacent to the inner surface 110a. The hole 115 further includes a passage 113 connecting the first cavity 111 and the second cavity 112. The passage 114 is narrow relative to the cavities 111 and 112, comprising a smaller cross-sectional dimension than the corresponding cross-sectional dimensions of the cavities 111 and 112 it connects. The proximal end 120a of the insert 120 may include dimensions suitable for extending into or through the reduced cross-sectional dimension of the passage 113. When the insert 120 is received within the hole 115, the proximal end 120a of the insert 120 may extend through the passage 113 and into the second cavity 112. Thus, a portion of the proximal end 120a of the insert 120 (e.g., the proximal surface 120d) may at least partially extend into the second lumen 112. However, in other embodiments, the proximal end 120a of the insert 120 may not extend into the second lumen 112 or the passage 113. In one example, the proximal end 120a of the insert 120 extends into the passage 113 but does not extend into the second lumen 112.

The insert 120 can be shaped to have a cross-sectional dimension such that it is received within the flange 110 in a manner that minimizes the contact area, thereby reducing heat transfer to the grip 130. Similarly, the flange 110 can define a hole 115 having a cross-sectional dimension (e.g., shaped to receive the insert 120 in a manner that minimizes the contact area between the flange 110 and the insert 120). For example, the insert 120 can contact only a portion of the flange 110 or the hole 115 defined by the flange 110. In the embodiment shown in Figures 2A and 2B, the proximal end 120a of the insert 120 includes a cross-sectional dimension designed to fill the central passage 113.

In various embodiments, one or more cavities 111, 112 can have cross-sectional dimensions suitable for providing a space between insert 120 and the sidewalls defining aperture 115 when insert 120 is received within aperture 115. For example, one or more lengths of cavities 111, 112 can include a height or width dimension that is greater than the height or width dimension along the corresponding length of insert 120 to provide one or more continuous or non-continuous spaces (e.g., lateral, upper, or lower pockets) between insert 120 and flange 110 within aperture 115. In the illustrated embodiment, for example, the proximal end 120a of insert 120 can contact only the narrow central channel 113 of aperture 115, separating first cavity 111 from second cavity 112 of aperture 115. In some embodiments, once attached to flange 110, the proximal end 120a of insert 120 can contact flange 110 only via attachment means (e.g., welds, rivets, screws, bayonet pins, or detents). In one embodiment, the proximal end 120a of the insert 120 contacts the flange 110 directly along the channel 113 and through the attachment member.

The grip member 130 can be overmolded to cover at least a portion of the outer surface 120c of the insert 120 along the distal end 120b. The grip member 130 can therefore include a coating material, such as a polymer material. The polymer material can be molded from a resin material and include plastics, thermosetting polymers, elastomers, or other polymer materials. In various embodiments, the grip member 130 includes a high-temperature stable phenolic resin. The grip member 130 is preferably shaped (preferably molded) to include an outer surface profile 130c along the proximal end 130a (e.g., along the proximal face 130d) that is adapted to be flush with the adjacent portion 110c of the flange 110 when the proximal end 120a of the insert 120 is received through the first cavity 111 and secured within the hole 115.

The proximal end 120a can be secured within the first cavity 111 by attaching the insert 120 to the flange 110. The insert 120 can be attached to the flange 110 by welding the proximal end 120a to a portion of the flange 110 adjacent to the aperture 115 (e.g., a portion of the flange 110 defining the first cavity 111, the second cavity 112, or the channel 113). The weld can be a metal weld between metal surfaces. Other attachment methods can also be used. For example, the insert 120 can be attached to the flange 110 via rivets, screws, bayonet pins, or a forked detent mount. In the embodiment shown in Figures 2A and 2B, the proximal end 120a of the insert 120 includes a tab portion 124 having at least one cross-sectional dimension complementary to a corresponding cross-sectional dimension of the channel 113, so as to approach or engage the channel 113 at the intersection thereof along the corresponding cross-sectional dimensions. More specifically, tab portion 124 has a cross-sectional shape that is complementary to the cross-sectional shape of the channel 113 so as to fill the channel 113 when inserted therein. Insert 120 can be attached to flange 110 via a weld along the intersection of hole 115 and channel 113 to tab portion 124 or other portion of proximal end 120a (e.g., to the periphery or proximal face 120d of tab portion 124). The weld material remains within second cavity 112 and does not extend beyond proximal face 110a. However, to the extent that the remaining portion of the weld can extend further, the weld material can be easily rubbed or ground away without the need for further polishing, as second cavity 112 can abut against outer wall 210 of cookware article 200 and be covered when handle 100 is attached to cookware article 200.

The proximal end 120a of the insert 120 shown in Figures 2A and 2B also includes one or more optional notches 125. In some embodiments, the notch 125 can be adapted to fixedly engage a rod, such as a biased or spring-loaded bolt (not shown), in the hole 115. In some such embodiments, the insert 120 can be inserted into the hole 115 and reversely bias the rod therein. The insert 120 can then be further inserted, rotated, or otherwise manipulated to bias the rod into the notch 125. Once positioned in the notch 125, the rod can prevent the insert from moving from the first cavity 111. In other examples, the rod can be inserted into the hole 115 and into the notch 125 by the side of the flange 110. In some examples, the rod can fully extend through the proximal end 120, hole 115, or flange 110 of the insert 120.

3A and 3B illustrate another embodiment of a handle 100, comprising a flange 110, an insert 120, and a grip member 130. The grip member 130 extends around at least a portion of the distal end 120b of the insert 120 and includes an outer surface profile 130c (e.g., a proximal face 130d) along the proximal end 130a. This outer surface profile is adapted to align flush with the adjacent portion 110c of the flange 110 when the proximal end 120a of the insert 120 is received within the aperture 115 and secured within the first cavity 111. In this embodiment, the insert 120 includes cross-sectional dimensions that complement the cross-sectional dimensions of the corresponding portion of the aperture 115. In particular, the insert 120 has a wedge-shaped proximal end 120a having a proximally decreasing width dimension along its length (see FIG. 3A ) and a generally uniform height dimension (see FIG. 3B ). The distal end 120b of the insert 120 may include generally uniform width and height dimensions along its length. The width dimension along the distal end 120b can be smaller than the width dimension along the proximal end 120a. The height dimension along the distal end 120b can be similar to the height dimension along the proximal end 120a. The height dimensions along the proximal and distal ends 120a, 120b can be defined by the generally planar upper and lower sides of the insert 120.

2A and 2B , the aperture 115 extends between the inner face 110a and the outer face 110b of the flange 110 and includes at least one cavity 111. When received within the aperture 115, proximal translation of the insert 120 through the aperture 115 can be limited by one or more cross-sectional dimensions of the proximal end 120a of the insert 120 relative to the aperture 115. For example, the aperture 115 can include a height and width that are complementary to the wedge-shaped proximal end 120a of the insert 120, such that the proximal end 120a fills the aperture 115 when received therein. The insert 120 can be attached to the flange 110 by welding the proximal end 120a (e.g., along the perimeter of the proximal face 120d) to an adjacent portion of the flange 110 defining the aperture 115. The portion of the proximal end 120a that is welded to the flange can include a tab portion 124 having one or more complementary cross-sectional dimensions to engage the flange 110 at one or more of the upper, lower, or lateral sides of the aperture 115. Other attachment means can also be used. For example, the insert 120 can be attached to the flange 110 via rivets, screws, bayonet pins, or a bifurcated detent mount.

4A and 4B illustrate another embodiment of a handle 100, comprising a flange 110, an insert 120, and a grip member 130. The grip member 130 extends around at least a portion of the distal end 120b of the insert 120 and includes an outer surface profile 130c (e.g., proximal face 130d) along the proximal end 130a. This outer surface profile is adapted to align flush with the adjacent portion 110c of the flange 110 when the proximal end 120a of the insert 120 is positioned within the aperture 115 and secured within the first cavity 111. In this embodiment, the aperture 115 extends between the inner face 110a and the outer face 110b of the flange 110 and includes at least one cavity 111. The cavity 111 has a width ( FIG. 4A ) and height ( FIG. 4B ) that increase toward the proximal end. The aperture 115 also includes a narrow channel 114 extending between the cavity 111 and the inner face 110a of the flange 110. Similar to the embodiment described with respect to Figures 2A-3B, the proximal end 120a of the insert 120 includes cross-sectional dimensions that include a width dimension that is generally uniform along its length (see Figure 4B), and in this embodiment, can also be generally uniform along the entire length of the insert 120. The proximal end 120a of the insert 120 has a distal portion 122 that has a generally uniform width dimension. The proximal end 120a also includes a flared wedge-shaped portion 123 that is proximal to the distal portion 122 and has a larger width dimension than the distal portion 122 (see Figure 4A). The width dimension of the flared wedge-shaped portion 123 also increases proximally along its length (see Figure 4A). The width dimension of the flared wedge-shaped portion 123 can be complementary to the width dimension along the corresponding length of the aperture 115. Thus, Figures 4A and 4B illustrate an embodiment of the handle 100 in which the aperture 115 and the insert 120 include complementary proximal dimensions. The proximal end 120a of the insert 120 further includes a tab portion 124 proximal to the distal portion 122 and the flared wedge portion 123, having a reduced width dimension relative to the flared wedge portion 123. The tab portion 124 can have a larger width dimension than the distal portion of the proximal end 120a of the insert 120. In other embodiments, the tab 124 can have a similar or smaller width dimension than the distal portion 122.

As best shown in FIG4A , when insert 120 is received within aperture 115 of flange 110, the lateral sides of flared wedge portion 123 can wedge insert 120 within aperture 115, preventing distal translation and removal of insert 120 from aperture 115. In various embodiments, the lateral sides of flared wedge portion 123 can contact flange 110 within aperture 115, or can be slightly spaced from the sides of aperture 115, such that distal translation of insert 120 causes the lateral sides of insert 120 along flared wedge portion 123 to contact flange 110 along the lateral sides of aperture 115. In some embodiments, insert 120 can be removed from aperture 115 by rotating insert 120 a sufficient angle to clear the lateral sides of flared wedge portion 123 from the reduced width of aperture 115. For example, aperture 115 can have a cross-sectional dimension that is larger than the maximum width of flared wedge portion 123. 3A and 3B , proximal translation of the insert 120 through the aperture 115 can be limited by one or more cross-sectional dimensions of the proximal end 120 a relative to the aperture 115. In the illustrated embodiment, the width dimension of the flared wedge portion 123 is greater than the width dimension of the passage 113, thereby preventing the flared wedge portion 123 from being received into the passage 113 and, thereby, preventing further proximal translation of the insert 120 through the aperture 115.

Continuing with reference to Figures 4A and 4B, channel 113 is sized to receive tab portion 124. One or more cross-sectional dimensions of channel 113 may also complement corresponding dimensions of tab portion 124 to thereby prevent tab portion 124 from moving in one or more directions when received within channel 113. In the illustrated embodiment, for example, channel 113 and tab portion 124 have complementary height dimensions that prevent vertical movement of tab portion 124 when received within channel 113. Channel 113 and tab portion 124 may also include complementary width dimensions that prevent lateral movement of tab portion 124 when received within channel 113. For example, tab portion 124 may be sized to fill the length of the channel. However, lateral movement of proximal end 120a of insert 120 within aperture 115 is prevented by complementary width dimensions along corresponding portions of cavity 111 and flared wedge portion 123. In some embodiments, channel 113 and tab portion 124 do not include complementary width dimensions. If the insert 120 is attached to the flange 110 by welding between the tab portion 124 (e.g., along the proximal face 120d or its periphery) and the adjacent portion of the flange 110 defining the aperture 115 (e.g., along the channel 113), it may be desirable for the width dimension along the proximal face 120d to be complementary to or similar to the width dimension of the corresponding portion of the channel 113 to increase the number of available weld points. In one such example, the space between the tab portion 124 and the lateral side of the flange 110 can be provided within the channel 113, distal to the proximal face 120d. As described above, other attachment methods may also be used. For example, the insert 120 may be attached to the flange 110 via rivets, screws, bayonet pins, or a bifurcated detent mount, thereby securing the proximal end 120a within the first cavity 111. In one embodiment, no attachment member is used, and vertical, lateral, proximal, and distal movement of the insert 120 is prevented due to the sizing of the proximal end 120a of the insert 120 and the aperture 115, as described above.

Similar to the embodiment described above with respect to Figures 2A and 2B, when the proximal end 120a of the insert 120 is received within the aperture 115 and secured within the first cavity 111, a space within the aperture 115 (particularly cavity 111 in the embodiment shown in Figures 4A and 4B) is provided between the insert 120 and the flange 110. In particular, the proximal end 120a of the insert 120 is spaced apart from the flange 110 within the cavity 111 along the lateral, upper, and lower sides of the distal portion 122 and the upper and lower sides of the flared wedge portion 123. The space around the distal portion 122 can be continuous. Accordingly, two or more sides of the distal portion 122 and the flared wedge portion 123 can be free from contact with the flange 110 or the aperture 115, which reduces thermal conduction between them.

Figures 5A-5C illustrate another embodiment of a handle 100, wherein the handle includes a two-piece insert 120 comprising a proximal end 120a and a distal end 120b. The proximal end 120a of the insert 120 is sized to be received within a cavity 126 extending within the distal end 120b. A grip member 130 extends around the distal end 120b and includes an outer surface profile 130c (e.g., a proximal face 130d) along the proximal end 130a that is adapted to align flush with an adjacent portion 110c of the flange 110 when the proximal end 120a of the insert 120 is received in the aperture 115 and secured within the first cavity 111. Similar to the embodiment described above, the flange 110 illustrated in Figures 5A-5C defines an aperture 115 extending from the outer face 110b toward the inner face 110a and including at least the first cavity 111. The aperture 115 also includes a narrow channel 113 that is dimensioned to receive a tab portion 124 of the insert 120 in a manner similar to that described with respect to Figures 4A and 4B and accompanying structure. For example, the relative cross-sectional dimensions (e.g., height or width dimensions) of the tab portion 124 and the channel 113 can be configured such that the tab portion 124 engages or approaches one or more cross-sectional dimensions of the channel 113 along an interface. Thus, when the tab portion 124 is positioned within the channel 113, movement of the proximal end 120a of the insert 120 within the channel 113 can be prevented in a proximal, lateral, or vertical direction. In one example, the cross-sectional shape and dimensions of the tab portion 124 complement the corresponding cross-sectional shape of the channel 113, such that the tab portion 124 can fill the channel 113. In one embodiment, proximal end 120a of insert 120 can be attached to flange 110 via welding along the intersection of proximal face 120b and channel 113 (eg, the intersection between tab portion 124 and channel 113). Other attachment members, such as those described elsewhere herein, can also be used.

The illustrated handle 100 is configured to compress the proximal end 120a of the insert 120 toward the channel 113, thereby attaching the insert 120 along the proximal end 120a within the channel 113 and retaining the tab 124 within the channel 113. In one embodiment, the channel 113 extends to an opening along the inner face 110a, and proximal movement of the tab portion 124 is prevented by the outer wall 210 of the cookware article 200. In another embodiment, the aperture 115 may not extend to or include an opening at the inner face 110a of the flange 110 and the tab portion 124, thereby preventing proximal movement of the proximal end 120a of the insert 120 from being prevented by the base of the aperture 115. In yet another embodiment, the channel 113 may include a proximal length having a smaller dimension than a corresponding dimension of the tab portion 124, preventing proximal movement of the tab portion 124 beyond the proximal length. Similarly, the tab portion 124 can include a distally enlarged dimension configured to wedge into the channel 113, which prevents further proximal movement. In yet another embodiment, the proximal end 120a can include a portion distal to the tab portion 124 having a larger dimension than the corresponding dimension of the channel 113, such as the flared wedge portion 123 described above with respect to Figures 4A and 4B, which prevents the portion from entering the channel 113 and thereby prevents further proximal movement of the proximal end 120a of the insert 120.

Continuing with reference to Figures 5A-5C, the distal end 120b of the insert 120 can be adapted to engage and couple with the flange 110, thereby at least partially attaching the insert 120 to the flange 110. For example, the distal end 120b of the insert 120 can include a proximal mating structure 129a configured to mate with a mating structure 129b disposed along the flange 110. Example mating structures can include tracks, grooves, compression fittings, snap fittings, slots, notches, or other suitable structures. In the illustrated embodiment, the mating structures 129a, 129b include threads disposed along a proximal portion 128 of the distal end 120b of the insert 120 and along an outer face 110b of the flange 110, wherein the proximal portion 128 of the distal end 120b of the insert 120 comprises a male connector and the outer face 110b of the flange 110 comprises a female connector. In another embodiment, the proximal portion 128 of the distal end 120b of the insert 120 may include a female connector and the outer face 110b of the flange 110 may include a male connector.

The extent to which proximal end 120a can be accommodated within the hollow portion of distal end 120b can be limited by a dimension along proximal end 120a that is larger than a corresponding dimension of the hollow portion. For example, a rod or other type of stopper can extend into the hollow portion and abut proximal end 120a, thereby preventing additional distal translation of proximal end 120a within cavity 126. In the illustrated embodiment, proximal end 120a includes a distal portion 122 having at least one distally increasing dimension configured to wedge within cavity 126 of the hollow portion at a predetermined location corresponding to the junction of flange 110 and handle 130 and the limit of proximal movement of proximal end 120a through aperture 115. It will be appreciated that proximal end 120a can also include a hollow portion.

The handle 100 shown in Figures 5A-5C also includes an optional screw-on cap-type cover 140, which can optionally house and seal electronic components within a cavity 126 accessible upon removal of the cover or cover 140. As shown, the distal end 120b includes a distal mating structure 129c configured to mate with a mating structure 129b located along the cover 140. Example mating structures may include tracks, grooves, compression mechanisms, snap mechanisms, slots, notches, or other suitable structures. In the illustrated embodiment, the mating structures 129c and 129d include threads, with the distal mating structure 129c located along the distal end 120b of the insert 120 comprising a male connector and the mating structure 129d located along the cover 120 comprising a female connector. In another embodiment, the distal mating structure 129c may comprise a female connector, while the mating structure 129d of the cover 140 may comprise a male connector.

In various embodiments, the insert 120 may include a mating structure arranged along another portion of the insert 120, such as a middle portion, and when the mating structure is mated with a corresponding mating structure arranged on the flange 110, the proximal end 120a can be accommodated in the hole 115 of the flange 110 and can be compressed proximally therein, as described herein. The handle 100 described with respect to Figures 5A-5C shows one such example. In a modified embodiment, the proximal end 120a and distal end 120b of the insert 120 described with respect to Figures 5A-5C may include a single structural unit. In such an example, one or both of the proximal end 120a or distal end 120b may include or not include a hollow portion. In another embodiment, the handle 100 may be similar to the embodiment described with respect to Figures 5A-5C, but does not have the proximal end 120a of the insert.

6A-6E illustrate embodiments of a handle 100 and components and accessories of the handle 100 assembled to a cookware vessel 200 according to various embodiments. FIG6A illustrates the flange 110 and insert 120 of the handle 100 before the proximal end 120a of the insert 120 is received in the aperture 115 of the flange 110 ( FIG6C ) and the distal end 120b of the insert 120 is overmolded with the grip member 130 ( FIG6B ). FIG6B-6E illustrate the components of the assembly of FIG6A transformed to provide the handle 100 attached to the cookware vessel 200.

The assembled handle 100 in Figures 6A-6E can be similar to the handle 100 described above with respect to Figures 3A and 3B. In one embodiment, a method of assembling the handle 100 for a cookware vessel 200 can include providing a flange 110 (Figure 6A), wherein the flange 110 defines a first curved inner surface 110a adapted to contact a curved outer wall 210 (see, e.g., Figure 6E) of the cookware vessel 200 and an outer surface 110b opposite the inner surface 110a. A hole 115 can extend from the outer surface 110b to the inner surface 110a. The method may further include providing an elongated insert 120 ( FIG. 6A ), the insert 120 having a proximal end 120a adapted to be received in a portion of the hole 115 of the metal flange 110 extending from the exterior face 110b toward the interior face 110a, the distal end 120b attached to the proximal end 120a or otherwise extending distally from the proximal end 120a, the distal end 120b being adapted to extend out from the distal end 110b of the flange 110 when the proximal end 120a is inserted into the hole 115 of the metal flange 110 at the exterior face 110b.

As shown in FIG6B , the polymer grip member 130 can be molded onto the distal end 120b of the insert 120 and include an outer surface profile 130c along the proximal face 130d that is adapted to form a flush interface at the outer edge of the outer face 110b of the flange 110 when the proximal end 120a of the insert 120 is inserted into the aperture 115. As also shown in FIG6B , the flange 110 can include first and second side holes 117, 117′ for receiving a fixing member such as a rivet (see, e.g., FIG6D ). The side holes 117, 117′ can be arranged on opposite sides of the aperture 115. In various embodiments, the side holes 117, 117′ can be drilled, punched, molded through the flange 110, or otherwise formed through the flange 110.

The proximal end 120a of the insert 120 can be inserted into the aperture 115 of the flange 110 at the outer face 110b, so that the grip member 130 contacts the outer face 110b of the flange 110. When received in the aperture 115, the insert 120 can be secured to the flange 110 to secure the proximal end 120a within the cavity 111, as shown in FIG6D . For example, the proximal end 120a of the insert 120 can be welded to an interior portion of the flange 110 disposed between the proximal face 110a and the distal face 110b of the flange 110. As shown, the proximal face 120d along the tab portion 124, which includes a metal surface, or its edge, is welded to meet or be adjacent to the metal surface along the narrowed proximal length of the aperture 115. The insert 120 can also be secured to the flange 110, for example, within the aperture 115, as described elsewhere herein.

FIG6D , together with FIG6E , illustrates the steps of attaching the handle 100 to the cookware vessel 200. Specifically, the inner face 110a of the flange 110 can be secured to the curved outer wall 210 of the cookware vessel 200 to provide a gripping member 130 molded as a handle for the cookware vessel 200. More specifically, rivets 217, 217′ can be inserted through holes 207, 207′ in the side wall 210 of the container 200 opposite each of the first and second side holes 117, with the tails 217a, 217a′ of the rivets 217, 217′ extending beyond each of the side holes 117. In some embodiments, the distal end of the tail 217a, 217a′ of each rivet 217, 217′ can be deformed to extend beyond the perimeter of each of the first and second side holes 117, 117′ of the flange 110.

As described above, the handle 100 can be configured to provide a variety of shapes for the grip member 130. For example, in various configurations, the grip member 130 can be substantially straight or linear, curved, U-shaped, bulbous or L-shaped for a long handle, an auxiliary handle, a cap handle, or a short side handle. In these and other embodiments, the insert 20 can extend the entire length of the grip member 130 or only a portion of the grip member 130. In some embodiments, the insert 120 can be shorter than the grip member 130 (see, e.g., Figures 3A-4B). In some embodiments, the grip member 130 can extend further distally from the flange 110 than the insert 120 (see, e.g., Figures 2A-4B). In other embodiments, the insert 120 can extend further distally from the flange 110 than the grip member 130 (see, e.g., Figures 5A-5B).

7A-9C illustrate various views of a handle 100 having a U-shaped grip member 130 according to various embodiments. With particular reference to the views of FIG7A and FIG8B , the U-shaped grip member 130 may include two proximal ends 130a, 130a' adapted to be disposed along the outer faces 110b, 110b of the flange 110. With further reference to the exploded view of FIG8A , the proximal ends 130a, 130a' of the grip member 130 include outer surface profiles 130c, 130c' adapted to lie flush with adjacent portions 110c, 110c' of the flange 110 when the proximal ends 120a, 120a' of the inserts 120, 120' are received in and secured to the respective apertures 115, 115'.

The proximal ends 120a, 120a' of the insert 120 shown in Figures 7A-9C and the corresponding apertures 115, 115' defined by the flange 110 can be configured similarly to the structure described above with respect to Figures 2A and 2B. For example, with continued reference to Figures 8A and 8B and further reference to the cross-sectional views shown in Figures 7B and 7C, each aperture 115, 115' can extend between the outer face 110b, 110b' and the inner face 110a of the flange 110 and include at least a first lumen 111, 111'. The portion of the flange 110 that defines each aperture 115, 115' extending inwardly from the corresponding inner face 110a, 110a' can define a second lumen 112, 112'. Each aperture 115, 115' can further include a narrowed channel 113, 113' connecting the corresponding first lumen 111, 111' with the second lumen 112, 112'. Each channel 113, 113' can include a cross-sectional dimension that is smaller than the corresponding cross-sectional dimension of the corresponding cavity 111, 111', 112, 112' to which it is connected. The proximal end 120a, 120a' of the insert 120 can also be sized to extend into or through the reduced dimension of the corresponding channel 113, 113'. The proximal end 120a, 120a' of the insert 120 can be welded or otherwise secured to the flange 110 using an attachment member, as described herein.

Although not employed in the illustrated embodiment, the proximal ends 120a, 120a' of the insert 120 each include one or more optional notches 125, 125'. As described above, the notches 125, 125' can be adapted to engage a rod (such as a biased or spring-loaded latch) into the holes 115, 115'. In some such embodiments, the insert 120 can be inserted into the holes 115, 115' and counter-bias the rod therein. The insert 120 can then be further inserted into the holes 115, 115' to bias the rod into the notches 125, 125'. Once positioned in the notches 125, 125', the rod prevents the movement of the insert 120 relative to the first cavity 111, 111'. The rod can also be inserted into the holes 115, 115' and into the notches 125, 125' through one or more sides of the flange 110. In some examples, the rod may extend completely through the proximal end 120a, 120a' of the insert 120, the aperture 115, 115', or the flange 110.

In other embodiments, the U-shaped handle 100 can be configured with the insert 120 and flange 110 as described elsewhere herein, such as described with respect to Figures 3A-6E.

9A and the cross-sectional views provided in 9B and 9C , insert 120 can extend the entire length of handle member 130 and into corresponding holes 115, 115′ of flange 110 to provide secure attachment of handle member 130 at flange 110. Flange 110 can be suitably secured to a wall of a cookware article, such as by using rivets passing through holes 117, 117′ and corresponding holes in an outer wall of the article, e.g., as described with respect to FIGs. 6A-6E , to provide a handle 100 for the article, wherein flange 110 engages handle member 130 to provide a flush interface.

The disclosed handles described herein, including handle assemblies thereof, can provide improved handles and cookware articles incorporating such handles. For example, embodiments of the handle can utilize a cast metal flange for a molded resin handle. Metal polishing can also be performed before attaching the molded handle, reducing labor and defects that might otherwise occur if the polishing of the exposed metal is performed after the resin handle is overmolded. The handles described herein can also provide an aesthetic improvement by having a polished metal component that is flush with the molded handle at their outer periphery. The handle can optionally be configured as a lighter assembly than a solid metal handle of a similar shape, further reducing the likelihood of the container tipping because the handle's mass can be positioned closer to the container's center of gravity. In contrast to forged, overmolded metal handles that contact the entire container sidewall and are exposed to combustion exhaust gases exiting the pot, the handle assembly of the present invention can be maintained at a lower temperature because less heat is transferred to the grip portion, as the contact area with the flange can be minimized to weld or other attachment areas.

While the present invention has been described in conjunction with preferred embodiments, it is not intended to limit the scope of the invention to the specific forms set forth, but rather to cover such alternatives, modifications, and equivalents as may fall within the spirit and scope of the invention as defined by the appended claims. For example, as described above, the insert can be secured into a hole, such as the first cavity, and can be welded or otherwise secured to the flange along the hole. In one such embodiment, the insert can be secured to the flange in a non-visible portion before the handle member is attached or molded to the insert.

It will be appreciated that although features have been described using terms such as lateral, upper, interior, width, height, etc., such terms are used for convenience and should not be construed as limiting unless otherwise indicated. Such terms as used herein are not intended to be limiting to the extent that the handles described herein or their portions may be attached or utilized in other orientations. For example, in some embodiments, a feature may be rotated so that height becomes width and lateral becomes upper and interior.

Claims (19)

1. A handle assembly for a cooking utensil, comprising: (a) A metal flange having an inner surface and an outer surface, the inner surface being adapted to contact a curved outer wall of a cookware article, wherein a hole extends from the inner surface toward the outer surface and defines at least a first cavity therebetween; (b) An insert having a proximal end and a distal end, wherein the proximal end is adapted to be received within a first cavity of the aperture and fixed therein when the proximal end is attached to a flange within the aperture, wherein the insert is a two-piece insert including the proximal end and the distal end, and wherein the proximal length of the distal end of the insert defines a cavity adapted to receive the distal length of the proximal end of the insert; and (c) A grip member having a proximal end and a distal end and comprising a polymer material that overmolds at least a portion of the distal end of the insert, the grip member having an outer surface profile located at the proximal end that is adapted to be flush with an adjacent portion of the flange when the proximal end of the insert is secured in the first cavity. 2. The handle assembly for a cookware article as claimed in claim 1, wherein the proximal end of the insert has a metal sheet portion having a cross-sectional dimension complementary to the cross-sectional dimension of the hole, wherein the metal sheet portion engages with the hole along the corresponding complementary cross-sectional dimension of the hole when received in the hole, and wherein the proximal end is attached to the flange by welding along the engagement interface of the metal sheet portion and the hole. 3. The handle assembly for a cookware article as claimed in claim 2, wherein the hole defines a channel extending proximally from the first cavity toward the inner surface of the flange, the channel having at least one cross-sectional dimension smaller than the cross-sectional dimension of the first cavity, and wherein the complementary cross-sectional dimension of the hole is positioned along the channel. 4. The handle assembly for a cookware article as claimed in claim 1, wherein the hole extends from the outer surface of the flange to the inner surface, and wherein the first cavity is adjacent to the outer surface and the hole defines a second cavity adjacent to the inner surface. 5. The handle assembly for a cookware article as claimed in claim 4, wherein the proximal end of the insert includes a metal sheet portion that extends at least partially into the second cavity, and wherein the metal sheet portion is attached by welding to the portion of the hole that defines the second cavity. 6. The handle assembly for a cookware article as claimed in claim 1, wherein the hole defines a channel extending between the first cavity and the second cavity, the channel having at least one cross-sectional dimension smaller than the cross-sectional dimension of the first cavity, and wherein the length of the proximal end of the insert is adapted to fill at least a portion of the length of the channel when the proximal end of the insert is secured within the first cavity. 7. The handle assembly for a cookware article as claimed in claim 1, wherein the hole defines a channel extending proximally from the first cavity toward the inner surface of the flange, the channel having at least one cross-sectional dimension smaller than the cross-sectional dimension of the first cavity, and wherein the length of the proximally end of the insert and the length of the channel comprise complementary cross-sections such that the length of the proximally end of the insert fills the length of the channel when the proximally end of the insert is secured to the first cavity. 8. The handle assembly for a cookware article as claimed in claim 1, wherein when the proximal end of the insert is secured in the first cavity, the length of the proximal end within the first cavity is spaced apart from the surrounding portion of the flange defining the first cavity. 9. The handle assembly for a cookware article as claimed in claim 1, wherein the hole defines a channel extending proximally from the first cavity toward the inner surface of the flange, the channel having at least one cross-sectional dimension smaller than the cross-sectional dimension of the first cavity, and wherein the proximally end of the insert comprises: (a) A metal sheet portion having at least one cross-sectional dimension that is complementary to the cross-sectional dimension of the channel; (b) A flared wedge-shaped portion, located at the distal end of the metal sheet portion, having a distally tapering cross section adapted to be complementary to the distally tapering cross section of the first cavity along the corresponding length of the hole when the proximal end of the insert is fixed in the first cavity; and (c) The distal portion, the distal end of the flared wedge portion, wherein the distal portion has a cross-sectional dimension smaller than the corresponding cross-sectional dimension of the flared wedge portion along the distally decreasing cross-section, and wherein the distal portion is spaced apart from the surrounding portion defining the first cavity when the proximal end is fixed therein. 10. The handle assembly for a cookware article as claimed in claim 1, wherein the outer surface of the flange includes a mating structure adapted to mate with a mating structure arranged along the proximal length of the distal end of the insert, wherein when the proximal end of the insert is secured in the first cavity, the distal end of the insert is flattened between the flange and the distal end of the insert. 11. The handle assembly for a cooking utensil article as claimed in claim 10, wherein the mating structure arranged along the proximal length of the distal end of the insert is the proximal end of the grip member. 12. The handle assembly for a cookware article as claimed in claim 10, wherein the mating structure includes threads adapted to engage the distal end of the insert with the distal end face of the flange. 13. The handle assembly for a cookware article as claimed in claim 1, wherein the distal end of the insert further includes a cavity defining a distal portion thereal, and wherein the handle assembly further includes a closing cap having a mating structure adapted to engage with a mating structure arranged along the distal portion of the distal end of the insert to close the cavity. 14. A cooking utensil, comprising: (a) A vessel having a bottom and surrounding sidewalls extending upward to form an edge and defining an internal volume between the bottom and the surrounding sidewalls for containing and retaining liquid; and (b) The handle assembly of claim 1, wherein the handle assembly is engageable at its flange to the outside of the surrounding sidewall. 15. A method for forming a cookware vessel, the method comprising the steps of: (a) A metal flange having a curved inner surface and an outer surface, the curved inner surface being adapted to contact the curved outer wall of the cookware, wherein a hole extends from the outer surface toward the inner surface; (b) An insert having a proximal end and a distal end, wherein the proximal end is adapted to be received in a portion of a hole extending from the outer side of the flange toward the inner surface, and wherein the distal end is adapted to extend away from the outer side of the flange when the proximal end is inserted into the hole at the outer side, wherein the insert is a two-piece insert including the proximal end and the distal end, and wherein the proximal length of the distal end of the insert defines a cavity adapted to receive the distal length of the proximal end of the insert. (c) A grip portion is provided, the grip portion comprising a polymer material molded on the distal end of the insert and adapted to form a flush interface at the outer periphery of the flange when the proximal end is inserted into the hole; (d) Insert the proximal end of the insert into the hole of the flange at the outside, so that the grip portion contacts the outside of the flange; (e) securing the proximal end of the insert to the flange within the hole; and (f) Attaching the inner surface of the flange to the curved outer wall of the cookware to provide a grip for a handle assembly molded for the cookware. 16. The method for forming a cookware as claimed in claim 15, wherein securing the proximal end of the insert to the flange within the hole comprises welding the proximal end of the insert to the flange along a proximal portion of the hole. 17. The method for forming a cookware as claimed in claim 15, wherein the handle assembly for the cookware is one of an elongated handle assembly and a U-shaped handle assembly. 18. The method for forming a cookware as claimed in claim 15, wherein the metal flange has first and second side holes for receiving rivets, the first and second side holes being arranged on opposite sides of the holes. 19. The method of forming a cookware as claimed in claim 18, wherein attaching the inner surface of the flange to the curved outer wall of the cookware to provide a grip molded for a handle assembly of the cookware comprises: (a) A rivet is inserted through each of the first and second holes in the sidewall of the container and the corresponding first and second side holes in the flange, wherein the tail of each rivet extends beyond the corresponding side hole; and (b) Deform the distal end of the tail portion of each rivet extending beyond the respective side hole to secure the rivet, wherein the distal end of the deformed tail portion extends beyond the periphery of each of the first and second side holes in the flange.