Insulated double walled drinking vessel and method of making the same

Abstract

An insulated vessel, e.g., a tumbler, and method of making the same is disclosed. The vessel basically comprises a pre-molded inner vessel formed of a plastic material having a sidewall is disposed within a pre-molded outer vessel formed of a plastic material having a sidewall to form a subassembly having an insulating air space between the sidewalls. A ring of plastic material is molded in-situ on top portions of the inner and outer vessels of the subassembly to cause portions of the plastic material of the inner and outer vessels to melt and intermingle with the plastic material of the ring to form a non-superficial homogenous joint. The ring forms the rim or lip of the insulated drinking vessel.

I claim: 
     
         1 . An insulated vessel comprising:
 an inner vessel formed of a plastic material, said inner vessel being pre-molded and including an inner surface and a top edge portion, said top edge portion of said inner vessel comprising an outwardly-facing annular flange;   an outer vessel formed of a plastic material, said outer vessel being pre-molded and including an outer surface and a top edge portion, said top edge portion of said outer vessel comprising an inwardly-facing annular recess, said inner vessel being disposed within said outer vessel with said outwardly-facing annular flange disposed within said inwardly-facing annular recess to support said inner vessel within said outer vessel without any other means of support and with said top edge portion of said inner vessel forming a common top surface with said top edge portion of said outer vessel; and   a ring molded in-situ on said common top surface to cause the plastic material thereof to fuse together and intermingle with said plastic material of said ring to form a non-superficial homogenous joint, said ring having an outer surface flush with said outer surface of said outer vessel, said ring having an inner surface flush with said inner surface of said inner vessel, said ring forming a rim of said vessel.   
     
     
         2 . The insulated vessel of  claim 1  wherein said plastic material of said inner vessel, said outer vessel and said ring is the same plastic material. 
     
     
         3 . The insulated vessel of  claim 2  wherein said plastic material comprises copolyester. 
     
     
         4 . The insulated vessel of  claim 1  wherein said inner vessel, said outer vessel and said ring are transparent. 
     
     
         5 . The insulated vessel of  claim 1  wherein said inner vessel and said outer vessel are transparent and wherein said ring is colored. 
     
     
         6 . The insulated vessel of  claim 1  wherein said ring includes a top free edge, and wherein the thickness of said ring tapers downward in thickness in a direction from said inner and outer vessels toward said top free edge. 
     
     
         7 . The insulated vessel of  claim 1  wherein said outer vessel is transparent and wherein said vessel additionally comprises a decorative member located between said inner vessel and said outer vessel and visible through said transparent outer vessel. 
     
     
         8 . The insulated vessel of  claim 1  wherein said inner vessel includes a sidewall and wherein said outer vessel comprises a sidewall, and wherein portions of said sidewall of said inner vessel are spaced from portions of said sidewall of said outer vessel to form an insulating air space therebetween. 
     
     
         8 . The insulated vessel of  claim 8  wherein said sidewall of said outer vessel is transparent and wherein said vessel additionally comprising a decorative member disposed within said insulating air space and visible through said transparent sidewall. 
     
     
         10 . The insulated vessel of  claim 1  wherein said vessel is a tumbler. 
     
     
         11 . A method for making an insulated vessel comprising:
 a) providing a pre-molded inner vessel formed of a plastic material and having a top edge portion;   b) providing a pre-molded outer vessel formed of a plastic material and having a top edge portion;   c) disposing said inner vessel within said outer vessel whereupon said top edge portion of said inner vessel is disposed adjacent said top edge portion of said outer vessel; and   d) molding a ring of plastic material in-situ on said top edge portions of said pre-molded inner and outer vessels to cause the plastic material thereof to fuse together and intermingle with said plastic material of said ring to form a non-superficial homogenous joint, said ring forming a rim of said vessel.   
     
     
         12 . The method of  claim 11  wherein said plastic material of said inner vessel, said outer vessel and said ring is the same plastic material. 
     
     
         13 . The method of  claim 12  wherein said plastic material comprises copolyester. 
     
     
         14 . The method of  claim 11  wherein said top edge portion of one of said pre-molded inner and outer vessels comprises an annular flange and wherein said top edge portion of the other of said pre-molded inner and outer vessels includes an annular recess for receipt of said annular flange. 
     
     
         15 . The method of  claim 14  wherein said pre-molded inner vessel comprises said annular flange and wherein said pre-molded outer vessel comprises said annular recess. 
     
     
         16 . The method of  claim 11  wherein said pre-molded inner vessel, said pre-molded outer vessel and said ring are transparent. 
     
     
         17 . The method of  claim 11  wherein said pre-molded inner vessel and said pre-molded outer vessel are transparent and wherein said ring is colored. 
     
     
         18 . The method of  claim 11  wherein said ring includes a top free edge, and wherein the thickness of said ring tapers downward in thickness in a direction from said pre-molded inner and outer vessels toward said top free edge. 
     
     
         19 . The method of  claim 11  wherein said inner vessel includes a sidewall and wherein said outer vessel comprises a sidewall, and wherein portions of said sidewall of said inner vessel are spaced from portions of said sidewall of said outer vessel to form an insulating air space therebetween when said inner vessel is disposed within said outer vessel. 
     
     
         20 . The method of  claim 19  additionally comprising disposing a decorative item within said insulating air space. 
     
     
         21 . The method of  claim 11  wherein said vessel is a tumbler.