NZ759174B2 - Refrigerator - Google Patents
Refrigerator Download PDFInfo
- Publication number
- NZ759174B2 NZ759174B2 NZ759118A NZ75911818A NZ759174B2 NZ 759174 B2 NZ759174 B2 NZ 759174B2 NZ 759118 A NZ759118 A NZ 759118A NZ 75911818 A NZ75911818 A NZ 75911818A NZ 759174 B2 NZ759174 B2 NZ 759174B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- insulating
- outer shell
- inner liner
- insulating device
- insulating layer
- Prior art date
Links
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- 239000000463 material Substances 0.000 claims description 86
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Abstract
The invention relates to a multi-purpose tile system, in particular a floor tile system, comprising a plurality of multi-purpose tiles. The invention also relates to a tile covering, in particular floor covering, consisting of mutually coupled tiles according to the invention. The invention further relates to a tile for use in multi-purpose tile system according to the invention. The multi-purpose tiles comprise a rigid base layer, at least one first coupling part and/or at least one second couple part, upward/downward tongues and upward/downward flanks, wherein the base layer has a composition that includes toughening agents and fillers and is free of plasticizer. The aim of the invention is to provide a floor panel with improved physical properties (strength, resilience, acoustic, etc.). relates to a tile for use in multi-purpose tile system according to the invention. The multi-purpose tiles comprise a rigid base layer, at least one first coupling part and/or at least one second couple part, upward/downward tongues and upward/downward flanks, wherein the base layer has a composition that includes toughening agents and fillers and is free of plasticizer. The aim of the invention is to provide a floor panel with improved physical properties (strength, resilience, acoustic, etc.).
Description
INSULATING DEVICE
Cross Reference to Related Application
This application claims ty to U.S. Provisional Patent Application No. 62/517,490, filed
June 9, 2017, which is expressly incorporated herein by reference in its ty for any and
all non-limiting purposes.
Field
The present disclosure relates generally to non-rigid, portable, insulated devices or ners
useful for keeping food and beverages cool or warm, and, more particularly, an insulating
device with a roof closure.
Background
Coolers are designed to keep food and beverages at lower temperatures. Containers may be
composed of rigid materials such as metal or plastics or le materials such as fabric or
foams. Coolers can be designed to promote portability. For example, rigid containers can be
designed to incorporate wheels that facilitate ease of transport or coolers can be designed in
smaller shapes to allow individuals to carry the entire device. Non-rigid containers can be
provided with straps and/or handles and may in certain instances be made of r weight
materials to facilitate mobility. Non-rigid coolers that maximize portability can be designed
with an aperture on the top that allows access to the interior contents of the cooler. The
aperture can also be provided with a e.
Summary
This Summary provides an introduction to some general concepts relating to this invention in
a simplified form that are further bed below in the Detailed Description. This Summary
is not intended to identify key features or essential es of the invention.
Aspects of the disclosure herein may relate to insulating s having one or more of (1) a
waterproof closure (2) an outer shell, (3) an inner liner, (4) an ting layer floating freely
in between the outer shell and the inner liner, (5) a waterproof storage compartment, or (6)
a lid assembly, which can include at least a portion of the insulating layer that extends below
a closure d to close the opening.
Brief Description of the Drawings
The foregoing Summary, as well as the following Detailed Description, will be better
understood when ered in conjunction with the accompanying drawings in which like
reference numerals refer to the same or similar elements in all of the various views in which
that reference number appears.
Fig. 1A shows a left front perspective view of an e insulating device in ance with
an aspect of the disclosure;
Fig. 1B shows a frontside perspective view of the example insulating device of Fig. 1A without
the shoulder strap;
Fig. 2 shows a backside perspective view of the example insulating device of Fig. 1A without
the shoulder strap;
Fig. 3A shows a top perspective view of the example insulating device of Fig. 1A without the
shoulder strap;
Fig. 3B shows a top view of a portion of the example insulating device of Fig. 1A;
Fig. 3C shows a portion of an alternate top perspective view of the example insulating device
of Fig. 1A;
Fig. 4 shows a bottom perspective view of the example insulating device of Fig. 1A;
Fig. 5A rates a schematic of a cross-sectional view of the example insulating device of Fig.
Fig. 5B illustrates r schematic of an enlarged portion of a cross-sectional view of the
example insulating device of Fig. 1A;
Fig. 6 illustrates an exemplary process flow diagram for forming an insulating device;
Figs. 7A-7J rate exemplary methods of g an insulating device;
Figs. 8A and 8B depict perspective views of an alternative example insulating .
Fig. 9 s a portion of an exemplary closure and an example test method for determining
if an insulating device maintains the contents therein.
Fig. 10 depicts an example test for ining the strength of an insulating device.
Fig. 11 shows a front view of another exemplary insulating device.
Fig. 12 shows a side view of the exemplary insulating device of Fig. 11.
Fig. 13 shows a front perspective view of the exemplary insulating device in an alternate
configuration.
Fig. 14A shows a side and cross-sectional view of the exemplary insulating device of Fig. 11.
Fig. 14B shows an enlarged section of Fig. 14A.
Fig. 15 shows a tic exploded view of an exemplary insulation layer for the example
insulating device of Fig. 11.
Fig. 16A shows a portion of another example insulating device.
Fig. 16B shows a side view of the example insulating device of Fig. 16A.
Fig. 17 shows a perspective view of another example insulating .
Fig. 18 shows a front view of the insulating device of Fig. 17.
Fig. 19 shows a rear view of the insulating device of Fig. 17
Fig. 20 shows a side view of the insulating device of Fig. 17.
Fig. 21 shows a cross-sectional view of the insulating device of Fig. 17.
Fig. 22 shows a schematic ed view of an exemplary insulation layer for the example
insulating device of Fig. 17.
Fig. 22A shows a front view of an exemplary insulation layer for the example insulating device
of Fig. 17.
Fig. 23 illustrates an exemplary testing method.
Fig. 24 shows a front view of an example insulating device in accordance with an aspect of the
disclosure;
Fig. 25 shows a side view of the example insulating device of Fig. 24.
Fig. 26 shows a rear view of the example insulating device of Fig. 24.
Fig. 27 shows a top view of the e insulating device of Fig. 24.
Fig. 28 shows a bottom view of the e insulating device of Fig. 24.
Fig. 29A shows a cross-sectional view of the example insulating device of Fig. 24.
Fig. 29B shows a portion of a cross-sectional view of the example ting device of Fig. 24.
Fig. 30 shows an isometric view of an exemplary insulation layer of the example insulating
device of Fig. 24.
Fig. 31 shows an alternative embodiment for an inner liner of an insulating device.
Fig. 32 shows the ting device of Fig. 24 in the opened position.
Fig. 32A shows an example manufacturing method for forming an ting device.
Fig. 33 shows an example method of securing a handle to an insulating device.
Fig. 34 illustrates an exemplary testing method.
Fig. 35A shows a front view of another exemplary insulating device.
Fig. 35B shows a side view of the exemplary ting device of Fig. 35A.
Fig. 35C shows a rear view of the exemplary insulating device of Fig. 35A.
Fig. 35D shows a top view of the exemplary insulating device of Fig. 35A.
Fig. 35E shows a bottom view of the exemplary insulating device of Fig. 35A.
Fig. 35F shows a cross-sectional view of the exemplary insulating device of 35A.
Fig. 36A shows a partial cross-sectional view of an ary lid.
Fig. 36B shows a transparent top view of the exemplary lid of Fig. 36A.
Fig. 37 shows a front view an alternate embodiment of the insulating device of 35A.
Fig. 38 shows a side view an alternate embodiment of the insulating device of 35A.
Fig. 39 shows an exploded view of the side view of the insulating device of .
Fig. 40A shows an alternate cross-sectional view of the exemplary ting device of 35A.
Fig. 40B shows the insulating device of Fig. 40A in an alternate opened configuration.
Fig. 41A shows an alternate cross-sectional view of the exemplary ting device of 35A.
Fig. 41B shows the ting device of Fig. 41A in an opened configuration.
schematically s an aerogel insulating structure, according to one or more aspects
described herein.
tically depicts one implementation of the aerogel insulating structure,
according to one or more s described herein.
schematically depicts one im plementation of the l, according to one or more
aspects described herein.
schematically depicts another implementation of the aerogel, according to one or
more aspects described herein.
schematically depicts another implementation of the aerogel, according to one or
more aspects described herein.
schematically depicts another implementation of the aerogel, according to one or
more aspects described .
schematically depicts another implementation of the aerogel insulating structure,
according to one or more aspects described herein.
schematically depicts another entation of the aerogel insulating structure,
according to one or more aspects described herein.
tically depicts another implementation of the aerogel insulating structure,
according to one or more aspects described herein.
schematically depicts another implementation of an aerogel insulating structure,
according to one or more aspects described herein.
depicts r implementation of an insulating device, according to one or more
aspects described herein.
schematically depicts a cross-sectional view of the insulating device along line 53-53
schematically depicted in .
schematically depicts a cross-sectional view of an alternative entation of an
insulating device and lid assembly, according to one or more aspects described herein.
schematically depicts another cross-sectional view of an alternative implementation
of an insulating device and lid assembly, according to one or more aspects described herein.
schematically depicts a cross-sectional view of an insulating device and lid assembly,
according to one or more aspects described herein.
schematically depicts a sectional view of an ting device, ing to one
or more aspects described .
schematically s a cross-sectional view of an insulating device, according to one
or more aspects bed herein.
schematically depicts an isometric view of an insulating container and lid structure,
according to one or more aspects described herein.
tically depicts an exploded isometric view of the insulating container, according
to one or more aspects described herein.
schematically s a cross-sectional view of an insulating device, according to one
or more aspects described herein.
depicts a cross-sectional view of a lid structure, according to one or more aspects
described .
depicts a deformable insulator, according to one or more aspects described herein.
depicts an insulating container, according to one or more aspects described herein.
schematically depicts a cross-sectional view of another entation of an
insulating container, according to one or more aspects described herein.
Detailed Description
In the ing description of the various examples and components of this disclosure,
reference is made to the accompanying gs, which form a part hereof, and in which are
shown by way of illustration various example structures and environments in which s
of the disclosure may be practiced. It is to be understood that other structures and
environments may be utilized and that structural and functional modifications may be made
from the specifically described structures and methods without departing from the scope of
the present sure.
Also, while the terms “frontside,” “backside,” “top,” “base,” “bottom,” “side,” rd,” and
“rearward” and the like may be used in this specification to describe various example features
and elements, these terms are used herein as a matter of ience, e.g., based on the
e orientations shown in the figures and/or the orientations in typical use. Nothing in
this specification should be construed as requiring a specific three ional or spatial
orientation of structures in order to fall within the scope of the claims.
FIGS. 1 -4 depict an exemplary insulating device 10 that can be configured to keep desired
contents stored cool or warm for an extended period of time. The insulating device can
generally include an outer shell 501, a closure 301, an insulating layer 502, and an inner liner
500. As shown in Fig. 3C, the inner liner 500 forms a chamber or receptacle 504 for receiving
the desired contents therein. As shown in Fig. 1A, various handles, straps, and webs (e.g. 210,
212, 218, 224) can also be included on the insulating device 10 for carrying, g, or
securing the insulating device 10.
The insulating device 10 can be ured to keep desired contents stored in the receptacle
504 cool or warm for an extended period of time. In one example, the insulating device 10
can also be designed to maintain water inside the inner chamber or receptacle 504, and the
insulating device 10 can be configured to be water “resistant” from the outside in. In other
words, the insulating device 10 can be formed “water tight” inside the inner liner 500, and
water cannot leak into the inner liner 500 from the outside or out from the inside of the inner
liner 500 when the closure 301 is in the closed position.
Fig. 4 depicts a bottom view of the insulating device 10. As shown in Fig. 4, the insulating
device 10 may include a base 215 and a base support ridge 400. The base support ridge 400
can provide structural integrity and support to the insulating device 10 when the insulating
device 10 is placed onto a surface.
In one example, as shown in Figs. 3A and 4, the top of the outer shell 501 has a first perimeter
ference (Tcir) and the bottom of the outer shell 501 has a second perimeter
circumference or a base ter 401 . The circumference of the top of the outer shell
501 can be equal to the circumference on the bottom when folded into a cylinder, and Bcir can
be equal to Tcir. In one example, the first circumference and the second circumference can
both have an oval shape to form an ted or elliptical cylinder. In one example, the top
outer layer 501a can have a length of 23.5 inches and a width of 5.5 inches. Therefore, the
length to width ratio of the top outer layer 501a can be approximately 4.3. Additionally, the
base 215 can have a length of 20.0 inches and a width of 12.25 inches. Therefore, the length
to width ratio of the base 215 is approximately 1.6. In this example, the length to width ratio
of the upper wall can be greater than the length to width ratio of the base.
In one example, as shown in Fig. 5A, the inner layer or inner liner 500 can be formed of a top
inner liner portion or first inner liner portion 500a, an inner layer mid portion or second
portion 500b, and an inner layer bottom portion 500c. The top inner liner portion 500a, the
inner layer mid portion 500b, and the inner layer bottom portion 500c are secured together,
by for example welding, to form the chamber 504. The chamber 504 can be a “dry bag,” or
vessel for g contents. In one example, after the top inner liner portion 500a, the inner
layer mid portion 500b, and the inner layer bottom portion 500c are d or joined
together, a tape, such as a TPU tape can be placed over the seams joining the sections of the
chamber 504. The inner liner 500 can, thus, either maintain liquid in the chamber 504 of the
insulating device 10 or prevent liquid contents from entering into the chamber 504 of the
insulating device 10. In one example, as will be described in further detail below, the inner
liner 500 can be suspended in the insulating device 10 by only the closure 301.
The insulating layer 502 can be located between the inner liner 500 and the outer shell 501,
and can be formed as an insulator to assist in maintaining the internal temperature of the
acle 504. In one example, the insulating layer 502 can be a free floating layer that is
not attached directly to the outer shell 501 or the inner liner 500. The insulating layer 502 can
be formed of a first n 502a and a second portion or base portion 502b. The first portion
502a and the second n 502b can be formed of an insulating foam al as will be
described in further detail below.
The first portion 502a can have a rectangular shape that maintains its form when folded into
a cylinder and placed in between the inner liner 500 and the outer shell 501 and when encased
from above by the outer shell 501. The insulating layer 502 maintains its shape which results
in the basic oval-cylindrical shape of the insulating device 10. Therefore, similar to the outer
shell 501, the top of the insulating layer 502 has a first perimeter circumference, and the
bottom of the insulating layer 502 has a second perimeter circumference. T he first perimeter
circumference of the insulating layer 502 can be equal to the second perimeter circumference
of the insulating layer 502.
The base portion 502b can be included to provide additional tion along the insulating
device 10 at base 215. The base portion 502b can be formed as an oval shape to close off a
lower opening 506 formed by the cylindrical shape of the insulating layer 502.
onally, the bottom n of the insulating device 10 can include an additional base
support layer 505, which adds to the insulation and the structural integrity of the insulating
device 10. The base support layer 505 may also provide additional protection around the
bottom of the insulating device 10. In one example, the base support layer 505 can be formed
from EVA foam. The base support layer 505 may e a certain design such as a logo or
name that can be molded or embossed directly into the material. The base support ridge 400,
which provides structural integrity and support to the insulating device 10 can also be molded
or embossed ly into the base support layer 505. In one example, the base support layer
505 and the base portion 502b can be detached for ease of assembly.
The outer shell 501 can be formed of a top outer layer portion or first shell portion 501a, an
outer layer or second outer shell portion 501b, and a bottom or third shell n 501c. The
outer shell 501 provides a covering for the insulating device 10. In one example, the insulating
layer 502 can be suspended freely within the outer shell 501. However, it is contemplated
that any of the layers could be secured or formed as a one-piece integral structure. The outer
shell 501 can be configured to support one or more optional handles or straps (e.g. 210, 212,
218). In this regard, the outer shell 501 can also include multiple reinforcement areas or
patches 220 that are ured to assist in structurally supporting the optional handles or
straps (e.g. 210, 212, 218). The handles or straps (e.g. 210, 212, 218) and other ments
can be stitched using s 222, however these threads 222 do not, in one e, extend
through the outer shell 501 into the insulating layer 502. Rather, the s are sewn to the
patches 220, and the patches 220 can be RF welded to the outer shell 501 or by any other
method disclosed herein.
As shown in Fig. 5A, the first outer shell portion 501a may be attached to the second shell
portion 501b by ing 510. However, the first outer shell portion 501a can be attached to
the second shell portion 501b using any known method, e.g., polymer welding, stitching, or
other adhesive around the entire perimeter of the second shell portion 501b.
Additionally, in one example, the base support layer 505, which can be formed from EVA foam,
can be d to bottom or third shell portion 501c by lamination. The second shell portion
501b can be secured to the third shell portion 501c and the base support layer 505 by polymer
welding (e.g. RF welding), stitching, or adhesives.
The insulating device 10 can include two carry handles 210 that are connected to the frontside
216 of the insulating device 10 and the de 217 of the insulating device 10. In one
particular example, a shoulder strap 218 can be ed via plastic or metal clip to the ring
214 attached to side handles 212 to facilitate carrying insulating device 10 over the shoulder.
The insulating device 10 may also include side handles 212 on each end of the cooler. The
side handles 212 provide the user with another option for grasping and carrying the insulating
device.
Carry handles 210 may also form a slot for receiving rings 214 near the bottom of the
attachment point of the carry handles to the insulating device 10. The rings 214 can be
secured to the carry handles 210 and the attachment points 213 by stitching, adhesive, or
r welding and can be used to help secure or tie down the insulating device 10 to
another structure such as a vehicle, vessel, camping equipment, and the like or various objects
such as keys, water bottle bottles, additional , bottle openers, tools, other personal
items, and the like.
Additionally, as shown in Fig. 2, webbing formed as loops 224 can be sewn onto the straps
forming the handles 210 on the back of the insulating device 10. The loops 224 can be used
to attach items (e.g., carabineers, dry bags) to the insulating device 10. The side s 212
can also provide the user with another option for securing the insulating device 10 to a
structure.
In one example, the carry handles 210, side handles 212, er strap 218 and attachment
points 213 can be constructed of nylon webbing. Other materials may include polypropylene,
neoprene, ter, a, Kevlar, cotton fabric, leather, plastics, rubber, or rope. The
carry handles 210 and side handles 212 can be attached to the outer shell by stitching,
adhesive, or polymer welding.
The shoulder strap 218 can be attached to the insulating device 10 at attachment points 213.
The attachment points 213 can be straps that also form a slot for receiving rings 214. The
rings 214 can provide for the attachment of the shoulder strap 218.
In one e, the rings 214 can be Acetal D-rings. Rings 214 in can be plastic, metal,
ceramic, glass, alloy, polypropylene, neoprene, polyester, Dyneema, and Kevlar, cotton fabric,
leather, cs, rubber, or rope. Rings 214 can include other shapes, sizes, and configurations
other than a “D” shape. Examples include round, square, gular, triangular, or rings with
multiple ment points. Additionally, pockets or other storage spaces can be attached to
the outside of the insulating device 10 in on to the carry handles 210 and side handles
212.
In one example, the closure 301 can be substantially waterproof or a barrier to prevent liquid
contents from either entering or exiting the insulating device. onally, the closure 301
can be impervious to liquid such that insulating device 10 liquid penetration is prevented at
any orientation of the insulating device 10. Also maintaining the closure 301 in flat plane can
assist in ing a water tight seal.
Figs. 3A-3C depicts top views of the insulating device 10, and depicts the top outer layer or
the first outer shell portion 501a and the closure 301. The top outer layer 501a ed in
Fig. 3A can be secured to the closure 301. In one example, the closure 301 can be a waterproof
zipper assembly and can be watertight up to 7 psi above heric pressure during testing
with compressed air. However, in other examples, the water tightness of the closure 301 can
be from 5 psi to 9 psi above atmospheric pressure and in other examples, the water tightness
of the e 301 can be from 2 psi to 14 psi above atmospheric pressure. The waterproof
zipper assembly can include a slider body 303 and pull-tab 302. Fig. 3B shows a magnified
view of the closure 301 that includes bottom stop 304 and teeth or a chain 305. In one
particular example, the waterproof zipper assembly can be constructed with plastic or other
non-metallic teeth 305 to prevent injury when retrieving food or beverages from the inner
chamber 504.
As shown in Fig. 3C, the closure 301 is open or unzipped and an aperture 512 formed in the
outer shell 501 and the inner liner 500 is open and reveals the inner liner 500 and the inner
chamber 504. It is contemplated that the closure or seal 301 can include s g
devices in addition to the depicted waterproof zipper assembly in Figs. 3A-3C. For example,
Velcro, snaps, buckles, zippers, excess material that is folded multiple times to form a seal
such as a roll-down seal, seals, metal or plastic clamps and combinations thereof could be
used to seal the inner liner 500 and the outer shell 501.
Figs. 8A and 8B depict another exemplary insulating device 1010, which has similar features
and functions as the example sed above in relation to Figs. 1A-5B in which like reference
numerals refer to the same or similar elements. However, in this example, a loop patch 1015
can be provided on the front of the bag. The loop patch 1015 can be configured to receive
many types of items or a corresponding group of hooks, which can be placed onto the surface
anywhere on various items, such as fishing lures, keys, bottle openers, card holders, tools,
other personal items, and the like. The loop patch 1015 can include a logo, company name,
personalization, or other customization. The loop patch 1015 can be formed of by needle
loops and can have a high cycle life of over 10,000 closures. In addition, the loop patch can
be washable and UV resistant to prevent discoloration. The loop patch can be selected based
on a desired sheer and peel strength depending on the types of materials that are to be
d to the insulating device 1010.
In the example shown in Figs. 8A and 8B, onally, a strip 1013 of material can be provided
along the bottom of the bag, which can provide additional strength and reinforcement to the
outer shell 1501, and may enhance the aesthesis of the insulating device 1010.
Example methods of g the insulating device 10 will now be described. A l
overview of an exemplary assembly process of the insulating device 10 is depicted
schematically in The various steps, however, need not necessarily be performed in the
order described. As shown in step 602 first the portions used to form the inner liner 500, the
outer shell 501, and the insulating layer 502 can be formed or cut to size. In step 604, a top
cap assembly 300 can be assembled to the closure 301. In step 606, the inner liner 500 can
be formed, and in step 608, the top cap ly 300 can be welded to the inner liner 500.
In step 610, the outer shell 501 can be formed. In step 612, the insulation layer 502 can be
assembled, and in step 616, the insulation layer 502 can be placed into the inner liner. y,
in step 618, the top cap ly 300 can be secured to the outer shell 501.
Referring to step 602, as shown in Fig. 7A and 7B, inner liner top portions or first inner liner
portions 500a and top outer layer 501a that form the top cap assembly 300 can be formed or
cut to size. Fig. 7C shows a second portion or base portion 502b of the insulating layer 502
being cut or formed to size from stock foam. In this example, the base portion 502b is cut
from the stock foam 530, by cutting tool 700. In one example, the cutting tool 700 can be
formed in the shape of the base portion 502b.
Referring now to step 604 and Fig. 7D, the top outer layer 501a and the top inner liner portion
500a can be d to the closure 301 to form the top cap assembly 300, and the top outer
layer 501a and the top inner liner portion 500a can be secured to the closure 301 in a flat,
horizontal plane. Referring to Figs. 5A-5B the top outer layer 501a can be ed by polymer
welding or adhesive to closure 301. In particular as shown schematically in Fig. 5B, the closure
301 can be provided with a first flange 301a and a second flange 301b, which can form
waterproof zipper tape 306. T he top outer layer 501a can be ed directly to the top
surfaces of the first flange 301a and the second flange 301b of the closure 301. In one
example, the first flange 301a and the second flange 301b, can be RF welded to the underside
of the top outer layer 501a. In another example, as shown in Fig. 7E, the top inner liner portion
500a can be provided with tabs 515. Tabs 515 can assist in the assembly process to keep the
outer strips of the top inner liner portion 500a in place during assembly and can be removed
after the top cap assembly 300 is .
In one e, the top inner liner portion 500a can be attached to the ure of the
insulating device 10 as shown schematically in Fig. 5B. In particular, the top inner liner portion
500a can be attached to the bottom of the closure 301. For example, as shown in Fig. 5B, and
a first end 540a and a second end 540b of the top inner liner portion 500a can be ed to
ides of the first flange 301a and the second flange 301b. The top inner liner portion
500a and the top outer layer 501a can be attached to the closure 301 by polymer welding or
adhesive. Polymer welding includes both external and internal methods. External or thermal
methods can e hot gas welding, hot wedge welding, hot plate welding, infrared welding
and laser welding. Internal methods may include mechanical and electromagnetical welds.
Mechanical methods may include spine welding, stir g, vibration welding, and
ultrasonic welding. Electromagnetical methods may include resistance, implant, electrofusion
welding, induction welding, dielectric g, RF (Radio Frequency) g, and microwave
welding. The welding can be conducted in a flat or horizontal plane to maximize the
effectiveness of the polymer welding to the construction materials. As a result, a rugged
watertight seam can be created that prevents water or fluids from escaping from or into the
inner chamber 504.
In a particular example, the polymer welding technique to t the top inner liner portion
500a to the bottom of the closure 301 can include RF g. The RF welding technique
provides a waterproof seam that prevents water or any other fluid from penetrating the seam
at pressure up to 7 psi above atmospheric pressure. The insulating device 10, therefore, can
be inverted or submerged in water and leakage is prevented both into and out of the internal
chamber 504 formed by inner liner 500. In one example, the insulating device 10 can be
submerged under water to a depth of about 16 feet before water leakage occurs. However,
it is contemplated that this depth could range from about 11 feet to 21 feet or 5 feet to 32
feet before any leakage occurs.
Next referring to step 606 and Fig. 7F, the inner layer mid-portion 500b can be formed by RF
welding. As shown in Fig. 7F, the inner layer mid-portion 500b can be formed of a rectangular
sheet of al. The inner layer mid-portion 500b can also be secured to the inner layer
bottom portion 500c in a uent step not shown.
Referring to step 608 and Figs. 7G and 7H, the inner layer mid portion 500b and the inner layer
bottom n 500c can be secured to the top cap ly 300 using an RF welding
operation.
Referring to step 610, the second shell portion 501b and the third shell portion 501c, which
supports the base support layer 505, can be RF welded to construct the outer shell 501 for the
insulating device 10. In one e, as shown schematically in Fig. 5A, the top outer layer
501a can be sewed to the perimeter of the second shell portion 501b to form the outer shell
501 of the insulating device. A fabric binding can be used to cover the ed seam edges of
the second shell portion 501b and the top outer layer 501a. This assi sts in closing or joining
the outer shell 501 around the insulating layer 502.
Referring to step 612 and Fig. 7I, the insulating layer 502 can be constructed. In one example
the first portion 502a of the insulating layer 502 can be formed into a rectangular shape and
can be secured at the smaller sides of the rectangular shape using double sided tape to form
the cylindrical shape. The second portion or base portion 502b can be formed into an oval
shape that can have a smaller circumference than the circumference of the cylindrical shape
of the first portion 502a. The second portion 502b can be d to the first portion 502a
also using a double-sided tape to form the insulating layer 502. In one example, double sided
tape can be placed either around the inner perimeter of the first portion 502a cylinder or
around the outer perimeter of the base portion 502b, and the base portion 502b can be
adhered to the first portion 502a. Other methods of securing the base portion 502b to the
first portion 502a to form the insulating layer 502 are contemplated, such adhesives or
polymer welding.
Referring to step 614, the assembled insulating layer 502 can be placed into the outer shell
501. In step 616, the formed inner liner 500 and top cap ly 300 can be placed into the
insulating layer 502.
Finally in step 618 the top cap assembly 300 can be sewed to the outer shell 501 to form seams
520 as depicted schematically in Fig. 5A. In this way, neither the inner liner 500 nor the outer
shell 501 need to be bound to the insulating layer 502. Also the inner liner 500 is only
connected to the closure 301 and the closure 301 holds the inner liner and the outer shell 501
together, which results in a simpler manufacturing process. After sewing the top cap assembly
300 to the outer shell 501, a fabric binding is added to cover the raw edges adjacent the seams
520. Thus, the top seams 520 can be the only y seams on the ting device 10 that
are created by stitching.
In one particular example, the inner liner 500 and the outer shell 501 can be constructed from
double laminated TPU nylon fabric. Nylon fabric can be used as a base material for the inner
liner 500 and the outer shell 501 and can be coated with a TPU laminate on each side of the
fabric. The TPU nylon fabric used in one particular example is 0.6 eters thick, is
roof, and has an antimicrobial additive that meets all Food and Drug Administration
requirements. r, it is contemplated that the fabrics used to construct the ting
device incorporate antimicrobial materials to create a mildew-free environment that is food
contact surface safe. In one specific example, the nylon can be 840d nylon with TPU.
Alternative materials used to manufacture the inner shell or chamber 504 and outer shell 501
include PVC, TPU coated nylon, coated fabrics, and other weldable and waterproof fabrics.
A closed cell foam can be used to form the insulating layer 502 that is situated in between the
inner liner 500 and the outer shell 501. In one example, the insulating layer 502 is 1.0 inches
thick. In one example, the insulating layer 502 can be formed of NBR/PVC blend or any other
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suitable blend. The thermal conductivity of an example ting layer 502 can be in the
range of 0.16– 0.32 BTU.in/(hr·sqft⋅°F), and the density of the insulating layer 502 can be in
the range of 0.9 to 5 lbs/ft3. In one example, the thermal conductivity of the insulating layer
502 can be in the range of 0.25 BTU.in/(hr·sqft⋅°F), and the density of the insulating layer 502
can be 3.5 lbs/ft3.
The foam base can be manufactured from an NBR/PVC blend or any other suitable blend. In
addition to the base portion 502b of the ting layer 502, the insulating device 10 may also
include an outer base support layer 505 constructed of foam, plastic, metal or other material.
In one example, the base portion 502b can be detached from the base support layer. In one
e, the base portion 502b is 1.5 inches thick. Additionally as shown in Fig. 5A, the EVA
foam base support layer 505 can be 0.2 inches thick. Although the base support layer 505 is
laminated to the base outer layer or third shell portion 501c, in an alternative example, the
base support layer 505 can be attached to the bottom of the base portion 502b by co-molding,
polymer welding, adhesive, or any known methods.
A heat gain test was conducted on the exemplary insulating device 10. The purpose of a heat
gain test is to ine how long the insulating device can keep temperature below 50°F at
an ambient of 106°F ± 4 with the amount of ice based on its internal capacity.
The procedure is as follows:
1. Turn on the oven and set to 106°F ± 4. Allow the oven to stabilize for at least one hour.
2. Turn on the chart recorder. The recorder shall have three J-thermocouples connected to it
to chart the following temperatures: (1) Test unit, (2) Oven, and (3) Room ambient.
3. Stabilize the test unit by filling it to half its capacity with ice water, and allowing it to sit for
minutes at room temperature (72 °F ± 2).
4. After 5 minutes, pour out the contents, and immediately t the mocouple end
to the inside bottom center of the unit. The thermocouple wire end must be flush to the
inside bottom surface and d with an adhesive masking tape.
5. Pour the correct amount of ice ensuring the thermocouple wire is not moved. Amount of
ice is based on 4 lbs. per cubic feet of the internal capacity of the unit.
6. Close the lid and position the test unit inside the oven.
7. Close the oven making sure the thermocouple wires are functioning.
8. Mark the start of the chart er.
Apparatus: 1. Oven. 2. Ice. 3. Chart Recorder. 4. J-Thermocouples (3). Results: 1. Cold
Retention Time: Elapsed time from <32°F to 50°F in decimal hours. 2. Heat Gain Rate (°F/Hr):
(50°F – 32°F) ÷ d Time = 18°F ÷ d Time
In one test of the example ting device, the heat gain rate equaled 1.4 degF/hr assuming
26.5 quarts capacity and used 3.542lbs of ice for the test.
The ability of the insulating device 10 to withstand interior leaks can also be tested to see how
well the ting device maintains the contents stored in the storage compartment or
receptacle 504. In one example test, the insulating device 10 can be filled with a liquid, such
as water, and then can be inverted for a ermined time period to test for any moisture
leaks. In this example, the insulating device 10 is filled with a liquid until approximately half
of a volume of the receptacle 504 is filled, e.g. 3 s of water, and the closure 301 is then
closed fully to ensure that the slider body 303 is completely sealed into the horseshoe-shaped
portion 308. The entire insulating device 10 is then inverted and held inverted for a time
period of 30 minutes. The insulating device 10 is then reviewed for any leaks.
The insulating device 10 can be configured to withstand being held inverted for 30 minutes
without any water escaping or leaving the receptacle 504. In alternative examples, the
insulating device can be configured to withstand being held inverted for 15 minutes to 120
minutes without any water escaping or g the receptacle 504. To perform this test, it
may be helpful to lubricate the closure to ensure that the closure is adequately sealed. For
example, as shown in Fig. 9, a horseshoe-shaped portion 308 of the closure 301 is provided
with lubricant 309.
The strength and durability of the fabric forming the outer shell 501, inner liner 500 and the
insulating layer 502 of the insulating device 10 may also be tested. In one example, the test
can be devised as a puncture test. In particular, this test can be designed as an ASTM D751-
06 Sec. 22-25 screwdriver puncture test. In one e, the insulating device 10 can
withstand 35 lbs to 100 lbs of puncture force.
The handle strength and lity of the insulating device 10 can also be tested. One such
e test is depicted in Fig. 10. As depicted in Fig. 10, the e 310 can be fully closed,
one of the carry handles 210 can hooked to an overhead crane 600, and the opposite carry
handle 210 is hooked to a platform 650, which can hold weight. In one example, the platform
650 can be configured to hold 200 lbs. of weight. During the test, the crane 600 is slowly
raised, which suspends the insulating device 10 in a position where the bottom plane of the
insulating device 10 is perpendicular with the floor. In one example, the insulating device 10
can be configured to hold 200 lbs. of weight for a minimum of 3 minutes without showing any
signs of failure. In alternative examples, the insulating device can be configured to hold 100
lbs. to 300 lbs. of weight for 1 to 10 minutes without showing signs of failure.
Figs. 11-15 show another example insulating device 2010. The example insulating device 2010
can be of a similar construction to the above examples, where like reference numerals
ent like features having similar functionality. However, the example insulating device
2010 can also e a fold-down flap or portion 2307 to assist in ting the closure 2311
of the insulating device 2010. Specifically, the closure 2311, which can be a zipper in
accordance with the other examples discussed herein, can be included on a fold-down flap or
portion 2307 and can be front facing in that it is located on a front surface or wall of the
ting device 2010. The front facing closure 2311, can allow for additional user access to
the insulating device 2010, and the fold-down flap or portion 2307 can help to e
additional insulation at the closure 2311. In this example, when the fold-down flap 2307 is in
the extended position and the e 2311 is open or unsealed, the contents in the insulating
device 2010 maintain the closure 2311 in the open position for better access of the contents
of the insulating device 2010. This may assist the user to be able to more easily access the
contents of the insulating device 2010. Also as shown in Fig. 11, when the fold-down flap 2307
is in the extended on, the insulating device 2010 can approximate a trapezoidal shape
for providing an elongated closure at the top of the insulating device 2010.
As shown in the side and cross-sectional views, i.e., Figs. 12 and 14A, the insulating device
2010 can approximate a pentagon, when the fold-down flap 2307 of the insulating device
2010 is in an extended on. This general shape may e for an insulating device 2010
that may be easily shipped in that several ting devices can be fit into a shipping
container. Nevertheless, other shapes and configurations are contemplated e.g., square,
rectangular, triangular, l, curved, and frusto-shapes which may provide an ed
closure at the top of the ting device 2010 and that can be easily packaged.
Like in the above es, the insulating device 2010 may include an outer shell 2501, an
inner liner 2500 forming a e compartment, a receptacle, or inner chamber 2504 and an
insulating layer 2502 positioned in between the outer shell 2501 and the inner liner 2500. The
insulating layer 2502 provides insulation for the storage compartment 2504. The closure 2311
can be configured to substantially seal an opening 2512, which is located on an angled front
facing surface and extends through the outer shell 2501 and the inner liner 2500 to provide
access to the storage compartment 2504. Also, the closure 2311 can include similar features
and functionality in accordance with the examples discussed above. In one example, the
closure 2311 can be a zipper and can be substantially waterproof so as to resist liquid from
exiting the opening when the insulating device 2010 is in any orientation. Also, similar to the
above examples, the insulating device 2010 can be provided with one or more of carry handles
2210, shoulder straps 2218, webbing loops 2224 formed with threads 2222 by stitching for
example, rings 2214, and attachment points 2213 which can have r features and
functionality as in the examples above.
As shown in Figs. 11 and 12 and as noted above, the fold-down flap 2307 may include the
front facing closure 2311 and can be folded over and secured to a sidewall of the ting
device 2010 to further insulate the front facing closure 2311. The fold -down flap 2307 of the
fastening mechanism 2301 can include first and second end hooks or clips 2313a, 2313b. In
one example, each of the end clips 2313a, 2313b can include a slot 2317a, 2317b for being
received in corresponding loops 2315a, 2315b located on the sides or the lls of the
insulating device 2010. To close the insulating device 2010, the fold-down flap 2307 along
with the front facing closure 2311 are folded over onto a front face or wall of the insulating
device 2010. The fold-down flap 2307 folds over with and conceals or covers the front facing
closure 2311. The fold-down flap 2307 is held into place by the first and second end clips
2313a, 2313b and maintains the fastening mechanism 2301 in the closed position.
onally, when the fold-down portion 2307 is secured to the sidewalls of the insulating
device 2010, the fold-down portion 2307 extends at least partly in a substantially horizontal
direction, which orients a carrying handle 2318 in position for a user to grasp for holding and
carrying the insulating device 2010. As in the other handles and straps, the carry handle 2318
can be secured to the outer shell with a rcement patch (not shown). The carry handle
2318 can be provided on the rear surface of the insulating device 2010 to oppose the closure
2311 on the front facing e, which can be used by the user to grasp during opening and
closing the insulating device 2010 to make it easier for the user to open and close the closure
2311. The carry handle 2318 may also be used for hanging the insulating device 2010, or for
carrying the insulating device 2010; r, other uses are also contemplated.
Fig. 14A shows a cross-sectional side view of the insulating device 2010. The insulating device
2010 includes an inner liner 2500, an insulating layer 2502, and an outer shell 2501. As shown
in Fig. 14A, like in the above examples, the insulating layer 2502 can be located between the
inner liner 2500 and the outer shell 2501, and can be formed as a foam insulator to assist in
maintaining the internal ature of the receptacle 2504 for storing contents desired to
be kept cool or warm. Also the insulating layer 2502 can be d in between the inner liner
2500 and the outer shell 2501, and can be ched to either the inner liner 2500 or the
outer shell 2501 such that it floats between the inner liner 2500 and the outer shell 2501. In
one example, the inner liner 2500 and the outer shell 2501 can be connected at the top
portion of the ting device 2010 such that the insulating layer 2502 can float freely within
a pocket formed by the inner liner 2500 and the outer shell 2501.
In this example, the inner layer or inner liner 2500 can be formed of a first inner liner sidewall
n 2500a and a bottom inner liner portion 2500b. The first inner liner sidewall portion
2500a and the bottom inner liner portion 2500b can be secured er, by for example
welding, to form the chamber 2504. Like in the above example, the chamber 2504 can be a
“dry bag,” or vessel for storing contents. In one example, a tape, such as a TPU tape, can be
placed over the seams joining the ns of the r 2504, after the first inner liner
sidewall portion 2500a and the bottom inner liner portion 2500b are secured or joined
together. The tape seals the seams formed between the first inner liner sidewall portion
2500a and the bottom inner liner portion 2500b to provide an additional barrier to liquid to
prevent liquid from either entering or exiting the chamber 2504. The inner liner 2500 can,
thus, either maintain liquid in the chamber 2504 of the insulating device 2010 or prevent liquid
contents from ng into the chamber 2504 of the insulating device 2010. It is also
contemplated, however, that the inner liner 2504 can be formed as an integral one-piece
structure that may be secured within the outer shell.
As shown in both Figs. 14A and 15, the insulating layer 2502 can be formed of a first portion
or an upper portion 2502a, a second portion or base portion 2502b, and a base support layer
2505. In addition, the first portion 2502a can include a top flap or smaller rectangular shape
2502a1. When the fold-down flap 2307 is folded onto the top portion of the insulating device
2010, the top flap 2502a1 of the insulating layer together with the remainder of the first
portion 2502a and the base portion 2502b surrounds substantially all of the inner chamber
2504 with insulation to e a maximum amount of insulation to the inner chamber 2504
of the insulating device 2010.
When the upper portion 2502a is rolled flat, the upper portion 2502a of the insulating layer
2502 lly resembles a “T” shape such that the insulating layer defines a first heightH1
and a second height H2 where the first height H1 is greater than the second height H2. In this
example, a majority of the insulating layer can extend to the second height H2, which is less
than the first height H1. Also, the first portion 2502a can be formed of two inter-connected
rectangular shapes, where the bottom of the first portion 2502a forms a first larger
rectangular shape 2502a2 and an upper section of the first portion 2502a forms the top flap
2502a1 of the smaller rectangular shape. It is also contemplated that the first larger
rectangular shape 2502a2 can be formed as a separate piece from the r gular
shape 2502a1. The first rectangular shape 2502a2 can have a first rectangular width and the
second rectangular shape 2502a1 can have a second rectangle perimeter and first rectangular
shape 2502a2 width approximates the second rectangular shape 2502a1 perimeter. In one
example, the r gular shape 2502a1 forms a top flap of the insulation layer of the
upper portion 2502a, which extends into the fold-down portion 2307.
The first portion 2502a and the second portion 2502b can be formed of an insulating foam
material as discussed herein. In one example, the second portion 2502b can be formed of a
thicker foam material than the first portion 2502a. For example, the thickness of the second
portion 2502b can be formed n 20 mm and 50 mm thick, and, in one particular
example, can be formed of a 38 mm thick foam, and the first portion 2502a can be formed
between 15 mm and 30 mm, and, in one particular example, can be formed of a 25 mm thick
foam. In one example, the foam can be a NBR/PVC blended foam, a PVC free NBR foam, or
other iendly type foam.
Also as shown in Fig. 15, a base support layer 2505 adds to the insulation and the structural
integrity of the insulating device 2010 at base 2215. The base support layer 2505 may also
provide additional protection around the bottom of the insulating device 2010. In one
example, the base t layer 2505 can be formed from EVA foam. The base support layer
2505 may include a certain design such as a logo or name that can be molded or embossed
directly into the material. A base support ridge 2400, which provides structural integrity and
support to the insulating device 2010 can also be molded or embossed directly into the base
support layer 2505. In one example, the base t layer 2505 and the base portion 2502b
can be detached or unsecured for ease of assembly in reducing the number of assembly steps.
The base portion 2502b can be formed as an oval shape to close off a lower opening 2506
formed by the open shape of the upper n 2502a.
The bottom of the first portion 2502a maintains its form when folded into an oval-cylindrical
shape and placed in between the inner liner 2500 and the outer shell 2501. The insulating
layer 2502 maintains its shape which results in the basic ylindrical shape of the insulating
device 2010.
The outer shell 2501 can be formed of an upper sidewall portion 2501a, a lower sidewall
portion 2501b, and a base portion 2501c. Each of the upper sidewall portion 2501a, the lower
sidewall portion 2501b, and the base portion 2501c can be secured by stitching. Other
securing methods are also contemplated, such as, using welds or ves.
Additionally, the fold-down portion 2307 can be at least partly free of foam to make it easier
to close the fastening mechanism 2301. In particular, the fold-down portion 2307 can include
a first section 2307a and a second n 2307b. T he first section 2307a can be free of the
insulation layer 2502 and the second section can include the insulation layer 2502.
Referring to Fig. 14B, like in the above examples, the closure 2311 can be mounted on a
backing or fabric. In the case of a zipper this can be referred to as zipper tape 2306. Also, like
in the above examples, the zipper tape 2306 can be attached between the inner liner 2500
and the outer shell 2501 and, in particular, the zipper tape 2306 can be d to the upper
ll portion 2501a of the outer shell and the first inner liner sidewall portion 2500a. As
shown in Fig. 14B, the zipper tape 2306, the upper sidewall portion 2501a of the outer shell,
and the first inner liner sidewall portion 2500a can form a stacked arrangement of a sandwich
structure where the zipper tape 2306 is located between the upper sidewall n 2501a of
the outer shell and the first inner liner sidewall portion 2500a.
The insulating device 2010 can be formed using similar techniques in relation to the examples
as discussed above. For example, the upper sidewall portion 2501a of the outer shell 2501
can be . Also the base 2215 can be formed separately with the base n 2502b of
the insulation layer 2502, the base support layer 2505, the lower sidewall portion 2501b, and
a base portion 2501c of the outer shell 2501 according to the techniques discussed herein.
The base 2215 can be d to the bottom of the upper sidewall portion 2501a of the outer
shell 2501 using the techniques discussed herein. The upper portion 2502a of the insulation
layer 2502 can be placed within the upper sidewall portion 2501a of the outer shell 2501. The
first inner liner sidewall portion 2500a and the bottom inner liner portion 2500b can then be
secured to form the inner liner 2500 and chamber 2504. Tape, such as a TPU tape, can be
placed over the seams joining the sections of the inner liner 2500 and chamber 2504. The
inner liner 2500 can then be placed within the insulation layer 2502. The e 2311 can
then be attached n the inner liner sidewall portion 2500a and the upper ll
portion 2501a. At this point in the process the insulating device 2010 assembly will have a
cylindrical shape with an open top. To close the open top, the upper ends of the inner liner
sidewall portion 2500a and the upper sidewall portion 2501a can then be secured together by
welding or by using any of the techniques discussed herein to form the insulating device 2010.
A binding 2518 can be applied to the top portion of the ting device 2010 to cover and
conceal the seam between the outer shell 2501 and the inner liner 2500. The loop patch (not
shown), carry handles 2210, shoulder strap 2218, webbing loops 2224, and rings 2214 can be
added to the outer shell 2501 by the various techniques discussed , after the formation
of the outer shell or once the insulating device 2010 is formed. It is contemplated that the
inner liner and the outer liner can be formed by welding, gluing, or stitching and combinations
thereof.
In another example, a ic connection can be ented for securing the fold-down
portion 2307 to the body of the insulating device 2010. As shown in Figs. 16A and 16B, the
insulating device 2010 can be ed with a magnetic clip 3313, which can be ed by a
corresponding magnet (not shown) on the sidewall of the insulating device 2010. However,
it is also contemplated that the clip and clip receiving n on the insulating device 2010
could be one or more of permanent magnets, metal , or ferromagnetic materials. In
addition, other methods of securing the own flap 2307 over the front facing closure
2311 are also contemplated. For example, one or more of hook and loop, buckle, snap, zipper,
detent, spring loaded detent, button, cams, or threads could be used to secure the fold-down
flap 2307 to the sidewall of the insulating device 2010.
Figs. 17 -22 show another exemplary insulating device 4010. The example insulating device
4010 can be of a similar construction to the above examples and, in particular, the example
discussed above in relation to Figs. 11-16B, where like reference ls represent like
features having the same or similar functionality. In this example, the insulating device 4010
does not include a fold-down flap and can include a different overall shape than the example
insulating device 2010. Additionally, the insulating layer 4502 can have a different
configuration along with other variations that will be sed below. Like in the above
example, the closure 4311 can be placed on a front face or wall of the insulating device 4010.
As shown in Figs. 18 and 19, when viewed from the front and rear, the insulating device 4010
can generally form a trapezoidal shape, where the insulating device diverges or tapers upward
toward the top of the insulating device 4010. The trapezoidal shape may provide certain
insulation, user accessibility, and packaging ts. For example, the trapezoidal shape can
provide an extended period of ice coverage because of the additional foam that can be placed
between the outer shell 4501 and the inner liner 4500 due to the trapezoidal shape.
onally, the overall shape of the insulating device 4010 can help to maintain the
insulating device 4010 in the opened position when the closure 4311 is in the opened position
and permits the user to be able to easily access the contents of the insulating device 4010.
The trapezoidal shape as discussed herein also allows the e 4311 to be formed longer
relative to the insulating device 4010. Other shapes that allow for an extended g at the
upper portion of the insulating device 4010 are also contemplated. For example, the upper
n of the insulating device 4010 could be formed with an ed curvature either
upward or downward to allow for a larger closure extending across the upper portion of the
insulating device 4010. Also as shown in Fig. 20, when viewed from the side, the insulating
device 4010 can be formed generally conical, tapered or funnel-shaped such that the sides
converge to the top of the insulating device 4010. Also the sides can be formed substantially
parabolic in shape in certain examples. Therefore, the insulating device 4010 converges to an
apex along the top of the insulating device 4010 as opposed to an oval shape with the same
perimeter as the bottom of the insulating device 4010.
In certain examples, a trapezoidal shape may also provide for an insulating device 4010 that
may be easily shipped in that several insulating devices 4010 can be fit into a shipping
container. For example, multiple insulating devices 4010 could be arranged in a ng
container in different orientations so as to utilize more space within a ng container.
In alternative ments, when the closure 4311 is in the opened or unsealed position, the
contents in the insulating device 4010 may maintain the closure 4311 in the open position for
easier access to the contents of the insulating device 4010. In this example, the weight of the
contents can force a lower half of the closure 4311 away from an upper half of the closure
4311 such that the user can better see the contents of the insulating device 4010 and more
easily remove the contents or add contents to the insulating device 4010.
In this example, the outer shell construction, insulating layer, and the inner liner construction
can be similar to that of the embodiment discussed above in relation to Figs. 11-16B, the
details of which are not repeated here. The outer shell 4010 may also include a top portion
4316, which is configured to receive the closure 4311 therein. The top portion 4316 can be
formed of the same material as the remaining outer shell 4501, which in one specific example,
can be nylon and specifically an 840d nylon with TPU.
Similar to the example discussed in relation to Figs. 11-16B, the insulating device 4010 can be
provided with one or more of carry handles 4210, a shoulder strap 4218, webbing loops 4224,
which are formed by threads 4222, rings 4214, and attachment points 4213 which can have
similar features and functionality as in the examples above. Additionally, a rear carry handle
4318 can be provided on the rear surface of the insulating device 4010 to oppose the closure
4311, which can be used by the user to grasp during opening and g the insulating device
4010 to make it easier for the user to open and close the closure 4311. The rear carry handle
4318 may also be used for hanging the insulating device 4010 for drying the inner r
4504, or for carrying the insulating device 4010. Each of the carry handles 4210, shoulder
strap 4218, webbing loops 4224, and attachment points 4213 can be reinforced by one or
more of additional structures in the form of g or suitable polymeric materials. This
reinforcement material may be applied to any of the es discussed herein.
Also as shown in Figs. 17 and 21 a binding 4518 can be included that s over the top of
the ting device 4010 to secure the outer shell 4501 to the inner liner 4500. The binding
4518 can be folded over the top of the ting device 4010 and then stitched over the over
outer shell 4501 and the inner liner 4500 to form a cover to the joint or seam between the
inner liner 4500 and the outer shell 4501. As shown in Fig. 18, the binding 4518 can be folded
into thirds to form a first folded portion 4518a where the first third is attached to a first side
of the insulating device 4010, the second third is extends over the top of the insulating device
4010, and the last third is attached to a second side of the insulating device 4010. The binding
4518 covers the seam between the outer shell 4501 and the inner liner 4500 along the top of
the insulating device 4010. Also, as shown in Fig. 17, the binding 4518 extends from the top
of the insulating device 4010 and forms a second folded portion 4518b where the binding
4518 is folded in half and a third unfolded portion 4518c, which forms and extends to
attachment points 4213 that receive rings 4214. Each side of the ting device 4010 can
include a second folded portion 4518b and a third unfolded portion 4518c such that the
insulating device 4010 can include two second folded portions 4518b and two third unfolded
portions 4518c. The binding 4518 can unfold closer to the attachment points 4213 and may
also be formed unfolded from the ment points 4213 to the top of the insulated device
4010. In either of these configurations, a section of the binding 4518, e.g., the second folded
n 4518b, can be ched to the insulating device 4010 and forms a strap between
the folded portion 4518a and the attachment points 4213. In this example, two straps can be
formed by the two second unfolded portions 4518b and can be grasped by the user for
handling the insulating device, can be used for hanging the ting device 4010 for drying,
and the like. Also , the attachment points 4213 formed by the binding 4518 can be a loop or
slot for receiving the rings 4214.
Figs. 22 and 22A show the insulating layer 4502 in additional detail, which is similar to the
example insulating device 4010 discussed above where like reference numerals represent like
components with the same or similar functionality. The ting layer 4502 can be formed
of the materials as discussed herein and, in certain examples, can be PVC free and/or can have
non-thermoset properties such that the foam is fully resilient. Like the above examples, the
upper portion 4502a of the insulating layer 4502 can be formed of a single sheet of material
which is rolled into the shape defined by the opening between the inner liner 4500 and the
outer shell 4501. As shown in Fig. 22, the insulating layer 4502, like in the above examples,
can be formed of a first n or an upper portion 4502a and a second portion or base
portion 4502b. The rear top flap 4502a1 can be formed in smaller rectangular shape. The
rear top flap 4502a1 extends higher than the front side of the first n 4502a of the
insulating layer 4502a to accommodate for the front facing closure 4311. Specifically, the rear
top flap 4502a1 can extend to a first height H3, and the first portion 4502a can extend to a
second height H4, and the first height H3 can be greater than the second height H4.
onally, as shown in Fig. 22, a majority of the insulating layer 4502 can extend to the
second height H4. Alternatively, as shown in Fig. 22A, the rear half of the insulating layer 4502
can extend to the first height H3 and the front half of the insulating layer 4502 can extend to
the second height H4. Additionally, as shown in Fig. 22A, the insulating layer 4502 can taper
from the first height H3 to the second height H4. Also, this provides the areas of the insulating
layer 4502 near the top with tapered or chamfered portions along the sides of the insulating
device 4010 to provide a smaller e on each side of the insulating device 4010.
In one example, the first portion 4502a can define a first area A1, and the rear top flap 4502a1
can define a second area A2, which is smaller than the first area A1. When installed between
the inner liner 4500 and the outer shell 4501, the ting layer 4502 generally follows the
conical and trapezoidal shape of the profile of the insulating device 4010. Additionally, the
upward tapered profile of the outer shell 4501 and the inner liner 4500 can help to position
the insulating layer 4502 such that the insulating layer covers a majority of the inner liner
4500.
In particular, as shown in Fig. 21, the insulating layer 4502 occupies a majority of the space
formed between the inner liner 4500 and the outer shell 4501. The insulating layer 4502
s substantially to the top of the insulating device 4010 in both the front and the rear
portions of the insulating device 4010 to insulate a majority of the tment 4504. As a
result, the insulating layer 4502 surrounds substantially the entire inner chamber 4502 to
provide a maximum amount of insulation to the inner chamber 4504 of the insulating device
2010. In one example, the ting layer 4502 covers 80% or more of the inner liner 4500
covering the inner chamber 4504, and in particular examples the insulating layer 4502 covers
85%, 90%, or 95% or more of the inner liner 4500 ng the inner chamber 4504.
In the es discussed in relation to Figs. 11-22, the front facing closures 2311, 4311 can
be formed such that they extend a majority of the way along the front facing surface of the
insulating devices 2010, 4010. As discussed above, the front-facing closures 2311, 4311 can
be formed as zipper closures in accordance with the examples discussed herein. In one
example, the closures 2311, 4311 can be substantially waterproof or highly water resistant
and can be water tight and air tight. The front facing es 2311, 4311 can be formed as
long as possible in the front facing surface of the insulating devices 2010, 4010 to provide for
extended user accessibility and visibility of the contents stored in the insulating devices 2010,
4010. In one example, the closures 2311, 4311 can define a first length L1, and the top portion
of the insulating device 4010 can define a second length L2.
In one example, L2 can be 3 cm to 10 cm longer than L1, the length of the front facing closures
2311, 4311 and in one specific example can be 5 cm longer than the facing closures
2311, 4311. The closures 2311, 4311 first length L1 can extend at least 80% of the second
length L2 and up to 98% of the second length L2. In one particular e, the length of the
closures 2311, 4311, L1 can extend across 87% of the second length L2.
Additionally, the length L1 of the front-facing closures 2311, 4311 can be formed longer than
the length L3 of the bases of the ting devices 2010, 4010. In certain examples, the front
facing closures 2311, 4311 can be formed approximately 1% to 25% longer than the length L3
of the bases of the insulating devices 4010. In one specific e the length L1 of the front
facing closures 2311, 4311 can be 10% longer than the length L3 of the bases. For example,
the front-facing closures length L1 can be formed 3 cm to 12 cm longer than the length L3 of
the bases of the insulating devices, and, in one ular example, the length L1 of the front
facing closures 2311, 4311 can be 5 cm longer than the length L3 of the base.
In still other embodiments, the insulating device can include a closure that extends around
the entire perimeter or a majority of the perimeter of the insulating device and a front facing
closure 2311, 4311 as discussed above. In this particular e, the contents of the
insulating device can be easily accessed by the user once the entire or a majority of the top
portion is removed or through the closure 2311, 4311.
In another example, the insulating device can be formed modular such that the top and/or
the bottom can be removed and multiple ures can be onnected to form larger or
smaller insulating s. For example, the insulating device can be formed of different
sections by way of removable ers, such as snaps, zippers, threads, seals, hook and loop,
and the like.
In relation to the examples discussed herein, a series of vents can be provided along the outer
shells of the insulating devices. The vents allow for any gases that are trapped between the
inner liner and the outer shell to escape. Without the vents, the gases trapped between the
inner liner and the outer shell can cause the insulating device to expand, which in certain
instances, may not be desired. In certain examples, the one or more joints or seams that
connect the various portions of the outer shell provide vents for gases. Vents can be provided
in areas of the outer shell where the outer shell fabric is d. For example, tiny openings
can be provided at any of the stitching ons where the various components are located
on the insulating s. ically, t he vents can be provided in the areas where the
handles, molle loops, straps, reinforcement patches, bindings, D-rings, loop patches, etc. are
attached to the outer shell of the ting device. For example, stitching that may be used
to secure these components to the outer shell provides openings into the outer shell, which
creates venting between the insulation layer and the outer shell. In one specific example, the
insulating device may vent through binding 4518.
The example insulating device 4010 was tested to determine ice retention. As such, the ice
retention testing may be utilized to determine insulative ties of example insulating
device 4010. In an exemplary test, the duration of the increase from 0°F to 50°F when the
insulating device 4010 was filled with ice was determined according to the test parameters
below. In certain examples, the ature of the insulating device increases from 10°F to
32°F in a duration of 24 hours to 24 hours, the temperature of the insulating device increases
from 32°F to 50°F in a duration of 36 hours to 68 hours, and the ature of the insulating
device increases from 0°F to 50°F in a duration of 70 hours to 90 hours.
The ice retention was tested using the following test. More than 24 hours before the test, the
following steps are performed:
• Ensure test coolers are clean inside and out.
• Mark test s with unique identifier and record identifier and description in test log
or notes.
• Using duct tape, place a thermocouple (T) in the approximate center of the test cooler
(C).
• The couple tip should be approximately 1 inch above the cooler floor. (See Fig.
23 for an example of proper thermocouple set-up.)
• Condition test coolers by keeping test coolers inside (ambient temperature 65-75° F) with
lids open for a minimum of 24 hours.
• Calculate the amount of ice required for testing (to nearest 0.1 lbs.) using the equation
below.
o Ice per cooler = 0.52 lbs. x Quart capacity of cooler
o Ice required = Ice per cooler x number of coolers
• Condition the ice by g the ice in a freezer (-15 to -5 °F) for a minimum of 24 hours
prior to use.
The day of the test, the following steps are performed:
• Gather Test Equipment
• Allow thermal r to reach a temperature of 100°F
• Scale – place scale near freezer with test ice
• Data Logger – ensure Data Logger has charged battery
The test procedure is as s:
• Bring test coolers to freezer with test ice.
• Place test cooler on scale and tare the scale.
• Break test ice with hammer.
• Using the scale as reference, quickly fill the test cooler with the required amount of ice.
• Ensure that the ice is evenly distributed throughout the test cooler.
• Ensure that the connector end of the thermocouple is outside of the test cooler and close
and secure the cooler lid.
• Repeat steps for the remaining test coolers.
• Arrange the s in the test area such that they all have even amounts of direct
sunlight and airflow (one cooler does not block the other).
• Connect all thermocouples to the data logger.
• Check all thermocouple readings to ensure that all connections are complete and the
channels are recording properly. (Note: The starting temperature inside each test cooler
should be < 10° F).
• Power up the data logger and configure to record with temperatures recorded at less
than 10 minute intervals.
• Begin recording and note time in test log.
• Allow the test to continue until the inside temperature of each test cooler is ≥ 50 °F.
• Stop recording.
• nect thermocouples from data logger.
• e data from data logger.
• Remove test coolers from test area.
• Empty test coolers and allow them to dry.
• Remove thermocouples from test coolers
The heat gain rate of the insulating devices 2010, 4010 can be approximately 0.5 to 1.5
r, and, in one particular example, the heat gain rate can be approximately 1.0 degF/hr.
Like in the above examples, the ability of the insulating devices 2010 and 4010 are also
configured to withstand interior leaks and were also tested to see how well the insulating
devices 2010, 4010 maintain the contents stored in the storage compartment or receptacles
2504, 4504. In one example test, the ting devices 2010, 4010 can be filled with a liquid,
such as water, and then can be inverted for a predetermined time period to test for any
moisture leaks. In this example, the insulating s 2010, 4010 are filled with a liquid until
approximately half of a volume of the receptacle 4504 is filled, e.g. 3 gallons of water, and the
closures 2301, 4301 are then closed fully. The entire insulating s 2 010, 4010 are then
inverted and held inverted for a time period of 30 minutes. The insulating devices 2010, 4010
are then reviewed for any leaks.
The insulating s 2010, 4010 can be configured to withstand being held inverted for 30
minutes without any water escaping or leaving the receptacles 2504, 4504. In ative
examples, the insulating devices 2010, 4010 can be configured to withstand being held
inverted for 15 s to 120 minutes without any water escaping or leaving the acles
2504, 4504.
Figs. 24-32 show another example insulating device 3010. The example insulating device 3010
can be of a similar construction to the above examples, where like reference numerals
represent like features having similar functionality. In this example, as can be seen in Figs. 24-
26 and 32, the closure 3311 and opening 3512 is formed through a first sidewall 3507A, a
second ll 3705B, and a third sidewall 3507C and partially through a fourth sidewall
3507D of the insulating device 3010. Moreover, the opening 3512 is configured to provide
access to the inner chamber 3504 as is shown in Figs. 29A and 32. Like in the above examples,
the closure 3311 can be substantially waterproof so as to resist liquid from exiting the opening
3512 when the insulating device 3010 is in any orientation.
As shown in the cross-sectional view of Fig. 29A, the e insulating device 3010 generally
includes a body assembly 3350 and a lid assembly 3300, which together form the three main
components of the insulating device 3010: the inner liner 3500, the insulating layer 3502, and
the outer shell 3501. The inner liner 3500 can, in one example, be formed of double laminated
TPU nylon fabric, the insulating layer 3502 can, in one example, be formed of can be formed
of NBR/PVC foam blend or any other suitable blend or foam, and the outer shell 3501 can, in
one example, be formed of TPU nylon fabric. It is also contemplated that the inner liner and
the outer shell 3501 can be formed of one or more of PVC, TPU coated nylon, coated fabrics,
and other weldable and/or waterproof fabrics.
As shown in Figs. 24-26, the closure 3311 s between the body assembly 3350 and the
lid assembly 3300 to substantially seal the body assembly 3350 and the lid assembly 3300
from water. Additionally, as shown in Fig. 29A, the lid assembly 3300 can be ted to the
body assembly 3350 by the outer shell 3501, which forms a living hinge 3503. In one example,
the living hinge 3503 can be formed as a portion of the outer shell 3501 and/or the inner liner
3500 and specifically from the flexible nature of the material of the outer shell 3501 and/or
the inner liner 3500 to provide a larger opening in the insulating device 3010. The living hinge
3503 can also be reinforced by an inner piece of fabric 3503A, which can be formed of the
inner liner material or other waterproof materials. In this way, the chamber 3504 and
contents of the ting device 3010 can be accessed by opening the closure 3311 and
folding back or opening the lid assembly 3300.
In this example, the ting device 3010 can be in the shape of a cuboid or prism. For
example, the outer shell 3501, the insulating layer 3502, and the inner liner 3500 define the
first sidewall, 3507A, the second sidewall 3507B, the third sidewall 3507C, and the fourth
sidewall 3507D of the . Also the lid assembly 3300 forms a top wall 3300a and the base
3215 forms a bottom wall 3215a to enclose the cuboid. However, the contents of the
insulating device 3010 are accessed through the opening 3512 formed at the top of the
insulating device and again can extend through each of the first sidewall, 3507A, the second
sidewall 3507B, the third sidewall 3507C and can extend partly through the fourth sidewall
3507D. Other shapes are also contemplated for the insulating device 3010, for e,
cylindrical, spherical, conical, pyramidal, frusto-conical, frusto-spherical, frusto-pyramidal,
etc. The height of the insulating device 3010 can, in one example, be in the range of 15 cm to
50 cm and in one particular example can be 29 cm. The length of the insulating device 3010
can be in the range of 15 cm to 50 cm and in one ular example can be 32 cm. Also the
width of the insulating device can, in one e, be in the range of 15 cm to 50 cm and in
one specific e be 25.5 cm. The e capacity of the insulating device 3010 can be
to 15 quarts and in one particular example can be 12.7 quarts. However, it is contemplated
that the insulating device 3010 may comprise any height, length, width and volume
dimensions, without departing from the scope of these disclosures.
Like in the above es, the insulating device 3010 can include one or more handles 3210,
3212, rings 3214, and webbing loops 3224 for attaching various items, e.g. straps (shoulder),
carabineers, dry bags, keys, storage cases, etc. The rings 3214 can be D-rings, and a shoulder
strap (not shown) can be connected to the D-rings for easy carrying of the insulating device.
Also the rings 3214 can be attached to the ting device 3010 at attachment points 3213,
which can form loops or straps 3315a that also form a slot for receiving the rings 3214. The
insulating device may also e side, front and/or rear carry handles, pockets, tie downs,
and s anywhere on the external surface of the outer shell. The s can be sized for
ing keys, phones, wallets, etc. and can be formed waterproof. The pockets may also
include a waterproof zipper to prevent the contents therein from getting wet.
Likewise, similar to the above examples, the outer shell 3501 can also include multiple
reinforcement areas or patches 3320 that are configured to assist in structurally supporting
the optional handles, straps, and webbing loops (e.g. 3210, 3212, 3213, 3214, and 3224). The
handles or straps (e.g. 3210, 3212, 3213, 3214, and 3224) and other ments can be
stitched to the patches using threads 3222. In certain examples, these threads 3222 do not
extend through the outer shell 3501 into the insulating layer 3502. The optional handles or
straps can be sewn to the patches 3320, and the patches 3320 can be RF welded to the outer
shell 3501. Also, in other examples, the patches 3320 can be sewn or adhered to the outer
shell 3501. Apertures from the stitching operation can provide venting to the interior defined
by the outer shell 3501 and the inner liner 3500 of the insulating device 3010. In on,
other techniques are contemplated for securing the handles or straps to the insulating device
3010.
The al components of the insulating device 3010, the body assembly 3350, and the lid
assembly 3300 can be seen in the sectional view of Fig. 29A. In addition, Fig. 29B shows
a magnified cross-sectional view of the lid assembly 3300.
The lid assembly 3300 includes an upper inner liner portion 3500A, an upper insulating layer
portion 3502A and an upper outer shell portion 3501A. The upper insulating layer portion
3502A can be formed of a single layer of foam, which corresponds to the overall shape of the
lid assembly 3300. The foam can, in one example, be an insulating foam, as discussed herein,
which can be the same foam as is used in the body assembly 3350, and can be ched to
and floating between the upper inner liner portion 3500A and the upper outer shell portion
3501A. As shown in Fig. 29B, the upper inner liner portion 3500A can be formed of a sheet of
material 3500A1 and a strip of material 3500A2 that is attached to the binder 3518. In other
embodiments the sheet of material 3500A1 can connect directly to the binder 3518 thus
eliminating the need for the strip of material 3500A2. The strip of material 3500A2 can
p and be welded to the sheet of al 3500A1. Seam tape 3509 can be placed over
the connection between the sheet of material 3500A1 and the strip of material 3500A2. It is
also contemplated that the upper inner liner n 3500A can be formed as a unitary
structure by injection molding, for example.
The upper inner liner n 3500A can be ted to the upper outer shell portion 3501A
by joining the upper inner liner strip of material 3500A2 to an upper outer shell strip of
material 3501A3 at a RF weld joint 3522. However, it is contemplated that other types of
securing methods could be used such as other forms of welding, stitching, adhesives, rivets,
etc. Additionally, as will be discussed in further detail, a binding material 3518, in the form of
a strip or band can be sewn over the ends of the upper inner liner strip of material 3500A2
and the upper outer shell strip of material 3501A3. It is also contemplated that the binding
al 3518 can be coupled over the ends of the upper inner liner strip of material 3500A2
and the upper outer shell strip of material 3501A3 by a plurality of rivets, or by using one or
more adhesives.
As shown in Figs. 29A and 29B, the upper outer shell portion 3501A of the lid assembly 3300
may include two separate layers 3501A1, 3501A2 and an upper outer shell strip of material
3501A3 extending perpendicular to the two separate layers 3501A1, 3501A2. The upper outer
shell strip of material 3501A3 can be integral and attached to a first outer shell section 3501B1
as discussed in further detail below. For example, the upper outer shell strip of material
3501A3 and the first outer shell section 3501B1 can be formed or cut from the same material.
However, it is also contemplated that outer shell strip of material 3501A3 and the first outer
shell section 3501B1 are formed of separate structures or different als. In one e,
the top layer 3501A1 can be formed of a TPU coated nylon laminate, and the bottom layer
3501A2 can be formed of a compression molded EVA material. The upper outer shell portion
3501A may also be formed of a unitary piece of material in an injection molding process, for
example.
As shown in Figs. 29A and 29B, the binding al 3518 can both secure the lid assembly
3300 together and secure the lid assembly 3300 to the body assembly 3350. The binding
material 3518, in certain examples, can be formed of a strip, band or ribbon and can be made
of nylon. It is contemplated that the binding material 3518 can be formed from additional or
alternative polymers, without departing from the scope of these disclosures. ically, the
first outer shell section 3501B1 can be secured er with the upper inner liner 3500A, the
separate layers 3501A1, 3501A2, and the upper outer shell strip of material 3501A3 of the
upper outer shell portion 3501A by stitching the binding material 3518 around the perimeter
of the lid assembly 3300. The stitching, therefore, extends through the binding material 3518,
the lower outer shell portion 3501B, the upper inner liner portion 3500A, the top layer
3501A1, the bottom layer 3501A2 and the strip of material 3500A2 to form a seam 3517.
The weld joint 3522 can also both secure the lid assembly 3300 together and secure the lid
assembly 3300 to the body assembly 3350. As alluded to above, the weld joint 3522, which
can be an RF weld joint, also secures the lid assembly 3300 together by connecting the upper
inner liner n 3500A and the upper outer shell n 3501A by joining the upper inner
liner strip of material 3500A2 to an upper outer shell strip of material 3501A3. It is also
contemplated, however, that the joint 3522 could be formed by stitching or by an adhesive.
Again once the lid ly 3300 and the body assembly 3350 are secured together, the living
hinge 3503 is formed between the lid assembly 3300 and the body assembly 3350.
The lid assembly 3300 and the body assembly 3350 are also connected by the closure, which
as discussed below, in one example, can be a zipper. Specifically, zipper tape 3306 can be
attached between the upper outer shell strip of al 3501A3 and the first outer shell
section 3501B1 of the lower outer shell portion 3501B by ing, welding, adhesives, etc.
In this way, an upper portion 3306a and a lower portion 3306b of the zipper tape 3306 secures
the lid assembly 3300 and the body assembly 3350 together.
Referring again to Fig. 29A, the body ly 3350 includes lower inner liner portion 3500B,
lower insulating layer n 3502B, and lower outer shell n 3501B. The lower inner
liner portion 3500B can be formed of a top strip , a middle portion , and a
bottom portion 3500B3. The top strip 3500B1, the middle portion , and the bottom
portion 3500B3 can be welded or stitched together at seams 3508. The seams 3508 can be
covered with a seam tape 3509, which can be formed of a waterproof or water resistant
material, such as PU (polyurethane). However, the seam tape 3509 can be formed of a
breathable material that is impervious to water but allows gases to escape from the in the
inner chamber 3504.
In an alternative example, the lower inner liner portion 3500B can be formed of a single
integral piece by, for example, injection molding. Fig. 31 shows an example inner liner portion
7500B that is formed by an injection molding process. In this example, the lower inner liner
n 7500B can be formed of one or more of urethane, PVC, TPU, or other weld-able
material. The lower inner liner portion 7500B can be welded into place onto the outer shell,
after the lower insulating layer is placed within the outer shell.
Referring again to Figs. 29A and 30, the lower insulating layer portion 3502B can include a first
sheet of insulating material 3502B1 and a second sheet of insulating material 3502B2. Similar
to the above examples, the first sheet of insulating material 3502B1 and the second sheet of
insulating material 3502B2 can be free floating layers of insulating material that are not
attached to either the lower inner liner portion 3500B or the lower outer shell portion 3501B.
However, it is also contemplated that the first sheet of insulating material 3502B1 and the
second sheet of insulating material 3502B2 can be attached to either the lower inner liner
portion 3500B or the lower outer shell portion 3501B. Moreover, it is also contemplated that
the lower insulating layer portion 3502B be formed of a single unitary piece.
The lower outer shell portion 3501B can be formed of several sections. In this e, the
lower outer shell portion 3501B can include a first outer shell n 3501B1, a lower outer
wall section 3501B2, a first base layer 3501B3, and a second base layer 3501B4. Similar to the
lid assembly, the first base layer 3501B3 can be formed of a TPU coated nylon laminate, and
the second base layer 3501B4 can be formed of a compression molded EVA material. Each of
the lower outer wall section 3501B2, the first base layer 3501B3, and the second base layer
3501B4 can be joined er by stitching, welding or adhesives. Also like in the above
examples, a base support ridge 3400 can be formed into the first base layer 3501B3 and the
second base layer 3501B4 to provide for structural integrity and support to the insulating
device 3010 when the ting device 3010 is placed onto a surface. In alternative examples,
the lower outer shell portion 3501B can be formed as a singular component and may, in
certain examples, be formed by an injection g process.
Like in the above examples, the closure 3311 can be a zipper and can be substantially
waterproof. Moreover, the zipper may comprise a pull tab or handle 3302, which in this
example can formed of a hard c. It is also contemplated that the pull tab 3302 can be
formed of a metal or alloy, a le polymer, cloth, string, or rope, among others. Forming
the pull tab 3302 of a cloth, string, or rope may prevent the wear of the connection between
the pull tab 3302 and the zipper. Specifically, when the zipper is closed about the
circumference of the outer shell 3501, the pull tab 3302 can be rotated or d by the user.
The cloth, string, or rope can withstand the twisting action by the user. Other pull tabs are
also contemplated. For example, the pull tab could be provided with a bearing connection
that allows the pull tap to be rotated 360° in all directions.
A series of vents can be provided along the outer shell 3501 of the ting device 3010. The
vents allow for any gases that are trapped between the inner liner 3500 and the outer shell
3501 to escape. Without the vents, the gases trapped between the inner liner 3500 and the
outer shell 3501 will cause the insulating device 3010 to expand, which in certain ces,
may not be desired. In certain examples, the joint or seams that connect the inner liner and
the outer shell provides a vent to gases.
The venting can be provided in the lid assembly 3300. Specifically in the lid assembly 3300,
the seam 3517 may provide a series of small openings in the lid assembly 3300 where the
stitching on the binder material 3518 occurs. These openings act as vents for gases to escape
the inner volume of the lid assembly 3300.
Moreover, venting can be provided in the body ly 3350. In the body ly, the
vents can be provided in areas of the lower outer shell portion 3501B where the lower outer
shell portion 3501B fabric is pierced. For example, as shown in Fig. 26, tiny openings can be
provided at the box and cross-shaped stitching 3521 where the rear carry handle 3210 is
attached to the insulating device 3010. The vents can also be provided in the areas or
locations where the handles 3212, 3210, molle loops 3224, and D-rings 3214 are attached to
the outer shell 3501 of the insulating device 3010. For example, the ing that secures the
handles, webbing or molle loops 3224, and D-rings 3214 to the outer shell provides openings
into the outer shell 3501 to create venting to the storage compartment or inner chamber 3504
of the insulating device 3010. Fig. 33 shows an example schematic where stitching 3519
extends through the outer shell 3501, a handle 3212 a rcement areas or patches 3320.
To form the insulating device 3010, the body assembly 3350 can be formed and then the lid
assembly 3300 can be formed by joining the lid assembly 3300 to the body assembly 3350. To
form the body ly 3350 of the insulating device 3010, the lower outer shell portion
3501B and the lower inner liner portion 3500B can be formed independently. Once the lower
outer shell portion 3501B is formed, the insulating layer 3502 can then be placed within the
lower outer shell portion 3501B. The lower inner liner portion 3500B can be attached to the
lower outer shell portion 3501B to secure the ting layer 3502 within the lower outer
shell portion 3501B and the lower inner liner portion 3500B. However, the insulating layer
3502 can freely float between the lower outer shell portion 3501B and the lower inner liner
portion 3500B. The lid assembly 3300 can be secured together and the lid assembly 3300 can
be secured to the body assembly 3350 by g the upper inner liner portion 3500A to the
upper outer shell portion 3501A and the lower outer shell portion 3501B at the weld joint
3522. y, the lid assembly 3300 can be further attached to the lower outer shell portion
3501B by way of stitching the top portion of the lower outer shell portion 3501B together with
the top layer 3501A1, the bottom layer 3501A2, the upper inner liner portion 3500A, the strip
of al 3501A3, and the binding material 3518.
ically, the lower outer shell portion 3501B can be formed by attaching each of the first
outer shell section 3501B1, the lower outer wall section 3501B2, the first base layer 3501B3,
and the second base layer 3501B4 together. Next, each of the first sheet of insulating material
3502B1 and the second sheet of insulating material 3502B2 can be placed within the lower
outer shell portion 3501B. The lower inner liner portion 3500B can then be formed by welding
each of the top strip , the middle portion 3500B2, and the bottom n 3500B3
together and then by adding the seam tape 3509 over each of the welds. Alternatively, as
discussed above, the lower inner liner portion 3500B can be formed by injection molding the
material. Once the lower inner liner portion 3500B is formed, the inner liner portion 3500B
can be placed within the lower insulating layer portion 3502B, and the inner liner portion
3500B can be welded to the lower outer shell portion 3501B at seam 3511 all along the inner
perimeter of the body assembly 3350 of the insulating device 3010. The seam 3511 can be
formed in this example by either welding or stitching.
Fig. 9 shows an exemplary welding que that can be used to weld the lower inner liner
portion 3500B to the lower outer shell portion 3501B. Once the lower inner liner portion
3500B is placed within the lower insulating layer portion 3502B, the lower inner liner portion
3500B can then be joined to the lower outer shell portion 3501B on its side using a threepiece
tool, which can include a top ed portion 3514A, a plate portion 3516, and a
bottom U-shaped portion 3514B. The curvature of the top U-shaped portion 3514A, the plate
portion 3516, and the bottom U-shaped portion 3514B, can correspond to the shape of the
perimeter of the body assembly 3350 of the insulating device 3010.
To form the seam 3511 as a weld, the lower inner liner portion 3500B is placed into contact
with the lower outer shell portion 3501B and the plate portion 3516 is placed within the lower
inner liner portion 3500B and the top ed portion 3514A, and the bottom U-shaped
portion 3514B can be placed into contact with lower outer shell portion 3501B. The top U-
shaped portion 3514A and the bottom U-shaped portion 3514B can be connected to two lead
wires such that current can pass through the top ed portion 3514A, the lower outer
shell portion 3501B and the lower inner liner portion 3500B. Current can then be applied first
to the top U-shaped portion 3514A to form a weld along the top U-shaped portion 3514A
including the curves and the straight portions. After the top section is welded, the ty of
the lead wires can then be reversed to then weld the bottom n along the bottom U-
shaped portion 3514B.
After the bottom section is welded by the bottom U-shaped portion the remaining two sides
can then be welded by using the plate portion 3516 and a pair of straight side bars or another
ng mechanism or vice. Similar to the curved portions of the body assembly 3350,
current can be applied to the pair of straight side bars by lead wires. Again, the sides can be
welded separately by ng the current in a first direction to weld a first side and by then
switching polarity of the leads and running the current in the opposite direction to weld a
second side. In one example, each of the sections can be welded for imately 10
seconds. Once the weld is complete around the entire perimeter of the body assembly 3350,
the body assembly 3350 can be assembled to the lid assembly 3300.
In one example, the closure 3311 can be substantially waterproof so as to resist liquid from
exiting the opening when the insulating device is dropped from a ce of six feet. In this
test, the insulating device can be filled completely with water and then dropped from six feet
onto a concrete surface on each of the faces of the insulating device 3010, which in this case
is six.
The example insulating device 3010 was tested to determine ice retention. As such, the ice
retention testing may be utilized to determine insulative properties of example insulating
device 3010. In an exemplary test, the duration of the increase from 0°F to 50°F when the
insulating device 3010 was filled with ice was determined ing to the test parameters
below. In certain examples, the temperature of the insulating device increases from 0°F to
°F in a duration of 0.5 hours to 1.5 hours, the temperature of the insulating device increases
from 10°F to 50°F in a duration of 22 hours to 28 hours, and the temperature of the insulating
device increases from 0°F to 50°F in a duration of 24 hours to 30 hours.
The ice retention was tested using the following test. More than 24 hours before the test, the
following steps are med:
Ensure test coolers are clean inside and out.
Mark test coolers with unique identifier and record identifier and description in test log or
notes.
Using duct tape, place a thermocouple (T) in the approximate center of the test cooler (C).
The thermocouple tip should be imately 1 inch above the cooler floor. (See Fig. 11 for
an example of proper couple set-up.)
Condition test coolers by keeping test coolers inside (ambient temperature 65-75° F) with lids
open for a minimum of 24 hours.
Calculate the amount of ice ed for testing (to nearest 0.1 lbs.) using the equation below.
Ice per cooler = 0.52 lbs. x Quart capacity of cooler
Ice ed = Ice per cooler x number of coolers
Condition the ice by placing the ice in a freezer (-15 to -5 °F) for a minimum of 24 hours prior
to use.
The day of the test, the following steps are performed:
Gather Test Equipment
Allow thermal chamber to reach a temperature of 100°F
Scale – place scale near freezer with test ice
Data Logger – ensure Data Logger has charged battery
The test procedure is as follows:
Bring test coolers to freezer with test ice.
Place test cooler on scale and tare the scale.
Break test ice with hammer.
Using the scale as nce, quickly fill the test cooler with the required amount of ice.
Ensure that the ice is evenly distributed throughout the test cooler.
Ensure that the tor end of the thermocouple is outside of the test cooler and close and
secure the cooler lid.
Repeat steps for the remaining test coolers.
Arrange the coolers in the test area such that they all have even amounts of direct sunlight
and airflow (one cooler does not block the other).
Connect all thermocouples to the data logger.
Check all thermocouple gs to ensure that all connections are complete and the channels
are recording properly. (Note: The starting temperature inside each test cooler should be <
° F).
Power up the data logger and ure to record with temperatures recorded at less than 10
minute intervals.
Begin ing and note time in test log.
Allow the test to continue until the inside temperature of each test cooler is ≥ 50 °F.
Stop recording.
Disconnect thermocouples from data logger.
Receive data from data logger.
Remove test coolers from test area.
Empty test coolers and allow them to dry.
Remove thermocouples from test coolers
Two samples were tested according to the above procedure. The results of which are
reflected below.
Time from Time from Time from
0°F to 10°F 0°F to 50°F 10°F to 50°F
Time (mins.) Days Hrs Min Days Hrs Min
Test #1 53 1 3 53 1 3 0
Test #2 49 1 3 37 1 2 48
Figs. 35A-36B show various views of another exemplary insulating device 5010. The example
insulating device 5010 is similar to the e discussed above in relation to Figs. 24-30. Like
reference numerals refer to the same or similar elements of similar functionality in all of the
s views; and, ore, these elements are not described in detail. However, in this
example the exemplary insulating device 5010 can be formed of a smaller size, can include a
top handle 5216, and may include an optional reinforcement sheet or panel. Nevertheless, it
is contemplated that the insulating device examples sed herein could include a similar
top handle and reinforcement sheet or panel.
Figs. 36A and 36B show a partial view of an example lid assembly 5300. Fig. 35A shows a
partial section view of the e lid assembly 5300. The example lid assembly 5300
is similar to the examples above, however, can additionally include a reinforcement sheet or
panel 5217 in the lid assembly 5300. Fig. 36B shows a partial top view of the example lid
assembly to illustrate the rcement sheet 5217. The reinforcement sheet or panel 5217
is configured to assist in preventing bowing of the handle 5216 and the lid assembly 5300.
The reinforcement sheet or panel 5217 can be a relatively rigid sheet of material in
comparison to the outer liner 5501, insulating layer 5502, and the inner layer 5500. In one
particular example, the reinforcement sheet or panel 5217 can be formed of a le
polymer or plastic, such as polyethylene. However, any stiffener material that is flexible could
be used and other examples, may include a thermoformed PE, a TPU ion molded custom
component.
In certain examples, the reinforcement sheet or panel 5217 can be flat, corrugated or may
have a honey comb uration. The panel 5217, however, can include other patterns so as
to assist in ting bowing of the handle 5216. In certain examples, the reinforcement
sheet or panel can be 1 to 3 mm thick. The reinforcement sheet may e a cover, which
can in certain examples, can be configured to t water from penetrating the cover. In
other examples, additional fabric may be included to rce the handle.
A reinforcement area or patch 5320 can be included on the lid assembly 5300 for supporting
the handle 5216. In certain examples, the patch 5320 can be welded to the lid assembly 5300.
However, the patch 5320 may also be omitted entirely. The handle 5216 may be sewn to the
lid assembly 5300 and the reinforcement panel 5217 by way of thread 5219. The handle 5216
may also extend through the lid assembly and be directed connected to the reinforcement
panel 5217. In addition, instead of using a thread, the handle 5216 can be connected to the
reinforcement sheet or panel 5217 by one or more welds, bolts or other threaded-like
connection, bayonet, ball and socket, and the like. Other connection methods may include
providing either layers 5501A1 or 5501A2 with one or more slots and the rcement sheet
or panel 5217 with one or more corresponding projections that can be located within the one
or more slots, which allow for a more advanced connection of the sheet or panel 5217 to the
lid assembly 5300 of the insulating device 5010. Also a wireframe or steel wire can be placed
within the handle 5216 and extend through the handle 5216. The wireframe or steel wire can
be threaded through the sheet or panel 5217 to secure the handle to the lid assembly 5300.
It is also contemplated that all or portions of the lid assembly and/or handle can be injection
molded to provide a more rigid structure to prevent bowing of the handle.
The tion between the handle 5216 and the reinforcement panel 5217 also helps
prevent separation issues between the separate layers 5501A1, 5501A2, which can be a TPU
coated nylon laminate, and a compression molded EVA material respectively. In this example,
the connection between the handle and the reinforcement panel may allow water into the
lid. However, at the same time, the connection can allow for any liquid therein to escape by
evaporating h the opening formed by the connection. However, it is also plated
that the connection between the handle and the reinforcement panel may also be waterproof
or water resistant to limit the amount of moisture into the lid assembly.
Also the handle 5216 can be formed of a 1000D Nylon or other suitable polymer and may
include 50mm webbing. Additionally, the handle 5216 may include g on the gripping
portion of the handle. In one example, the padding may be a suitable foam, such as a 5 mm
polyethylene sponge foam. It is contemplated that the seal between the lid assembly 5300
and the body ly 5350 can be configured to withstand shock loading by the handle when
the insulating device 5010 is sealed and filled with contents. Nevertheless, a side bridge
linking the lid assembly 5300 to the body assembly 5350 is also contemplated for transporting
heavy items in the insulating device 5010.
Figs. 37-41B illustrate r ment of insulating device 6010. The example insulating
device 6010 can be of a r construction to the above examples, where like reference
numerals represent like features having similar functionality to nce numeral 3XXX and
5XXX. These features having like reference numerals 6XXX may have limited or no description
at all, but their functionality remains the same as their corresponding 3XXX and 5XXX
numerals. In this example, as can be seen in Figs. 37-41B, the closure 6311 and opening 6512
may be formed h a first sidewall 6507A, a second sidewall 6705B, and a third sidewall
6507C and partially through a fourth sidewall 6507D of the insulating device 6010. Moreover,
the opening 6512 is configured to provide access to the inner chamber 6504 as is shown in
Figs. 40A-41B. Like in the above examples, the closure 6311 can be substantially roof
so as to resist liquid from g the opening 6512 when the insulating device 6010 is in any
orientation.
As discussed above, the insulating device 6010 may include one or more handles 6210, 6212,
rings 6214, and webbing loops 6224 for attaching various items, e.g. straps (shoulder),
carabineers, dry bags, keys, storage cases, etc. The rings 6214 can be D-rings, and a shoulder
strap (not shown) can be ted to the D-rings for easy carrying of the insulating .
Also the rings 6214 can be attached to the ting device 6010 at attachment points 6312,
which can form loops or straps 6315a that also form a slot for receiving the rings 6214. For
example, the straps 6315a, 6315b each form a single loop on the second and third sidewalls
6507B, 6507C tively. The straps 6315a, 6315b may be only connected to their
tive sidewalls 6507B, 6507C on one side of the loop formed to receive the rings 6214.
For e, as shown in Figs. 37-39, the strap 6315a is connected to the sidewall 6507C
below the loop formed to receive the ring 6214. Alternatively, the straps 6315a, 6315b may
be connected to their respective sidewalls 6507B, 6507C above the loop formed to receive
the respective ring 6214.
Likewise, similar to the above examples, the outer shell 6501 can also include multiple
reinforcement areas or patches 6320 that are configured to assist in structurally supporting
the optional handles, straps, and webbing loops (e.g. 6210, 6212, 6213, 6214, and 6224). The
handles or straps (e.g. 6210, 6212, 6213, 6214, and 6224) and other attachments can be
stitched to the patches using threads 6222. In certain examples, these threads 6222 do not
extend through the outer shell 6501 into the insulating layer 6502. The optional handles or
straps can be sewn to the patches 6320, and the patches 6320 can be RF welded to the outer
shell 6501. Also, in other examples, the patches 6320 can be sewn or adhered to the outer
shell 6501. Apertures from the stitching operation can provide venting to the interior defined
by the outer shell 6501 and the inner liner 6500 of the insulating device 6010. In addition,
other techniques are contemplated for securing the handles or straps to the insulating device
6010.
Optionally or in addition to the venting configurations described above with respect to the
configurations of insulating devices 3010 and 5010, insulating device 6010 may have a
plurality of venting holes 6325 extending through the outer shell 6501. The exploded view of
Fig. 39 shows the plurality of venting holes 6325 positioned underneath patches 6320 and
further underneath and al handles or straps 6210, 6212. The plurality of g holes
6325 may comprise any number of holes, such as the three holes 6325 shown in Fig. 39.
Optionally, the plurality of holes 6325 may comprise two holes, four holes, or r than
four holes. The plurality of holes 6325 may be formed in a linear n to be positioned
under the patches 6320 such as to not be e from the exterior of the insulating device
6010. Additionally, the ity of holes 6325 may have a diameter of approximately 3 mm,
or within a range of 2 mm and 4 mm. The venting holes 6325 may help vent gases that
become trapped between the inner liner 6500 and the outer shell 6501.
Figs. 40A and 40B illustrate an alternate embodiment of the insulating layer 6502 of insulating
device 6010. The insulating layer 6502 may comprise a lower insulating layer portion 6502B
may include a first sheet of insulating al 6 and a second sheet of insulating material
6502B2. r to the above examples, the first sheet of insulating material 6502B1 and the
second sheet of insulating material 6502B2 can be free floating layers of insulating al
that are not attached to either the lower inner liner portion 6500B or the lower outer shell
portion 6501B. However, it is also contemplated that the first sheet of insulating material
6502B1 and the second sheet of insulating al 6502B2 can be attached to either the
lower inner liner portion 6500B or the lower outer shell portion 6501B. Moreover, it is also
contemplated that the lower insulating layer portion 6502B be formed of a single unitary
piece.
The upper insulating layer n 6502A may be connected to the lid assembly 6300 wherein
the lid assembly includes at least a portion of the upper insulating layer portion 6502A that
extends beyond the closure 6311 adapted to close the opening 6512. As the upper insulating
layer portion 6502A may extend beyond the closure 6311, a portion of the upper insulating
layer portion 6502A and the upper inner liner portion 6500A may contact the lower inner liner
n 6500B and the lower insulating layer portion 6502B when the closure 6311 is sealed
to improve the insulation of the storage compartment 6504. For example, the closure 6311
may force the upper inner liner portion 6500A to contact the top strip 6500B1 of the lower
inner liner portion 6500B. Optionally or in addition, a portion of the upper insulating layer
portion 6502A may be inwardly tapered to accommodate and provide space for the e
6311. Further, the upper insulating layer portion 6502A may extend along the length of the
closure 6311 to insulate the insulation container 6010 along a length of the e 6311. In
addition, the upper insulating layer portion 6502A may extend along the length of the hinge
6503 to insulate along the length of the hinge 6503.
The ting layer 6502 may have multiple thicknesses. For example, the upper insulating
layer n 6502A may have a thickness that is r than thickness of the lower insulating
layer portion 6502B and/ or greater than a thickness of the ting layer portions 6502B1
and 6502B3. As shown in Fig. 40A, the upper insulating layer portion 6502A may have a
constant ess of approximately 51 mm or within a range of 38 mm to 64 mm, while the
lower insulating layer portion 6502B2 and the insulating layer portions 6502B1, 6502B3 on
the sidewalls 6507A, 6705B, 6507C may have a constant thickness of approximately 38 mm or
within a range of 25.4 mm to 51 mm. In addition, the thickness of the upper insulating layer
portion 6502A may be expressed as a ratio of the thickness of the upper insulating layer
portion 6502A to the thickness of the lower ting layer portion 6502B of at least one of
the sidewalls 6507A, 6705B, 6507C may be approximately 1.3:1, or within a range of 1.2:1 and
1.5:1. Alternatively, the thickness of the upper insulating layer portion 6502A may be
expressed as a function of the ratio of the thickness of the upper ting layer portion
6502A to the overall height of the insulating device 6010, where the overall height 6513
defined as the vertical distance for the top of the lid assembly 6300 to the bottom of the body
assembly 6350. For example, in the ment shown in Fig. 40A, the ratio of the thickness
of the upper insulating layer portion 6502A to the overall height 6513 of the insulating device
6010 may be approximately 6.5:1, or within a range of 5.8:1 to 7.2:1. In addition, the thickness
of the lower insulating layer portion 6502B on the sidewalls 6507A, 6705B, 6507C may be
expressed as a function of the overall width of the insulating device. For example, the l
width 6519 of the insulating device 6010 compared to a thickness of the lower insulating layer
portion 6502B ted to at least one sidewall may be approximately 11.5:1, or within the
range of 10.3:1 to 12.7:1.
Figs. 41A and 41B shows another embodiment of where the upper insulating layer portion
6502A ted to the lid assembly 6300 includes at least a n of the upper insulating
layer portion 6502A that extends beyond the e 6311 adapted to close the opening 6512.
As shown in Figs. 41A and 41B, the upper insulating layer portion 6502A may comprise a
plurality of components. For example, the upper insulating layer portion 6502A may comprise
a substantially uniform thickness insulating layer portion 6502D nearer the top of the lid
ly and an insulating ring 6502F around the perimeter edges 6515 of the upper
insulating layer n 6502A. The insulating ring 6502F may extend underneath the
insulation sheet 6502D and have a shape that approximates the circumference of the
insulation sheet 6502D. As the upper insulating layer portion 6502A may extend beyond the
closure 6311, a portion of the insulating ring 6502F and the upper inner liner portion 6500A
may contact the lower inner liner n 6500B and the lower insulating layer portion 6502B
when the closure 6311 is sealed to improve the insulation of the storage compartment 6504.
For example, the e 6311 may force the upper inner liner portion 6500A to contact the
top strip 6500B1 of the lower inner liner portion 6500B. The upper inner liner portion 6500A
may follow the contour of the upper insulating layer 6502A to form a headspace 6527
extending above the closure 6311. Further, the insulating ring 6502F of the upper insulating
layer portion 6502A may extend along the length of the closure 6311 to insulate the insulation
container 6010 along a length of the e 6311. In addition, the insulating ring 6502F of
the upper insulating layer portion 6502A may extend along the length of the hinge 6503 to
insulate along the length of the hinge 6503.
Since the upper insulating layer n 6502A may have multiple thicknesses that may
include a first thickness around the perimeter edges 6515 and second thickness at the center
portion 6517. The thickness of the insulating ring portion 6502F may be greater than the
thickness of the uniform thickness ting layer portion 6502D. Additionally, the overall
thickness defined as the combined thicknesses of both the uniform ess insulating layer
portion 6502D and the insulating ring portion 6502F at the perimeter edges 6515 of the upper
insulating layer portion 6502A is greater than the overall thickness of the center portion 6517
of the upper insulating layer portion 6502A. The thickness of the overall combined thickness
at the perimeter edges 6515 may also be expressed as a ratio of the overall combined
thickness at the perimeter edges 6515 to the thickness of the center portion of the upper
insulating layer may be approximately , or within a range of 2:1 to 2.5:1. Optionally or
in addition, a portion of the upper ting layer portion 6502A may be tapered on each side
of the insulating ring portion 6502F to accommodate and e space for the closure 6311
and space for the hinge 6503. Alternatively, the upper insulating layer portion 6502A may be
formed with the insulating ring portion 6502F as a single unitary piece.
schematically depicts an aerogel insulating structure 7800, or aerogel structure 7800,
according to one or more aspects described herein. This schematic depiction of the l
insulating structure 7800 may be used in figures throughout this disclosure. Accordingly,
where used, the aerogel insulating structure 7800 may include one or more of the
implementations described in relation to FIGS. 43-51, among others. Additionally, it is
contemplated that, where used throughout these disclosures, an aerogel ting structure
7800 may represent a single, or multiple discrete aerogel insulating structure 7800, t
departing from the scope of these disclosures.
In one example, the aerogel insulating structure 7800 may represent a rigid or semi-rigid
structure that is configured to be positioned within or around another structure, such as one
or more insulating devices, as bed throughout these disclosures. While the aerogel
insulating structure 7800 is schematically depicted in as a simple rectangular shape, it
is contemplated that the aerogel insulating structure 7800 may be configured with any threedimensional
geometry, without departing from the scope of these disclosures. In one
example, the geometry of the aerogel insulating structure 7800 may be formed by one or
more molding, machining, and/or chemical processes, such that the aerogel insulating
structure 7800 is shaped to fit within or around a specific ure, or portion of a ure.
Further, the aerogel insulating structure 7800 may be deformable, and may be configured to
deform in se to an applied pressure, and conform to another geometrical feature, such
as a wall or a cavity of an insulating device within or onto which the l insulating
structure 7800 is configured to be positioned. In one example, the aerogel insulating structure
7800 may be manufactured as a material that is initially partially or fully deformable, and
subsequently partially or fully hardens. As such, the l ting structure 7800 may be
positioned by spraying or ing onto or into another geometrical feature, and such that
the l insulating structure 7800 may uently transition from a able to a
partially or fully rigid structure.
It is contemplated that the aerogel insulating ure 7800 may be coupled to another
surface (not depicted in ). This other surface may be an internal surface within a cavity,
or an external surface of another structure, such as an insulating device (e.g. device 10). The
coupling may be removable or movable, and use adhesives, an interference fitting,
welding, stitching, and/or one or more fasteners, or combinations thereof. It is further
contemplated that the aerogel insulating structure 7800 may be y positioned within
another ure such that it is uncoupled from other surfaces.
In another example, the aerogel insulating structure 7800 may be overmolded within another
structure, or may be ulated within another structure by spin welding parts of the
structure around the l insulating structure 7800.
schematically s one implementation of the aerogel insulating ure 7800,
according to one or more aspects described herein. In one example, the aerogel insulating
structure includes an aerogel material 7802, which may ise be referred to as aerogel
insulation 7802, aerogel foam 7802, or aerogel 7802. Advantageously, the aerogel 7802 may
reduce an overall/combined thermal tivity when used within a structure, such as one
or more of the insulating structures described hout these disclosures. Further, due to
lower densities, the aerogel 7802 may reduce the overall weight of a structure, when
compared to structures that have equivalent thermal performance, but do not use aerogels.
It is plated that any aerogel type (material type), having any physical properties
(thermal conductivity, density, among others), and/or dimensional properties (pore size,
length, width and thickness dimensions, among others) may be used, without departing from
the scope of these disclosures. For example, the aerogel 7802 may include a silica l, a
carbon aerogel, a metal oxide aerogel, or an organic polymer aerogel, or combinations
thereof, among others. In one example, the thermal conductivity of the aerogel 7802 may be,
in some examples, 0.1 W/m·K or less, 0.03 W/m·K or less, or 0.01 W/m·K or less, among
others. However, it is contemplated that aerogel with any thermal conductivity may be used,
without departing from the scope of these disclosures.
tically depicts one implementation of the aerogel 7802, according to one or
more aspects described herein. In one example, the aerogel 7802 may include an internal
structure 7806, which may be surrounded by an external shell 7804. The external shell 7804
may include a r that partially or wholly seals the internal structure 7806 from an external
environment around the aerogel 7802. As such, the external shell 7804 may include a material
that is partially or wholly impermeable to air and/or water. Further, the external shell 7804
may be partially or fully deformable. It is contemplated that the external shell 7804 may
include any a polymer, a fiber-reinforced material, a metal, an alloy, or combinations f.
The internal structure 7806 of the aerogel 7802 may include a ural frame of the aerogel.
This structural frame may be contiguous, or may e several separate portions.
Additionally, the internal structure 7806 may include an aerogel powder, among others. In
another example, the internal ure 7806 may e aerogel in combination with
lass
schematically depicts another implementation of the aerogel 7802, according to one
or more aspects described herein. Accordingly, in one implementation, the aerogel 7802 may
be used within a vacuum-insulated panel structure 7808. In one example, an aerogel lattice
may provide a bracing structure that retains the form of the vacuum-insulated panel structure
7808 under . In this regard, it is contemplated that any vacuum-insulated panel shell
material and vacuum level may be used, t departing from the scope of these
disclosures.
schematically depicts another implementation of the aerogel 7802, according to one
or more aspects described herein. Accordingly, in one example, the aerogel 7802 may include
multiple vacuum-insulated panel structures 7808c. Further, it is contemplated that any
number of vacuum ted panel structures may be used, and in any configuration within
the aerogel 7802, without departing from the scope of these disclosures.
schematically depicts another entation of the aerogel 7802, according to one
or more aspects described herein. In one example, the aerogel 7802 may be configured to be
rolled, bent and/or folded around s and/or curves of a structure onto or into which the
aerogel 7802 is positioned. As such, a layer or panel of aerogel 7802 may include geometric
features, such has skiving features 7810a-7810h that facilitate bending and/or folding of the
aerogel 7802.
schematically s r implementation of the aerogel insulating structure
7800, according to one or more aspects described herein. In one example, an aerogel 7802
may be used in combination with another insulating layer 7810. As such, the insulating layer
7810 may be similar to the insulating layer 502, and may include, among others, an insulating
foam, such as a NBR/PVC blended foam, a PVC free NBR foam, or other eco-friendly type foam,
or combinations thereof. It is contemplated that the insulating layer 7810 may be coupled to
the aerogel 7802 by one or more adhesives, by one or more welding processes, by stitching,
and/or one or more fasteners (rivets, screws, staples, nails, among others). In one
implementation, the aerogel 7802 and the insulating layer 7810 may be coupled to one
another during one or more processes used to manufacture the aerogel 7802 and/or
insulating layer 7810. In another example, the aerogel 7802, and the ting layer 7810
may not be d to one r, and may be loosely positioned proximate one another.
It is contemplated that the aerogel insulating structure 7800 may be positioned within
r structure in any orientation. For example, the layer of l 7802 may be
positioned within an insulating device (e.g. insulating device 10) such that it is internally
oriented and the insulating layer 7810 is externally oriented. As such, the aerogel 7802 may
be positioned closer to an al storage compartment, such as acle 504, than the
insulating layer 7810. However, the orientation of the aerogel insulating structure 7800 may
be reversed, without departing from the scope of these disclosures. It is also contemplated
that the aerogel 7802 and/or insulating layer 7810 may have any thickness values, without
departing from the scope of these disclosures.
schematically depicts r implementation of the aerogel insulating structure
7800, according to one or more aspects described herein. In one example, a layer of aerogel
7802 may be positioned between two insulating layers 7810a and 7810b. It is r
contemplated that additional corresponding or alternating layers of aerogel 7802 and
insulating layer 7810 may be used, without departing from the scope of these disclosures.
schematically depicts another implementation of the aerogel insulating structure
7800, according to one or more aspects described herein. In one example, a barrier structure,
or layer 7812 may be positioned n the aerogel 7802 and insulating layer 7810. The
barrier structure 7812 may facilitate improved adhesion of the aerogel 7802 and/or insulating
layer 7810 to one another, and/or serve to keep the aerogel 7802 and insulating layer 7810
separate from one another. It is contemplated that the barrier structure 7812 may be
ucted from any polymer, metal, alloy, or fiber-reinforced material, or combinations
f, without departing from the scope of these sures.
schematically depicts another implementation of an aerogel insulating ure 7800,
ing to one or more aspects bed herein. Accordingly, the aerogel ting
structure 7800 may include multiple randomly spaced portions of insulating layer material
7810a-7810f and aerogel 7802a-7802f
depicts another implementation of an insulating device 7010, according to one or
more aspects described herein. In one example, the ting device 7010 may be similar to
insulating device 3010 and/or insulating device 5010. It is contemplated that like reference
numerals may refer to the same or similar elements that have similar functionality. As such,
a like reference numeral may have a same last three digits as a previously described element.
In one specific example, the lid assembly 7300 of insulating device 7010 may be similar to lid
assembly 3300 and/or 5300, since all of these elements have the same last three digits (300).
In another example, elements that have the same last three digits followed by a letter, or
letter and number combination, may also represent similar elements that have similar
functionality. For example, element 7500B2 may be similar to element 5500B2. Accordingly,
it is assumed that any previous descriptions of these similar elements having like reference
numerals are applicable to insulating device 7010 and lid assembly 7300, without need for
repetition of the descriptions here.
schematically depicts a cross-sectional view of the insulating device 7010 along line
53-53 schematically depicted in . In one example, the insulating device 7010 may use
aerogel insulating structures 7800, as previously described. Additionally or atively, one
or more aerogel insulating structures 7800 may be used within the lid assembly 7300. Further,
the l insulating structures 7800 may be used in ation with ting layers 7502,
7502A, 7502B1, 7502B2, which may be collectively referred to as insulating layers 7502. These
insulating layer 7502 may include one or more insulating foams, as have been usly
described. The insulating layers 7502 and the aerogel insulating structures 7800 may be
bonded together using one or more adhesives. However, it is contemplated that any coupling
type or methodology may be utilized, without departing from the scope of these disclosures.
As such, it is contemplated that the insulating layers 7502 and aerogel insulating structures
7800 may be referred to as a combined or contiguous unit or ure.
In one e, the insulating layer 7502 and/or the aerogel insulating structure 7800 may be
loosely positioned between inner liner 7500 and the outer shell 7501. In this way, the
insulating layer 7502 and/or the aerogel structure 7602 may be described as floating between
the inner liner 7500 and the outer shell 7501. Alternatively, one or more of the insulating
layer 7502 and/or the l structure 7602 may be coupled to one or more of the inner liner
7500 and the outer shell 7501. Further, it is plated that any ve and/or ng
mechanism may be used, without parting from the scope of these disclosures.
In one implementation, and as schematically depicted in , the aerogel insulating
structures 7800 may be used on internal sides (proximate the internal chamber 7504), and
one or more insulating layers 7502 may be used on external sides of the insulating device 7010
and lid assembly 7300. It is contemplated, however, that the l insulating structure 7800
may alternatively be used on the al sides, and the insulating layers 7502 may be used
on the internal sides of the insulating device 7010 and lid assembly 7300, without departing
from the scope of these disclosures.
It is further contemplated that one or more aerogel insulating structure 7800 structures may
be used with any of the insulating containers, structures, and/or devices described hout
this sure to e, among others, enhanced thermal properties and/or weight
reduction.
In one example, the aerogel insulating ures 7800 may be rigid, or may be partially or
fully deformable such that the aerogel insulating structures 7800 may be configured to bend
and flex without failure as one or more structures of the insulating device 7010 and/or lid
assembly 7300 are deformed.
schematically s a cross-sectional view of an alternative implementation of an
insulating device 8010 and lid assembly 8300, according to one or more aspects described
herein. The insulating device 8010 may be similar to the insulating device 7010, and the lid
assembly 8300 similar to the lid assembly 7300. However, the insulating device 8010 and the
lid assembly 8300 may use aerogel ting structures 7800 without the insulating layers
7502 used in insulating device 7010, and lid assembly 7300.
schematically depicts r cross-sectional view of an alternative implementation
of an insulating device 9010 and lid assembly 9300. In one example, the ting device
9010 and lid assembly 9300 may be similar to the insulating device 6010 and lid ly
6300, respectively. However, the insulating device 9010 and lid assembly 9300 may include
aerogel insulating structures 7800. As before, it is contemplated that like reference numerals
may refer to the same or similar elements that have similar onality. A like reference
numeral may have a same last three digits as a previously described element, or a same last
three digits followed by a letter, or letter and number combination. Accordingly, it is assumed
that any previous descriptions of these similar ts having like reference numerals are
applicable to insulating device 9010 and lid assembly 9300, without need for repetition of the
descriptions here.
Accordingly, the lid ly 9300 may include an insulating ring 9502F and aerogel
insulating structure 7800F around one or more perimeter edges 9515 of the upper insulating
layer portion 9502A and upper aerogel ting structure 7800A. As the upper insulating
layer portion 9502A may extend beyond the closure 9311, a portion of the insulating ring
9502F and aerogel ring structure 9602F and the upper inner liner portion 9500A may contact
the lower inner liner portion 9500B and the lower insulating layer portion 9502B when the
closure 9311 is sealed to e the insulation of the storage compartment 9504.
As depicted in , the lid assembly 9300 and ting device 9010 may include aerogel
insulating structures 7800 that are coupled to insulating layer portions 9502 (the insulating
layer portions 9502 labels in may include additional letters and numbers to identify
specific locations of the same or similar insulating als within the insulating device 9010
and/or lid assembly 9300, e.g. 9502A, 9502B, 9502B1, 9502B2, 9502F, 9502D). As previously
described, the aerogel insulating structures 7800 may be d to the insulating layer
portions 9502 by one or more adhesives and/or fasteners. In r e, one or more
of the aerogel insulating structures 7800 may be loosely positioned proximate one or more of
the insulating layer portions 9502.
schematically depicts a cross-sectional view of an insulating device 10010, and lid
ly 10300, according to one or more aspects described herein. In one example, the
insulating device 10010 may be similar to ting device 6010, and the lid assembly 10300
may be similar to lid assembly 6300. Though, the insulating device 10010 and lid assembly
10300 may include aerogel ting structures 7800. However, the previous descriptions of
the elements of insulating device 6010 and the lid assembly 6300 may be applicable to those
elements of insulating device 10010 and lid assembly 10300 with similar reference numerals.
schematically depicts a cross-sectional view of an insulating device 11010, according
to one or more aspects described herein. In one example, the insulating device 11010 may
be similar to insulating device 10. , the insulating device 11010 may include aerogel
insulating structures 7800. However, the previous descriptions of the elements of insulating
device 10 may be applicable to those elements of insulating device 11010 with similar
reference numerals.
schematically depicts a cross-sectional view of an insulating device 12010, ing
to one or more aspects bed herein. In one example, the insulating device 12010 may
be similar to insulating device 4010, as described in relation to . Though, the insulating
device 12010 may include aerogel insulating structures 7800. However, the previous
descriptions of the elements of insulating device 4010 may be applicable to those elements
of insulating device 12010 with similar reference numerals.
schematically depicts an isometric view of an insulating ner 13001 and lid
ure 13003, according to one or more s described herein. In one e, the
insulating container 13001 may have a substantially cuboidal shape, and may be constructed
from one or more rs, metals, alloys, fiber-reinforced materials, or combinations
thereof. In one implementation, the lid structure 13003 may be hingedly-coupled to the
insulating container 13001. For example, the lid structure 13003 may be hingedly-coupled to
the insulating ner 13001 along a first edge 13005 of a top portion 13007 of the insulating
container 13001.
In one implementation, the insulating ner 13001 and lid structure 13003 may comprise
double wall construction. As such, one or more cavities formed within the insulating container
13001 and lid ure 13003 may be partially or wholly filled with an insulating material.
This insulating material may e one or more polymeric materials (e.g. a foam, a lattice, a
substantially solid structure, and the like), and/or an l structure, such as aerogel
ting structure 7800, which is schematically depicted inside the double wall construction
of the lid structure 13003. Additionally or atively, the insulating container 13001 and/or
lid structure 13003 may include vacuum-insulated double wall structures. As such, the aerogel
insulating structure 7800 may be used as a standoff structure to prevent the sidewalls of the
lid structure 13003 from deforming as a result of a vacuum within the double wall construction
of the lid structure 13003. In another example, the insulating container 13001 and/or lid
structure 13003 may include one or more vacuum-insulated panel structures.
schematically depicts an exploded isometric view of the insulating container 13001,
according to one or more aspects described herein. In one example, a cavity may be formed
between an inner structure 13009 and an outer shell 13011 of the insulating container 13001.
This cavity may be partially or wholly filled with an insulating al, such as a foam, an
l, or a vacuum insulated panel, or combinations thereof. Additionally or alternatively,
the cavity between the inner structure 13009 and an outer shell 13011 may contain a vacuum.
In one e, in order to reduce or t deformation of one or more sidewalls of the
inner ure 13009 and outer shell 13011, aerogel insulating structures 7800 may be
coupled to one or more surfaces of the insulating container 13001 (e.g. surface 13013 of the
inner structure 13009, as schematically depicted in ). These aerogel insulating
structures 7800 may be used to maintain a separation distance between the inner ure
13009 and outer shell 13011 in order to reduce or prevent deformation of the sidewalls of the
insulating container 13001 as a result of a vacuum being formed within the cavity between
the inner structure 13009 and outer shell 13011. Two aerogel insulating structure 7800 are
schematically depicted in , however, a single aerogel insulating structure 7800, or three
or more aerogel insulating structures 7800 may be used as standoffs within the insulating
ner 13001 and/or lid structure 13003, without departing from the scope of these
disclosures.
Further details of the double wall construction of the insulating container 13001 and lid
structure 13003 are bed in application , “Container and Method of
Forming a Container, filed 3 Feb 2017, the entire ts of which are incorporated herein
by reference for any and all non-limiting purposes.
schematically depicts a cross-sectional view of an insulating device 13021, according
to one or more aspects described herein. The insulating device 13021 may be a bottle that is
used to store a volume of liquid, and have an insulated container 13023 that is removably
coupled to a lid or closure 13025. A cavity 13027 may be formed between a first inner wall
13029 and a second outer wall 13031 of the ted container 13023. This cavity 13027 may
n a sealed . It is contemplated that the pressure of these vacuum may have any
value, without departing from the scope of these disclosures. Additionally or atively,
the cavity 13027 may be partially or wholly filled with one or more insulating materials, such
as one or more foams, or an aerogel structure. In one example, and as schematically depicted
in , the cavity 13027 may include an aerogel insulating structure 7800. Accordingly, it
is contemplated that the aerogel insulating structure 7800 within the cavity 13027 may be
coupled to one or more of the first inner wall 13029 and second outer wall 13031 before the
inner wall 13029 and second outer wall 13031 are coupled to one another by one or more
processes. These coupling processes may include welding, brazing, tacking, folding, molding,
or using one or more fasteners, or combinations thereof.
The lid 13025 may also include an aerogel insulating structure 7800. This aerogel insulating
structure 7800 within the lid 13025 may be overmolded with one or more polymers, metals
and/or . Additionally or atively, separate portions of the lid 13025 may be welded
er (e.g. by spin welding) to encapsulate the aerogel insulating structure 7800.
Further details of the insulating device 13021 are provided in U.S. Application No. ,180,
titled “Containers and Lids and s of Forming Containers and Lids,” filed 29 June 2016,
the entire contents of which are incorporated herein by reference for any and all non-limiting
purposes.
depicts a cross-sectional view of a lid structure 13033, according to one or more
aspects described herein. The lid structure 13033 may be similar to those lids described in
International Application No. PCT/US16/47043, “Container with Magnetic Cap,” filed 15 Aug.
2016, the entire contents of which are incorporated herein by reference for any and all nonlimiting
purposes.
The lid structure 13033 may include a spout opening 13035 and an outer shell 13037 that
encapsulates, in one example, an aerogel insulating structure 7800. The aerogel insulating
structure 7800 may be positioned within a cavity of the outer shell 13037 prior to one or more
welding processes that rigidly couple separate portions of the outer shell 13037 together. In
another example, the outer shell 13037 may be overmolded over the aerogel insulating
ure 7800. In yet another example, the aerogel insulating structure 7800 may be injected
into a cavity in the outer shell 13037 of the lid structure 13033.
depicts a able insulator 13041, according to one or more aspects described
herein. In one example, the deformable insulator 13041 may be configured to extend around
at least a portion of a container 13043 (e.g. an um beverage can, among others). In
one example, the deformable insulator 13041 may bend, fold and/or ss t
structural failure. In another example, the deformable insulator 13041 may have a lly
rigid ure. In one implementation, the deformable tor 13041 may be constructed
from an l insulating structure 7800, as schematically depicted in . In one
example, an outer surface 13045 of the deformable insulator 13041 may be formed by an
outer surface of the aerogel insulating structure 7800. In another implementation, the outer
surface 13045 may be an outer skin/ layer of material (e.g. a deformable layer of polymer)
that retains the aerogel insulating structure 7800. A similar inner surface (not depicted) may
be used inside the deformable insulator 13041, and this inner surface may be configured to
contact the container 13043.
depicts an insulating container 13051, according to one or more s described
herein. In one example, the insulating container 13051 includes a base portion 13053 that
may be similar to container 13001, and a lid portion 13055 that may be similar to lid structure
13003. Loosely, bly, or rigidly positioned on top of the insulating ner 13051 is a
cushion structure 13057. In one example, the cushion may include one or more layers of
compressible material configured to deform and provide cushioning to a user when seated on
the insulating container 13051. In one example, the one or more layers of compressible
material may include an aerogel insulating structure 7800, as schematically depicted in . In one implementation, the aerogel insulating structure 7800 may be encapsulated within
the cushion structure 13057 by an outer skin or layer or material. In another example, the
outer surfaces of the cushion structure 13057 may include at least a portion of the aerogel
insulating structure 7800. It is further contemplated that a r ure, including one or
more partially or wholly deformable aerogel ting structures 7800, may be used in
alternative ts, such as blankets, or items of apparel, among others.
schematically depicts a cross-sectional view of another entation of an
insulating container 13061, according to one or more aspects bed herein. In one
example, the insulating container 13061 may be a tumbler configured to store a volume of
liquid within an internal reservoir 13063. The container 13061 may have an opening 13071
that extends into the internal reservoir 13063. The container 13061 may include a first inner
wall 13065 and a second outer wall 13067. A sealed cavity 13069 may be formed between
the first inner wall 13065 and the second outer wall 13067. Accordingly, container 13061 may
be an ted double-wall ure. In one e, a vacuum may be formed within the
sealed cavity 13069. It is contemplated that this vacuum may be at any pressure level, without
departing from the scope of these sures. In another example, one or more insulating
materials may be positioned within the cavity 13069, such as one or more aerogel insulating
structures 7800.
Further details of insulating containers similar to container 13061 are found in U.S. Application
No. 15/285,268, titled “Container and Method of Forming a Container,” filed 4 Oct. 2016, the
entire contents of which are incorporated herein by reference for any and all non-limiting
An exemplary insulating device may include an outer shell, an inner liner, an insulating layer
floating freely in between the outer shell and the inner liner, and a waterproof closure. The
top of the shell has first ter ference, and the bottom of the shell has a second
perimeter circumference. The first perimeter circumference can be equal to the second
perimeter circumference. The closure can be a zipper assembly comprising a plurality of
zipper teeth, and the zipper teeth can be formed of plastic or metal. The outer shell can be
made of a double laminated TPU nylon fabric. The inner liner can be made of a double
laminated TPU nylon fabric. The insulating layer can be formed of a closed cell foam. The
insulating layer can be made of a NBR and a PVC blend, and at least a portion of the insulating
layer can be ucted with an EVA foam layer. The outer shell further can include at least
one of a strap or handle. The outer shell further can include at least one ring for securing the
insulating device.
An exemplary insulating device can include an outer shell, an inner liner, a closure adapted to
seal at least one of the outer shell or the inner liner, and an insulating layer between the outer
shell and the inner liner. The closure can have a first flange and a second flange, and the outer
liner can be secured to top surfaces of the first flange and the second flange and the inner
liner can be secured to bottom surfaces of the first flange and the second flange. The outer
liner and the inner liner can be connected to the closure by a polymer weld. The outer shell
can have a first ference and a second ference, the first circumference and the
second circumference both having an oval shape. The closure can be adapted to be a barrier
against fluid. The closure can be a zipper tus that is watertight up to 7 psi above
atmospheric pressure.
An exemplary method of assembling an insulating device may include forming an inner liner
having an inner vessel, forming an outer shell, forming an insulating layer between the inner
liner and the outer shell, and securing a closure configured to be a barrier against fluid
penetration in and out of the inner vessel wherein the closure is secured in a flat plane and is
secured to the outer shell and the inner shell. The outer shell and inner shell may only be
connected to the closure and not to the insulating layer between the outer shell and inner
liner.
A waterproof polymer weld can be formed between the closure and the inner shell and the
closure and the outer shell when the closure, the outer shell, and the inner liner are lying in a
horizontal plane. The outer shell and the inner layer can be formed of a TPU nylon material.
The closure can have a first flange and a second flange. The outer liner can be secured to top
surfaces of the first flange and the second flange and the inner liner can be secured to bottom
surfaces of the first flange and the second .
The method can also include forming the insulating layer from a rectangular shape, and rolling
the rectangular shape into a cylindrical shape. The top of the ting layer has a first
perimeter ference and the bottom of the insulating layer has a second perimeter
circumference. The first perimeter circumference can be equal to the second perimeter
circumference.
Another example insulating device can include an outer shell, an inner liner forming a storage
compartment, a foam layer ng freely in between the outer and inner liner, the foam layer
providing insulation, an opening extending through the outer layer and the inner layer, and a
closure d to ntially seal the opening. The closure can be substantially roof
so as to resist liquid from exiting the opening.
The insulating device can also include an upper wall and a base, the upper wall defining an
upper wall circumference, an upper wall length and an upper wall width, and the base defining
a base circumference, a base length and a base width. The upper wall circumference can be
equal to the base circumference and the ratio of the upper wall length to the upper wall width
can be greater than the ratio of the base length to the base width. In one example, a heat gain
rate of the insulating device can be approximately 1.0-1.5 degF/hr.
Another example method of forming an insulating device may include forming an inner liner
first n and an outer shell first portion, securing the inner liner first portion and the outer
shell first portion to a le closure to form a cap assembly, forming an inner liner second
portion and ng the inner liner second n to the inner liner first portion to form an
inner liner, forming an outer shell second portion, rolling a rectangular foam portion to form
a first cylindrical foam portion and securing a foam base portion to the first cylindrical portion
to form a foam assembly, inserting the foam assembly into the outer shell second portion,
inserting the inner liner into the foam assembly, and stitching the outer shell first portion to
the outer shell second portion. The inner liner first portion and the outer shell first portion
can be welded to the closure. The closure can be provided with at least one flange and the
flange can be d to a bottom surface of the outer shell first portion and a top surface of
the inner liner first portion. The foam can float between the outer shell second portion and
the inner liner second portion.
An example portable insulating device may include an outer liner, an inner liner forming a
storage compartment, a foam layer in between the outer and inner liner. The foam layer can
be adapted to provide insulation. The e portable insulating device may also include an
opening extending through one of the outer layer and the inner layer and a g means for
substantially sealing the opening. The e can be substantially waterproof.
In one example, a portable cooler may e an aperture on the top of the cooler that is
opened and closed by a zipper apparatus which allows access to a chamber within the cooler.
The re ts any fluid leakage out of the cooler if the cooler is overturned or in any
configuration other than upright. The zipper assembly also prevents any fluid from
permeating into the cooler chamber if the cooler is exposed to precipitation, other fluid, or
submersed under water.
An example method of assembling a zipper apparatus and re configured to be
impervious to water or other liquids and fluids can include attachment of a waterproof zipper
via material welding to both an outer shell and an inner liner. This method may result in a
chamber impervious to water and other liquids when the zipper apparatus on the aperture is
sealed.
In one example, an insulating device may include an outer shell, an inner liner forming a
storage compartment, a foam layer floating formed in between the outer and inner liner, the
foam layer providing tion, an opening extending through the outer layer and the inner
layer, a closure adapted to substantially seal the opening, the closure being substantially
waterproof so as to resist liquid from exiting the opening when the insulating device is in any
orientation. In one example, the top portion of the outer shell can have a first perimeter
circumference in a first configuration. The outer shell may include a bottom n, the
bottom portion of the outer shell can have a second perimeter circumference in a second
configuration that is different from the first uration, and the first perimeter
circumference can be equal to the second perimeter circumference. The first configuration
and the second configuration can be both oval shaped. In one example, the insulating device
may include an upper wall and a base, the upper wall can define an upper wall circumference,
an upper wall length and an upper wall width, and the base can define a base ference,
a base length and a base width. The upper wall circumference can be equal to the base
circumference and the ratio of the upper wall length to the upper wall width can be greater
than the ratio of the base length to the base width. The cold ion time of the insulating
device can be approximately 11 to 43 hours or more. However, in one example the cold
retention time can be 11 to 15 hours. In another example the cold ion time can be
approximately 12.24 hours. The heat gain rate of the insulating device can be imately
1 to 1.5 degF/hr, and, in one particular example, the heat gain rate can be approximately 1.4
r. The storage compartment can be configured to maintain a liquid therein while
inverted for r than 15 minutes. In one particular example, the storage compartment
can be configured to maintain the liquid for a period of greater than 30 minutes therein when
inverted and a half of a volume of the storage compartment is filled with the liquid.
In one example, the ting layer can be floating freely in between the outer shell and the
inner liner. The insulating layer can be formed of closed cell foam, and the insulating layer
can be made of a NBR and a PVC blend. In one example least a portion of the insulating layer
can be constructed with an EVA foam layer. The closure can be a zipper assembly comprising
a plurality of zipper teeth, and the zipper teeth can be formed of plastic.
In one example, the outer shell and the inner liner can be made of a double laminated TPU
nylon fabric. The outer shell further can include at least one of a strap or handle. The outer
shell can include at least one ring for securing the insulating device. The insulating layer can
be configured to maintain an internal temperature of the insulating device below 50 s
Fahrenheit for 65 to 85 hours. The closure can be formed with a first flange and a second
flange and the outer liner can be secured to top surfaces of the first flange and the second
flange. The inner liner can be secured to bottom surfaces of the first flange and the second
flange. The outer liner and the inner liner can be ted to the closure by a polymer weld.
In one example, the closure can be watertight up to 2 to 14 psi above atmospheric pressure.
A loop patch may also be provided on the insulating device.
In another example, an insulating device may e an outer shell, an inner liner g a
storage compartment, a foam layer ng in between the outer and inner liner, which
provides insulation, an opening extending through the outer layer and the inner layer, a
closure adapted to substantially seal the opening. The closure can be substantially waterproof
so as to prevent liquid from exiting the opening when the insulating device is inverted for a
period of greater than 15 minutes. The heat gain rate of the insulating device can be
approximately 1.0 to 1.5 degF/hr. The insulting device can e at least one handle. The
at least one handle can be configured to support 100 lbs. to 300 lbs. of weight for 1 to 10
minutes without showing signs of failure. In one example, the insulating device can be
configured to withstand 35 lbs. to 100 lbs. of puncture force.
An example method of forming an insulating device can include g an inner liner first
portion and an outer shell first portion, securing the inner liner first portion and the outer
shell first portion to a sealable closure to form a cap assembly, forming an inner liner second
portion and securing the inner liner second portion to the inner liner first portion to form an
inner liner, forming an outer shell second portion, g a rectangular foam portion to form
a first rical foam portion and ng a foam base portion to the first cylindrical foam
portion to form a foam assembly, inserting the foam assembly into the outer shell second
portion, ing the inner liner into the foam assembly, and securing the outer shell first
portion to the outer shell second portion to form the outer shell. The method may also include
securing a e configured to be a barrier against fluid penetration in and out of the inner
vessel and forming a waterproof polymer weld n the closure and the inner shell and
the closure and the outer shell when the closure, the outer shell, and the inner liner are lying
in a flat plane.
In an example, the inner liner first portion and the outer shell first portion can be secured to
the e. The closure can be provided with at least one flange, and the flange can be
secured to a bottom surface of the outer shell first portion and a top surface of the inner liner
first portion. The foam can freely float between the outer shell second portion and the inner
liner second portion. The outer shell and inner shell are only connected to the closure and
not to the insulating layer between the outer shell and inner liner. The outer shell can be
formed of a TPU nylon material, and the inner liner can be formed from a TPU nylon material.
The closure can include a first flange and a second flange. The outer liner can be secured to
top surfaces of the first flange and the second flange, and the inner liner can be secured to
bottom es of the first flange and the second flange. The top of the insulating layer can
have a first perimeter circumference. The bottom of the insulating layer can have a second
perimeter circumference. The first perimeter circumference can be equal to the second
ter circumference.
In one example, an insulating device can include an outer shell defining a sidewall, an inner
liner forming a storage compartment, an insulating layer positioned in between the outer shell
and the inner liner, the insulating layer providing insulation for the storage compartment, an
opening extending through the outer shell and the inner liner, and a closure d to
substantially seal the opening, the closure being ntially waterproof so as to resist liquid
from exiting the opening when the insulating device is in any orientation. The insulating
device may include a vertically extending front facing surface and the closure can be located
on the front facing surface. A cross section of the insulating device can approximate a
pentagon in an extended position, and a cross section of the ting device can
approximate a trapezoid in an extended position. The insulating device may also include a
base, and the insulating layer can insulate the base. The base may also include an additional
insulating layer.
The insulating device may also include a fold-down portion configured to cover the closure.
The fold-down portion comprising a first section and a second section and wherein the first
n is free of the insulation layer and the second section es the tion layer. The
own portion can be at least partially free of foam. The fold-down portion can be
configured to be secured to the sidewall. The fold-down portion can include at least one hook
and the ll can e at least one loop. The hook can be configured to engage the loop
to secure the fold-down portion to the sidewall. The fold-down portion can be secured to the
sidewall, and the fold-down portion may extend at least partly in a substantially horizontal
direction. The fold-down n may define a first width, and the closure extends across at
least 95% of the first width. The own portion may also include a handle configured to
be grasped by a user when the fold-down portion is secured to the ll.
The insulating layer may include a foam material. The insulating layer may include a first
portion and a second portion, and the second portion can be formed r than the first
portion. The insulating layer can be at least partly formed in a shape of a T. The insulating
layer can be at least partly formed of a first rectangle and a second rectangle and the first
rectangle can have a larger area than the second rectangle. The first rectangle can have a first
rectangle width and the second rectangle can have a second rectangle perimeter. The first
gle width can approximates the second rectangle perimeter. The second rectangle can
extend into the fold-down portion. The ting layer can have a first height and a second
height and the first height can be greater than the second height. A majority of the insulating
layer can extend to the second height.
A method of forming an insulating device may e forming an inner liner defining a storage
compartment, forming an outer shell defining a sidewall, placing an insulating layer in
between the outer shell and the inner liner, the insulating layer providing insulation for the
storage compartment, placing an opening in the inner liner and the outer shell, and g a
closure between the inner liner and the outer shell. The closure can be d to
substantially seal the opening, and the closure can be substantially waterproof so as to resist
liquid from exiting the opening when the insulating device is in any orientation. The method
may also e forming a fold-down portion configured to cover the closure, providing the
fold-down portion with a first section and a second section. The first section can be free of
the insulation layer and the second section can include the insulation layer. The fold-down
portion can be at least partially free of foam. The fold-down portion can be configured to
secure to the sidewall. The method may also include forming the insulating layer at least
partly in the shape of a T, forming the insulating layer at least partly of a first rectangle and a
second rectangle, and forming the first rectangle of a larger area than the second rectangle.
The method may also include extending the second rectangle into the fold-down portion and
providing the insulating layer on a base and providing an additional insulating layer along the
base.
In r example, an ting device can include an outer shell defining a sidewall, an
inner liner forming a storage compartment, and an insulating layer positioned in between the
outer shell and the inner liner. The insulating layer can provide insulation for the storage
compartment. The insulating device can include an opening configured to allow access to the
storage compartment and a closure adapted to substantially seal the opening. The insulating
device can include a binding material, and the binding material can be placed over a joint
between the inner liner and the outer shell. The binding material can be stitched onto the
insulating device, and the stitching can create openings into the outer shell for g air
d between the insulating layer and the outer shell. The binding material can create at
least one strap for holding the insulating device. The binding al can e a first folded
portion attached to the outer shell and a second folded portion, and the second folded portion
can form a strap.
The insulation device can approximate a trapezoid from a front view and can approximate a
conical shape from a side view. In one example, the insulating device increases from 0°F to
50°F in a duration of 70 hours or greater when filled with 0.52 lbs. of ice per each quart in
capacity of the insulating device.
The closure can be ntially waterproof so as to resist liquid from exiting the opening
when the insulating device is in any ation. In one example, the insulating device can be
configured to withstand being held inverted for 15 minutes t any water escaping or
leaving the storage tment. The closure can be configured to stay in the opened
position when the closure is not sealed. The closure can be a zipper. In one example, the
closure extends at least 80% of the length of the insulating device when measured along the
e. The length of the closure can be longer than the length of the bottom of the insulating
device, and the length of the closure is at least 5% longer than the length of the bottom of the
insulating device. The insulating device can include a vertically extending front facing surface,
and the closure can be located on the front facing surface. A handle can be located on a rear
facing surface opposing the front facing surface.
In the example insulating device, the insulating layer can comprise a foam material. The
insulating layer can comprise a first portion and a second portion, and the second portion can
be formed thicker than the first portion. The ting layer can be at least partly formed of
a first rectangle and a second gle, and the first rectangle can have a larger area than the
second rectangle. The insulating layer can have a first height and a second height, and the
first height can be greater than the second height. In one example, a majority of the insulating
layer can extend to the second height. In addition, or alternatively, the front of the ting
layer can extend to the second height and the rear of the ting layer extends to the first
height. The insulating device can e a base, and the insulating layer can insulate the base.
Also the base can include an additional or separate insulating layer. In one example, the
insulating layer can cover 80% or more of the inner liner covering the storage compartment
or the insulating layer can cover 90% or more of the inner liner covering the storage
compartment.
In another example, a method of forming an insulating device may include forming an inner
liner the inner liner defining a storage compartment, forming an outer shell defining a
sidewall, placing an insulating layer in n the outer shell and the inner liner, the
insulating layer providing insulation for the storage compartment, g an opening in the
inner liner and the outer shell, placing a closure between the inner liner and the outer shell,
the closure d to substantially seal the opening, the closure being ntially
waterproof so as to resist liquid from exiting the opening when the insulating device is in any
orientation. The method can also include forming the insulating layer at least partly of a first
rectangle and a second rectangle and forming the first rectangle of a larger area than the
second rectangle. The method can also include providing the insulating layer on a base and
ing an additional insulating layer along the base.
An example insulating device can include an outer shell defining a first sidewall; an inner liner
forming a e compartment; an ting layer positioned in between the outer shell and
the inner liner, the insulating layer ing insulation for the storage compartment. The
outer shell and the inner liner can define an opening, and the opening can be configured to
allow access to the storage compartment. A e can be adapted to substantially seal the
g, and the closure can be ntially waterproof so as to resist liquid from exiting the
opening when the insulating device is in any orientation. The outer shell may include a second
sidewall and a third sidewall, and the opening may extend through the first sidewall, the
second sidewall, and the third sidewall. The insulating device can be in the shape of a cuboid.
The inner liner and the outer shell can form a joint, and the joint can include a vent to gases
that become trapped between the inner liner and the outer shell. The outer shell may include
one or more handles, and a vent can be formed adjacent to a location of the one or more
handles. The closure can be substantially waterproof so as to resist liquid from exiting the
opening when the insulating device is dropped from a distance of six feet.
The insulating device can also include a lid assembly and a body assembly. The lid assembly
and the body assembly can together form the inner liner, the insulating layer, and the outer
shell. The lid assembly can include at least a portion of the insulation layer. The lid assembly
may also e a handle and a reinforcement layer that is more rigid than the inner liner,
the insulating layer, and the outer shell.
The outer shell may define a bottom wall extending in a first plane, and the inner liner can be
secured to the outer shell in a second plane extending perpendicular to the first plane. The
liner may be formed of a first piece and a second piece and the first piece is joined to the
second piece by way of a weld to define a seam and the seam may be covered with a seam
tape. In one alternative example, the inner liner can be formed by way of injection g.
The closure can be a zipper and can be substantially roof. The zipper can include a pull,
and the pull can be formed of a cloth, string, or rope. In certain examples, the temperature
of the insulating device increases from 0°F to 10°F in a duration of 0.5 hours to 1.5 hours, the
ature of the insulating device increases from 10°F to 50°F in a duration of 22 hours to
28 hours, and the temperature of the insulating device increases from 0°F to 50°F in a duration
of 24 hours to 30 hours.
An e method may include forming a body assembly by forming a lower outer shell,
g a lower insulating layer into the lower outer shell, and securing a lower inner liner
portion to the lower outer shell; forming a lid assembly of an upper outer shell, an upper inner
liner portion and an upper insulating layer therebetween; and joining the lid assembly to the
body assembly by securing a closure between the lid assembly and the body assembly and by
securing a binding material to the body assembly and the lid assembly. The insulating layer
can float between the lower outer shell and the lower inner liner portion. The binding
material can be formed of nylon, and the binding material can be stitched to the body
assembly and the lid assembly. The lid assembly may also be welded to the body assembly.
Additionally, the lid assembly may be formed with a handle and a reinforcement layer that is
more rigid than the inner liner, the insulating layer, and the outer shell. The lower inner liner
portion in certain examples can be formed by injection g.
The lower inner liner portion can be secured to the lower outer shell by a weld. The weld can
be formed by clamping the lower outer shell to the lower inner liner portion with a top U-
shaped portion, a plate portion, and a bottom U-shaped portion and applying a current
through the top U-shaped portion, the plate portion, and the bottom U-shaped portion. The
current can be d through the top U-shaped n, the plate portion, and the bottom
U-shaped portion in a first direction to weld a first side and the t can be d in a
second direction to weld a second side.
Aspects of the disclosure herein may relate to insulating devices having an outer shell defining
a first sidewall, an inner liner forming a storage compartment, an insulating layer positioned
in between the outer shell and the inner liner, where the insulating layer providing insulation
for the storage compartment. The insulating device may have an opening configured to allow
access to the storage compartment, and a lid assembly and a body assembly, where the lid
ly and the body assembly together form the inner liner, the insulating layer, and the
outer shell. The lid assembly may include at least a n of the ting layer that extends
below a closure adapted to close the opening. The closure may be adapted to substantially
seal the opening, the closure being substantially waterproof so as to resist liquid from exiting
the opening when the insulating device is in any orientation. The insulating layer connected
to the lid assembly may include a perimeter edges and a center portion, where the insulating
layer connected to the lid assembly has an l first thickness near the ter edges
and a second thickness near the center portion, wherein the first thickness is greater than the
second thickness. The ratio of the first thickness to the second thickness may be in a range of
2:1 to 2.5:1. Additionally, a ratio of an overall height of the insulating device compared to a
thickness of the insulating layer ted to the lid ly of the insulating device may be
within a range of 5.8:1 to 7.2:1. The thickness of the insulating layer connected to the lid
assembly may be greater than a thickness of the insulating layer on the first ll.
Still other aspects of this disclosure may relate to an insulating device having an outer shell
r comprises a second sidewall and a third sidewall and wherein the opening extends
through the first sidewall, the second sidewall, and the third ll and where the insulating
device is in a shape of a cuboid. The insulating device may further include the outer shell
having one or more handles and where a ity of venting holes extend through the outer
shell underneath one or more handles. The plurality of venting holes may comprise three
holes.
Yet other aspects of this disclosure may relate to an insulating device having a lid assembly
that includes at least a portion of the insulating layer that extends below a closure adapted to
substantially seal the opening, and where the outer shell comprises one or more handles and
a plurality of venting holes extending through the outer shell positioned underneath the one
or more handles. The lid assembly may further comprise an insulation sheet and an insulating
ring, wherein the insulating ring extends underneath the insulation sheet and approximates a
ference of the tion sheet. A portion of the insulating layer on the lid assembly
and the inner liner may form a headspace extending above the closure. The portion of the
insulating layer and the inner liner of the lid assembly are contact with the inner liner and a
second portion of the insulating layer formed on the body assembly to form the storage
compartment when the closure is sealed. The insulating layer on the lid assembly may extend
along a length of the closure to te the storage compartment along the length of the
e. The outer shell may form a hinge and the portion of the insulating layer on the lid
assembly may extend along a length of the hinge to insulate the storage compartment along
the length of the hinge. In addition, the portion of the insulating layer may be tapered to
odate for the closure.
The present invention is disclosed above and in the accompanying drawings with reference to
a variety of examples. The purpose served by the disclosure, however, is to provide examples
of the s features and concepts related to the invention, not to limit the scope of the
invention. One skilled in the relevant art will recognize that numerous variations and
cations may be made to the examples described above without departing from the
scope of the present invention.
Claims (19)
1. An insulating device comprising: an impermeable outer shell defining a first sidewall; an inner liner forming a storage compartment; an insulating layer coupled to an aerogel structure, positioned in between the outer shell and the inner liner on an al side of the, the insulating layer and aerogel structure providing insulation for the storage compartment; an opening configured to allow access to the storage compartment; and a closure adapted to substantially seal the opening, the closure being substantially waterproof so as to resist liquid from exiting the opening when the insulating device is in any orientation, wherein the inner liner and the outer shell form a joint and wherein the joint comprises a vent to vent gases trapped between the inner liner and outer shell.
2. The insulating device of claim 1 wherein the outer shell further comprises a second sidewall and a third sidewall and wherein the opening extends through the first sidewall, the second ll, and the third ll.
3. The insulating device of claim 1 or claim 2 wherein the ting device is in a shape of a cuboid.
4. The ting device of any one of claims 1 to 3 n the outer shell comprises one or more handles and wherein a vent is formed adjacent to a location of the one or more handles.
5. The insulating device of any one of claims 1 to 4 wherein the outer shell defines a bottom wall ing in a first plane and wherein the inner liner is secured to the outer shell in a second plane extending perpendicular to the first plane.
6. The insulating device of any one of claims 1 to 5 wherein the inner liner is formed of a first piece and a second piece and wherein the first piece is joined to the second piece by way of a weld to define a seam and wherein the seam is covered with a seam tape.
7. The insulating device of any one of claims 1 to 6 n the inner liner is formed by way of injection molding.
8. The insulating device of any one of claims 1 to 7 wherein the closure is a zipper and is substantially waterproof and n the zipper comprises a pull, the pull being formed of a cloth, string, or rope.
9. A method comprising: forming a body assembly by forming an impermeable lower outer shell, placing a lower ting layer and aerogel structure into the lower outer shell, and securing a lower inner liner portion to the lower outer shell; forming a lid assembly of an impermeable upper outer shell, an upper inner liner portion and an upper insulating layer and aerogel structure therebetween; and joining the lid assembly to the body assembly by securing a closure between the lid assembly and the body assembly and by ng a binding material to the body assembly and the lid assembly, wherein the lower inner liner portion and the lower outer shell form a joint and wherein the joint comprises a vent to vent gases trapped between the inner liner and outer shell.
10. The method of claim 9 n the insulating layer and aerogel structure floats between the lower outer shell and the lower inner liner portion.
11. The method of claim 9 or claim 10 wherein the binding material is nylon.
12. The method of any one of claims 9 to 11 wherein the binding material is ed to the body ly and the lid assembly.
13. The method of any one of claims 9 to 12 wherein the lid assembly is also welded to the body assembly.
14. The method of any one of claims 9 to 13 wherein the lower inner liner portion is formed by injection g.
15. The method of any one of claims 9 to 14 wherein the lower inner liner portion is d to the lower outer shell by a weld.
16. An insulating device comprising: an impermeable outer shell defining a first sidewall; an inner liner forming a storage compartment; an insulating layer and aerogel structure positioned in between the outer shell and the inner liner, the insulating layer and aerogel structure providing tion for the storage compartment; an opening configured to allow access to the storage compartment; a lid assembly and a body assembly, wherein the lid assembly and the body assembly together form the inner liner, the insulating layer, the aerogel structure, and the outer shell; wherein the lid assembly includes at least a portion of the insulating layer and aerogel structure that extends below a e adapted to close the opening, wherein the inner liner and the outer shell form a joint and wherein the joint comprises a vent to vent gases trapped between the inner liner and outer shell.
17. The insulating device of claim 16, wherein the portion of the insulating layer and aerogel structure and the inner liner of the lid assembly contacts a second n of the insulating layer and aerogel structure and the inner liner formed on the body assembly to form the e compartment when the closure is sealed.
18. The insulating device of claim 16 or claim 17, wherein the insulating layer and aerogel structure connected to the lid assembly comprises a perimeter edges and a center portion, wherein the insulating layer and aerogel structure connected to the lid assembly has an overall first ess near the perimeter edges and a second thickness near the center portion, wherein the first ess is greater than the second thickness.
19. The insulating device of claim 1 or claim 16, substantially as herein described with reference to any one or more of the accompanying drawings. 215 216
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
CN201610642524.XA CN106196819A (en) | 2016-08-05 | 2016-08-05 | Refrigerator |
CN201710528829.2A CN107514863B (en) | 2016-08-05 | 2017-07-01 | refrigerator with a door |
CN201710528829.2 | 2017-07-01 | ||
PCT/CN2018/093578 WO2019007264A1 (en) | 2016-08-05 | 2018-06-29 | Refrigerator |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ759118A NZ759118A (en) | 2021-10-29 |
NZ759174B2 true NZ759174B2 (en) | 2022-02-01 |
Family
ID=
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