Patent Application
20240324783
The present invention relates generally to both coolers and furniture, both used outdoors in recreational settings. The invention relates more specifically to a cooler that forms part of an article of outdoor furniture, such as an Adirondack chair. The cooler forms the seat portion of the chair, and is easily assembled and disassemble for ease of shipping, setting up, and storing.
In my co-pending application entitled “Outdoor Furniture,” filed on Mar. 16, 2023, and designated Ser. No. 18/122,382, which is incorporated herein by reference, I describe traditional wooden outdoor furniture, such as “Adirondack” chairs, that are left for prolonged periods in the elements. It is not uncommon for such furniture to be outdoors for entire seasons, or even yearly, in parks, on patios, at camp sites, and virtually anywhere people frequent for outdoor events, sports, recreation and relaxation.
Adirondack chairs, like many other chair designs, have a seat portion, a back portion, and opposite side armrest portions, supported on legs. The main feature of the Adirondack chairs is that the seat portion is angled downwardly from front to rear, while the back portion is at an incident angle to the seat portion, at a reclining angle relative to the person seated thereon. Wooden outdoor chairs are either stained or painted to preserve the wood and thus extend the lifetime use of the chair.
While the design of the Adirondack chair is timeless, there are drawbacks to the use of traditional materials like wood for construction. One drawback is the repeated need for re-staining or re-painting as the elements degrade the last application of stain or paint. Even when properly stained or painted, wooden chairs can nonetheless experience rot where bolt, screw or nail holes penetrate the wood to connect different pieces of the chair together. These holes allow rainwater to enter the wood and over time cause premature degradation. These drawbacks are common to all wooden outdoor furniture. Another is that wooden materials can be expensive, especially if one chooses to use wood that is less likely to rot, such as hardwoods like cypress and teak.
In more recent times, manufacturers of outdoor furniture have begun using high density polyethylene (“HDPE”) as a replacement for wood or metal. As a plastic, this material does not rot or need painting or staining, and as a high density plastic, HDPE provides strength, fracture toughness, and hardness necessary to sustain the weight of any sized person and accidental/incidental impact from movement, collisions with surroundings, hard landings from delivery, etc. HDPE is a thermoplastic polymer produced from the monomer ethylene. A high strength to density ratio makes HDPE particularly suitable as a lumber substitute. HDPE is available from any number of commercial sources in sheet form, in thicknesses suitable for making furniture, such as 10 millimeters, comparable to the thickness of lumber that is used in wooden furniture. The sheets are available in sizes sufficient to allow parts of the furniture to be cut from the panels by known means, such as by computer numerical control, or “CNC,” which is a manufacturing machine and process where machines cut, carve and form parts based on computer codes that control the cutting tool's speed and movement.
Although HDPE solves the problems of maintenance and cost associated with wooden furniture, a new problem occurs in that HDPE can act as a heat sink and store extreme high and low temperatures created by the environment. On hot, sunny days, the plastic will become hot to the touch, to the point of scalding a person wearing shorts when sitting. Because of a relatively high thermal conductivity, the HDPE will continue to transfer heat or cold to the person sitting on the chair, until the store heat or cold is exhausted. Wood, on the other hand, does not have the ability to store heat or cold like HDPE, but even if it did, wood has a relatively low thermal conductivity. Once seated on a wooden chair, a person's body temperature will relatively quickly create a thermal equilibrium between the person and the surface of the seat portion and back portion of the chair, as well as the armrests when the person's arms come into contact with the armrests.
Another problem associated with outdoor furniture is that they tend to be bulky. Furniture such as Adirondack chairs are typically not easily assembled, and are most often built and sold in final form. Once in final form, they are shipped, deployed, and stored in the final form. As such, Adirondack chairs are not conveniently shipped, deployed or stored.
Yet another drawback to traditional outdoor furniture is that they are designed and built for a single purpose. For chairs, they are designed and built to be sat upon. Similarly, coolers are known to be used in outdoor settings and come in many different sizes and shapes. But they, too, are designed and built for a single purpose—to keep drinks cold for as long as is needed.
A need exists for outdoor furniture that has the durability and absence of maintenance like HDPE furniture, but the heat transfer properties of wood. A further need exists to lower the hardness of the surfaces of outdoor furniture that come into contact with the person using the furniture, without using traditional pads, pillows or cushions which are quickly degraded by the elements and difficult to clean and store. And a further need exists for outdoor products that can be combined so as to provide a single structure with multiple uses and functions.
In one aspect of the present invention, a cooler and chair combination includes a base, a back detachably connected to the base, first and second armrests detachably connected to the base and the back, and a cooler compartment formed inside the base.
Preferably, the back and first and second armrests are made of a high density polyethylene (HDPE). Such materials are commercially available in planar sheet form, in desired thicknesses, and are capable of being cut into desired shapes for assembly of parts or portions which comprise the chair.
The base preferably has a plurality of sidewalls defining an open top, a bottom integrally formed with the sidewalls, and a lid movably connected to and sealingly covering the open top in a closed position, the sidewalls, bottom and lid defining the cooler compartment as an insulated interior capable of providing thermal retention.
More preferably, the base is made by rotational molding, and more preferably the base is made of a high density thermoplastic polyethylene, and the top is pivotally connected to the sidewalls.
Preferably, the back is an elongated, rectangular planar member having a proximal end and a distal end, and the base has a slot formed in a rearward portion of the base, to slidably receive the proximal end of the rectangular planar member in a fixed, angled, upright position.
In a preferred embodiment, each of the first and second armrests comprise an L-shaped planar member having a forward portion and a rearward portion, and each forward portion of the first and second armrests is detachably connected to a corresponding one of the first and second vertical supports, and each rearward portion of the first and second armrests is detachably connected to the rectangular planar member.
Preferably, the rectangular planar member has a forward facing surface and a rearward facing surface, and wherein the rectangular planar member further comprises a pair of slats connected to the rearward facing surface of the rectangular planar member, and wherein the rearward portions of the L-shaped planar members are detachably connected to corresponding ones of the pair of slats.
In certain embodiments, the surfaces of the seat, back and armrests can be covered with sheets of EVA foam or similar materials made from blended copolymers of ethylene and vinyl acetate or other materials having a high level of chemical cross linking which results in a product with a fine uniform cell structure. Preferably, the EVA foam is adhesively bonded to the components of the cooler chair combination in thicknesses ranging from about 3 millimeters to about 20 millimeters.
Another aspect of the present invention is to provide a modular apparatus where a first structure has a first function, and detachably connected components are connected to the first structure to form another structure having a different function. Preferably, a modular apparatus includes a main body defined by a bottom and a plurality of sidewalls, an interior, insulated compartment disposed within the main body and having an open upper end, a plurality of legs disposed on the bottom of the main body and being disposed to support the main body when resting on a surface, an insulated cover movably disposed over the open upper end and being movable between open and closed positions, the main body having a first function, and means for detachably connecting component parts to the main body, the component parts having a second function when combined with the main body.
Preferably the means for detachably connecting components to the main body include a plurality of slots.
In a preferred embodiment, the plurality of slots includes a rear slot provided in a rear portion of the body, and the component parts include a back having a proximal end and a distal end, wherein the proximal end of the back is slidable into the rear slot to be mounted in a predominantly vertical, angled rearward disposition.
The main body includes a first side and a second side, and the plurality of slots includes first and second vertical slots disposed respectively on the first side and the second side of the main body, and the component parts include first and second vertical supports each having a proximal end and a distal end, the proximal ends of the first and second vertical supports being slidable respectively in the first and second vertical slots, and first and second armrests respectively detachably connected to the distal ends of the first and second vertical supports and to the back.
Preferably, the main body and component parts are all made of HDPE plastic, and at least one surface of the of the main body and component parts is at least partially covered with EVA closed cell foam material.
In another aspect of the invention, a method of building a modular product having two distinct functions includes the steps of forming a cooler from roto molded high density plastic, the cooler having an open top, a bottom and a sidewall between the bottom and open top, and a lid movable between open and closed positions and sealingly closing the open top when in the closed position, forming a rearward slot in a rearward portion of the cooler, forming two forward, vertical slots in a forward portion of the cooler, sliding a back into the rearward slot, sliding first and second vertical supports respectively into the two forward, vertical slots, forming first and second armrests each having a forward portion and a rearward portion, detachably connecting the forward portion of the first and second armrests respectively to the first and second vertical supports and to the back, wherein the modular product functions as both a cooler and a chair, wherein the lid of the cooler provides a seat for the chair.
Preferably, all component parts are made by cutting planar sheets of HDPE plastic material into parts which define the first and second armrests and the back.
Another aspect of the present invention is to provide an article of outdoor furniture which includes a roto molded cooler having a lid angled downwardly from front to rear, the lid having an outer surface which provides a seat for a user, a back detachably connected to a rear portion of the cooler, first and second vertical supports, each having a proximal end and a distal end, the proximal ends of the first and second vertical supports being slidably and detachably connected to a forward portion of the cooler, and first and second armrests respectively detachably connected to the distal ends of the first and second vertical supports and to the back.
Preferably, the cooler, back and first and second armrests are made of HDPE plastic.
Other aspects of the invention will become apparent in view of the following detailed description and claims.
Referring to
The base 12 includes a plurality of sidewalls 22, 24, 26, 28 defining an open top, a bottom 30 integrally formed with the sidewalls 22, 24, 26, and 28. A lid 32 is movably connect to and sealingly covering the open top in a closed position. The lid 32 is preferably pivotally connected and is movable between open and closed positions. Pivotal connection means are well known and need no further description. A latch 34, also of known construction, is provided at the forward end of the lid 32 to secure the lid in a sealing position over the open top. The cooler compartment is highly insulated and capable of maintain ice in a frozen condition 24 to 48 hours or more.
The cooler and chair combination 10 further includes first and second vertical supports 36, 38. As better seen in
The back 14 is an elongated, rectangular planar member having a proximal end and a distal end. The base 12 has a rear slot 44 formed in a rearward portion thereof for slidably receiving the proximal end of the back 14, which is preferably in the form of an elongated, rectangular planar member. When inserted into the slot, the back 14 is maintained in a fixed, angled rearwardly, upright position. Once inserted, the back 14 can be held in position either by a simple interference fit, by set screws (not sure) or any other fasteners or securing means of any known form. Since ease of assembly is desirable and preferred, simple fastener means can be provided.
Each of the first and second armrests 16, 18 comprise an L-shaped planar member having a forward portion 16a, 18a, and a rearward portion 16b, 18b, and each forward portion of the first and second armrests is detachably connected to a corresponding one of the first and second vertical supports 36, 38, and each rearward portion of the first and second armrests is detachably connected to the back 14. Securing the distal end of vertical support 36 to the underside of the forward portion 18a of armrest 18, and securing the distal end of vertical support 38 to the forward portion 16a of armrest 16 can be accomplished with any conventional fasteners, such as set screws, wood or metal screws, nuts and bolts, or any other suitable fasteners that are easy to engage and disengage. A bottle opener 48 can be secured to either vertical support and in one embodiment, the bottle opener has vertical and horizontal parts that can be secured to the vertical support and the horizontal, underside of either armrest.
As best seen in
The back 14, lid 32 and armrests 16, 18 are all preferably made of HDPE plastic. The lid 32 is roto molded to provide superior insulating properties, along with the sidewalls and bottom. The top surface of the lid 32 provides a seat on which a user can be seated.
The base 12 includes a plurality of legs, including two forward legs 56, 58 and two rearward legs 60, 62, with all four legs disposed a four corners of the base 12. The bottom 30 is disposed between the legs 56, 58, 60, 62, and the sidewalls 22, 24, 26 and 28 extend upwardly from the bottom to define an upper opening through which ice and drinks or other products can be placed in the cooler compartment 20. The lid 32 is movable between open and closed position over the upper opening. The lid 32 has an upper surface which provides a seat.
The invention can be described as a modular structure where a main body is defined by the aforementioned bottom and plurality of sidewalls. The body defines a cooler, which substantially corresponds in the drawings to element 12 and described above as the “base” 12. The cooler has an insulated compartment with an open upper end closed by a lid 14. The base 12 and the lid 14 constitute the cooler.
In describing a cooler, the legs 56, 58, 60 and 62 are integrally formed with the cooler, and function to support the base 12 in an elevated position off the ground. The legs are thus are a permanent part of the cooler, but are necessarily part of the chair, which is formed when modular parts are added to the cooler.
As previously noted, the lid 32 is part of the cooler, and can be pivotally mounted to the upper edge of the base 12 by hinges (
The modular aspect of the invention is that the cooler can be augmented to include chair parts, or detachable and attachable component parts, including the aforementioned back 14, armrests 16, 18 and vertical supports 36, 38. These additional, detachable component parts give the cooler a second function, that of a chair, when combined with the cooler.
The slots 40, 42, 44 ensure easy assembly and disassembly so that the modular structure can be take its initial form as a chair, and then augmented with additional parts to become a chair cooler combination. The back, armrests and vertical supports are detachably connected to the cooler (or main body 12) using the slots as a means for simple, quick and easy assembly and disassembly. The proximal end of the back 14 is slidable into the rear 44 slot to be mounted in a predominantly vertical, angled rearward disposition. The back 14 can be held in place by an interference fit, or set screws, threaded fastener or any other suitable means which would allow for a secure, yet detachable, connection. A quick coupling is preferred so the cooler chair combination can be easily assembled and disassemble. The back and corresponding slot may be provided with snap-fit structures which snap together when mating parts are in proper alignment, such as when the back is fully inserted into the slot.
When viewing the modular apparatus from the front, the apparatus has a first side and a second side, and the first and second vertical slots 40, 42 are disposed respectively on the first side and the second side of the main body. The component parts, including the first and second vertical supports 36, 38 each have a proximal end and a distal end, the proximal ends of the first and second vertical supports are then slidable into the first and second vertical slots. The modular parts that are added to the cooler include the first and second armrests 16, 18 respectively detachably connected to the distal ends of the first and second vertical supports 36, 38 and to the back 14.
The invention includes the method of building a modular product having two distinct functions, where the method includes the steps of forming a cooler from roto molded high density plastic, the cooler having an open top, a bottom 30 and a sidewall 22, 24, 26 and 28 (in alternative embodiments the sidewalls could be curvilinear, circular, or polyhedral with more or less than four sides. The lid 32 is formed by roto molding as well, since it is essential for long term cooling to have the entire enclosure insulated. Roto molding allows for insulation of the type shown in
The uniqueness of the present invention is to form by molding or cutting a rearward slot 44 in a rearward portion of the cooler, and to form two forward, vertical slots 40, 42 in a forward portion of the cooler. The methodology includes sliding the back 14 into the rearward slot 44, and sliding first and second vertical supports 36, 38 respectively into the two forward, vertical slots, 40, and 42. The first and second armrests 16, 18 are formed by taking rectangular sheets of HDPE, preferably about 7 millimeters to 15 millimeters in thickness, and cutting those sheets using a CNC machine, programmed to cut repetitively, and successively, the parts that are assembled to form the cooler chair combination. When forming the armrests, 16, 18, each is preferably cut to have a forward portion 16a, 18a and a rearward portion 16b, 18b, detachably connecting the forward portion of the first and second armrests respectively to the first and second vertical supports and to the back, wherein the modular product functions as both a cooler and a chair, wherein the lid of the cooler provides a seat for the chair.
Preferably, all component parts are made by cutting planar sheets of HDPE plastic material into parts which define the first and second armrests and the back.
Preferably, the cooler, back and first and second armrests are made of HDPE plastic or other plastic materials having similar physical properties in terms hardness, strength and fracture toughness.
Although specific embodiments of the present invention have been described, it will be understood by those of skill in the art that there are other embodiments that are equivalent to the described embodiments. Accordingly, it is to be understood that the invention is not to be limited by the specific illustrated embodiments, but only by the scope of the appended claims.
